Papers by Author: M. Ashraf Imam

Abstract: Microwave sintering of titanium and its alloys is a recent development in powder metallurgy of titanium. The sintering in an atmospheric pressure argon gas environment or vacuum is potentially cost effective and energy efficient compared to conventional sintering methods due to the possibility of direct microwave heating of the titanium powder via in-depth energy deposition augmented by hybrid heating in a ceramic casket. The in-depth heating permits very rapid processing (cycle times of potentially less than 10 minutes) which is intended to preserve a very fine grain structure in the final product resulting in excellent mechanical properties and the possibility of superplastic forming. We are investigating this approach using an S–Band microwave system. The process can be also used for composites, laminates, direct alloying, and functionally gradient materials. Evaluations to optimize different parameters for controlling the final density, microstructure, and properties of these materials are underway and results are discussed.

Abstract: Mg-Ti alloys are attractive for structural applications because of low density and improved corrosion resistance by selective oxidation including hydrogen storage and switchable mirror applications. Titanium has a melting point (1670°C) that greatly exceeds the boiling point of magnesium (1090°C) and therefore, alloying of Mg and Ti by conventional methods is extremely difficult. Secondly, the solubility of Ti in liquid Mg is very low and it is difficult to extend solubility by rapid solidification. Physical vapor deposition by electron beam deposition and magnetron co-sputtering has been used to extend the solubility of Ti in Mg. Mechanical alloying and anvil-cell processing at extreme temperatures and pressures have also used to enforce alloying of Mg with Ti. The present paper deals with the consolidation of blended magnesium-titanium powders by microwave heating, an approach that appears highly cost effective.

Abstract: The major reason that there is not more widespread use of titanium and its alloys is the high cost. In this paper, developments in one cost effective approach to fabrication of titanium components - powder metallurgy - will be discussed under various aspects of this technology. The aspects to be discussed are the blended elemental approach, pre-alloyed techniques, additive layer manufacturing, metal injection molding, spray deposition and microwave sintering. A brief review of a number of low cost powder production processes is also presented.

Abstract: Millimeter-wave sintering of ceramic laser host materials has been under investigation for high-energy laser (HEL) applications. Advantages of polycrystalline, compared to single-crystal, laser host materials include lower processing temperature, higher gain from higher dopant concentration, cheaper fabrication, and larger devices. We are currently investigating the solid-state reactive sintering of neodymium-doped yttrium aluminum garnet (Nd:YAG) using a high power millimeter-wave beam as the heat source. The 83 GHz beam is generated in the Naval Research Laboratory (NRL) High Frequency Materials Processing Facility that is powered by a 15 kW, CW, 83 GHz GYCOM gyrotron. The starting powder is a mixture of commercially available alumina, yttria, and neodymia powders. Near transparency and over 99% theoretical density have been achieved with grain sizes of 5 to 10 µm. The fluorescence lifetime of the Nd+3 1.06 µm lasing transition was measured to be about 200 µs, in good agreement with other work. SEM studies of the sintered microstructure show residual porosity caused by trapped pores that must be eliminated to produce fully transparent material.

Abstract: The isothermal oxidation behavior and thermal stability of a cobalt base alloy was investigated up to a period of 312 hr in air from 1000 to 1200°C. A comparison of oxidation behavior of this alloy with a conventional nickel-base superalloy (Inconel 713C) has been conducted in detail. This experimental alloy oxidizes by forming layers of Al2O3, Cr2O3, TiO2, CoO and traces of SiO2 with WO2 oxides on the surface of the specimen in contact with air. Scanning electron microscopy (SEM) was used to study the microstructure, morphology and compositions of oxides formed after the exposure. Thermal stability of the alloy after extended periods of exposures to air at 1000, 1100 and 1200°C was studied using transmission electron microscopy (TEM).

Abstract: The emerging reduction technologies for titanium from ore produce powder instead of sponge. Conventional methods for sintering and melting of titanium powder are costly, as they are energy intensive and require high vacuum, 10-6 Torr or better, since titanium acts as a getter for oxygen at high temperature, adversely affecting mechanical properties. Other melting processes such as plasma arcs have the additional problem of electrode consumption, and direct induction heating of the titanium powder is problematic. Microwave sintering or melting in an atmospheric pressure argon gas environment is potentially cost effective and energy efficient due to the possibility of direct microwave heating of the titanium powder augmented by hybrid heating in a ceramic casket. We are investigating this approach at the Naval Research Laboratory using an S–Band microwave system. The experimental setup and the results of melting and sintering experiments will be described including a rough estimate of energy usage.

Abstract: Titanium is the “wonder” metal, which makes sense as the material of choice for a wide variety of applications. However, because of its relatively high price- a result of extraction and processing costs- it is used basically only when it is the only choice; with the caveat that titanium has a bright “image” which can lead to use even when the economics are unfavorable. The major thrust in the area of titanium technology has been aimed at achieving cost reduction rather than developing alloys with enhanced properties. This paper will overview the potential areas which are amenable to cost reduction and present some applications of titanium and it’s alloys.

Abstract: We present results on microwave, millimeter-wave, and millimeter-wave-driven plasma-assisted processing of materials. The research is primarily based on two systems- a 2.45 GHz, 6 kW S-band system and an 83 GHz, 15 kW gyrotron-based quasi-optical system. The S-Band system is used to synthesize nanophase metals, metal mixtures, and metal oxides by our patented continuous microwave polyol process, which has potential for large scale and low cost production. This system is also being investigated to develop techniques for titanium melting and sintering. The 83-GHz system is used for rapid sintering of ceramic powder compacts to produce polycrystalline materials with limited grain growth. An important application is to the development of polycrystalline laser host materials for high power solid-state lasers, where the requirement is for transparency with high optical quality and good lasing efficiency. We are currently investigating solid-state reactive sintering of Nd-doped YAG (Yttrium Aluminum Garnet) from commercial oxide powders. This has thus far yielded translucent samples with good fluorescence lifetime of the lasing state. Techniques for further reducing light scattering by residual pores are being investigated. Finally, the millimeter-wave system is being used in the development of millimeter-wave plasma-assisted diamond deposition, as the quasi-optical system has significant advantages over conventional microwave plasma-assisted diamond deposition systems. The results and implications of this wide range of materials processing experiments are presented and discussed.

Abstract: Severe plastic deformation (SPD) by equal channel angular extrusion (ECAE) was investigated as a way to produce ultra fine grain (UFG) microstructure in Ti-5Al-1Sn-1V-1Zr-0.76Mo. DEFORM 3D Finite Element Model (FEM) was used to predict loads and strain distribution associated with ECAE which were validated experimentally The effects of resulting ultra fine grain microstructure on room temperature mechanical properties and high temperature super plasticity were investigated. ECAE processing: resulted in the conversion of coarse Widmanstatten structure to fine equiaxed microstructure with an average grain size of 4 μm. The alloy with fine grained equiaxed microstructure has 20- 25% higher yield strength, 15% higher ultimate tensile strength, and 50-100% higher % elongation to fracture and % reduction in area compared to the as received alloy containing coarse Widmanstatten microstructure. The ECAE processed alloy exhibits attractive superplastic formability charactersistics at 900-950oC with m value >0.4, flow stresses < 20 MPa, and superplastic elongations > 200%

Abstract: This study is considered as a method for producing multifunctional metal composite materials by using Single-walled Carbon Nanotubes (SWNTs). In this research, various metals (Ni, Cu, Ag ) were successfully deposited onto the surface of SWNTs. It has been found that homogenous dispersion and dense nucleation sites are the necessary conditions to form uniform coating on SWNTs. Functionalization has been applied to achieve considerable improvement in the dispersion of purified single-walled carbon nanotubes. A three-step electroless plating approach was used and the coating mechanism is described in the paper. The samples were characterized by using scanning electron microscopy (SEM), transmission electron microscopy (TEM), Raman spectroscopy, and energy-dispersive X-ray spectroscopy (EDX). The application of coated SWNTs in Titanium will be discussed in this paper.