Papers by Author: Takafumi Kusunose

Abstract: Two types of Aluminum nitride (AlN) based ceramic nanocomposite with multifunctionality were investigated to improve machinability or electrical conductivity of AlN ceramics with high thermal conductivity. The AlN/BN nanocomposite was fabricated by hot-pressing AlN-BN composite powder, which was prepared by reducing and heating AlN particles containing a mixture of boric acid, urea and carbon. The nanocomposite containing 20 vol.% BN showed high strength, good machinability and relatively high thermal conductivity. On the other hand, the sintered AlN ceramics with CeO2 as an additive indicated high thermal conductivity and electric conductivity which is possible for electric discharge machining.

Abstract: The polyaniline (PANI) coated titania (TiO2) has been prepared with ammonium persulfate (APS) as an oxidant in sodium dodecylsulfate(SDS) micellar aqueous solution. These nanosized powders could transfer into the organic phase. With increase in the amount of SDS, the dispersibility into the organic solvent was increased. Consequently, the electrical conductivity of the product was also decreased. The obtained composites showed 14.16 S/cm of conductivity at maximum while the value was almost independent on the polyaniline coating ratio in range of 100~20wt%. The conductivity value of composite with 20wt% polyaniline was 70000 times higher than that of raw titania. Modified titania had properties of polyaniline and titania together. In addition these composite showed the photoconductive response against the UV irradiation, which might show the existence of P-N junction between titania and polyaniline. The detailed structure and property analyses with X-ray, UV-spectroscopy, electron microscopy and so on will be discussed in relation to the synthetic conditions

Abstract: Thermal conductivity and microstructure of 3YSZ/monazite-type LaPO4 composites were investigated. Powders were prepared by two kinds of preparation methods such as conventional ball-milled and chemical precipitation of LaPO4 on the zirconia powder surface. Thermal conductivity of 3YSZ/monazite-type LaPO4 composites was lower than that of 3YSZ. That of 3YSZ/monazite-type LaPO4 composites was influenced on the powder preparation methods and as a function of measured temperature. Microstructure of 3YSZ/monazite-type LaPO4 composites was not much affected by the amount of dispersed LaPO4 particles. 3YSZ/monazite-type LaPO4 composites were observed to pores after thermal etched. The pore of synthesized specimens was observed remarkably in compared with conventional ball-milled specimens.

Abstract: In order to give machinability to hard and brittle AlN ceramics, the homogeneous dispersion of fine BN particles into AlN matrix was investigated. The AlN/BN nanocomposite was fabricated by hot-pressing AlN-BN composite powder, which was prepared by reducing and heating AlN particles containing a mixture of boric acid, urea and carbon. The nanocomposite containing 20 vol.% BN showed high strength, machinability and relatively high thermal conductivity.

Abstract: Machinable BN/Si3N4 and electroconductive TiN/Si3N4 nanocomposites were prepared, using powders synthesized through an in-situ nitridation method in flowing ammonia gas. Due to the homogeneous mixing of various components in the powders, nanocomposites with homogeneous second phase distribution in the matrix were obtained. These nanocomposites showed enhanced strengths and distinctive functionalities. BN/Si3N4 nanocomposite with 20-25vol% BN showed a relatively high strength of over 700 MPa and was able to be machined into complicated shapes with diamond bits. Electroconductive TiN/Si3N4 nanocomposite with 25vol% TiN showed a high strength of 1100MPa and low electrical resistivity of 1.1×10-2 ⋅cm, and was promising for electrical discharge machining.

Abstract: Multi-wall carbon nanotubes (MWCNTs) with a diameter of 20-30 nm were dispersed as a conductive phase into yttria stabilized tetragonal zirconia polycrystalline (3Y-TZP) to add electrical conductivity. The 3Y-TZP/MWCNT nanocomposites were fabricated by pressureless sintering under inert atmosphere. Electrical conductive function was successfully introduced by small amount of CNT addition. Critical volume fraction of the conductive phase for the percolation was analyzed and was found to be 0.390 vol% of CNT, which was much smaller than that for nano-sized carbon black dispersed 3Y-TZP (2.55 vol%). Microstructural investigation revealed that dispersed CNTs formed continuous 3-dimensional nano-network within the 3Y-TZP matrix, that contributed to the excellent conductive properties. Fracture strength was not improved much, while fracture toughness was increased by the CNT addition, due mainly to its crack bridging and/or pull-out mechanisms. It was considered that the use of anisotropic nano-sized conductive phase is advantageous to obtain electrically functionalized nanocomposite ceramics.

Abstract: 3Y-TZP/TiNiCo composites have been successfully fabricated by three step heating (dehydrogenation, hydrogen reduction, hot-pressing) of 3Y-TZP /NiO/TiH2/CoO powder mixtures. XRD analysis revealed that TiNi-base intermetallic compounds such as Ni4Ti3, NiTi, Ni3Ti had formed. The bending strength of 3Y-TZP/TiNiCo composites (~650 MPa) were much higher than those of 3Y-TZP monolith (
350 MPa) sintered at the same condition. The electrical resistivity characteristics indicated that 3Y-TZP/30 vol%TiNiCo composites were good electrical conductors. Cobalt addition to TiNi phase influenced on electrical properties of final composites, while their fracture strength was unchanged by the Co addition.

Abstract: Multi Wall Carbon Nanotubes (MWCNTs) with a diameter of 20-30 nm were used as a conductive phase to add electric conductivity to yttria stabilized tetragonal zirconia (3Y-TZP). Almost fully dense 3Y-TZP/MWCNTs nanocomposite was obtained by pressureless sintering under inert atmosphere and Hot Isostatic Pressing (HIP) treatment. The conductivity of the nanocomposites increased with increasing content of MWCNTs. Moreover, the fracture toughness increment of the composite was confirmed at 0.5 wt% addition. Scanning electron microscopy and transmission electron microscopy observation of the microstructures showed that MWCNTs were fairly homogeneously dispersed in the 3Y-TZP matrix.

Abstract: The Si3N4/YSiO2N composite in which crystalline YSiO2N was formed as grain boundary phase was fabricated by hot-pressing the mixture of SiO2, Si3N4 and Y2O3. The fracture toughness of this composite was significantly improved, compared to the Si3N4 composites containing Y5Si3O12N or Y2Si3O3N4 as a grain boundary phases. To clarify the toughening mechanism, the microstructure and the crack propagation profiles were observed.

Abstract: Si3N4 ceramics with V2O5 based glasses as sintering additives were successfully fabricated by a powder mixing process and rapid sintering by the PECS method. The fabricated materials by Pulsed Electric Current Sintering (PECS) exhibited very fine microstructure with α and β grains. Electric conductivity for the Si3N4/(V2O5-B2O3) and the Si3N4/(V2O5-B2O3-Al2O3) at room temperature were four and six orders of magnitude higher at room temperature, and two and three orders of magnitude higher at 1000 oC than the conventional Si3N4, respectively