Papers by Keyword: Pulsed Electric Current Sintering (PECS)

Abstract: Chromium oxide is a promising material for applications where excellent corrosion resistance, high hardness, and high wear resistance are needed. However, its use is limited because of low fracture toughness. Improvement of fracture toughness of chromium oxide while maintaining its afore mentioned key properties is therefore of high interest. In this communication we study the possibility of increasing the toughness of pulsed electric current sintered (PECS) chromium oxide by the addition of graphene oxide (GO). The indentation fracture toughness was improved markedly with the addition of graphene oxide. Materials prepared by direct chemical homogenization had better fracture toughness. In composites with 10 vol.% GO piling of thin graphene oxide layers resulted in the formation of graphite layers between Cr₂O₃ and in carbide formation, which were observed to be the main reasons for the degradation of the mechanical properties. The distribution of graphene oxide was more homogeneous, when the GO amount was 0.1 vol.% and the formation of graphitic layers were avoided due to lesser amount of GO as well as ultrasonic treatment following the ball milling.

Abstract: High temperature low friction materials are sought for use in engines in order to reduce energy consumption of the machines. Due to the high service temperatures solid lubricating materials are necessary. This study is designed to find the optimal processing conditions for preparing these materials by pulsed electric current sintering. In this study, the Al₂O₃ - 15wt% ZrO₂ (AZ) nanocomposite was modified with 3 wt% of self-lubricating component (CaF₂, BaF₂, MoS₂, WS₂, h-BN, or graphite). After the preparation of the alumina-zirconia powder mixture solid lubricant powder was added. Powders were then mixed in ethanol for 24 h, dried in a rotary evaporator, and in oven at 80°C for 24 h. The particle size distribution of the powders was established with the laser method. Powders were compacted by using pulsed electric current sintering technique at 1300 °C with 50 MPa for 5 min in vacuum. The structure of the materials was studied with XRD and SEM. Density of the compacts was measured with the Archimedes method and their hardness was evaluated by applying HV1 hardness with the instrumented indentation techniques. Their mechanical behavior was further studied with the instrumented scratch testing.

Abstract: The coefficient of friction was very important factor for the applications of high temperature parts. In vehicles, the coefficient of friction was decreased due to lubricants as like engine oil etc. Lubricant such as oils is difficult to apply at high temperature. To apply high temperature parts, lubricants were demanded for high temperature stability. This work is to use the pulsed electric current sintering (PECS) technique and the atmospheric plasma spraying (APS) method in order to make self-lubricating Al₂O₃-15wt% ZrO₂-solid lubricant composites. We focused on the coefficient of friction for the fabrication method of self-lubricating Al₂O₃-15wt% ZrO₂-solid lubricant composites. We compared with the coefficient of friction of PECSed and APSed composites. The surface roughness of PECSed Al₂O₃-15wt% ZrO₂-solid lubricant composites were 0.06 ~ 0.31 μm of Ra and 10.16 ~ 33.12 μm of Ry. In the case of APSed Al₂O₃-15wt% ZrO₂-solid lubricant composites, as-coated samples were 6.56 ~ 11.42 μm of Ra and 59.68 ~ 81.79 μm of Ry, and polished samples were 1.12 ~ 3.70 μm of Ra and 11.66 ~ 32.22 μm of Ry. The coefficient of friction of PECSed and APSed Al₂O₃-15wt% ZrO₂-solid lubricant composites were 0.19 ~ 0.49 and 0.41 ~ 0.61, respectively.

Abstract: Pulsed electric current sintering allows densifying most ceramics at high heating and cooling rates within very short times at elevated temperature, allowing to minimise grain growth. In order to fully explore the PECS potential, it is beneficial to flow the current through the powder compact by either using conductive powder or a powder compact that becomes conductive during densification. Although in-situ Joule heating of the powder compact allows very fast heating rates, it does not necessarily result in a homogeneous temperature distribution. The influence of the current flow on densification and the impact of electrical conductivity on the temperature distribution during PECS are illustrated. The PECS technology at present is limited to the fabrication of simple geometrical shapes. Electrical Discharge Machining (EDM) on the contrary allows production of complex shapes, providing the ceramic has a minimum electrical conductivity. Although EDM has no mechanical impact, the thermal impact is high and the EDM parameters should be carefully selected in order to optimise surface quality and component strength. During wire-EDM, the fast and rough initial cut has to be followed by a sequence of lower energy finishing cuts to optimise the surface quality. The case studies presented are B4C-TiB2 ceramics and ZrO2-based composites with electrically conductive phase addition.

Abstract: The intermetallic compound Nb3Al is widely investigated because of its high temperature strength, superior superconductivity and relatively small density. As Nb3Al has an extremely high melting point and lack of deformability, it is impossible to prepare it by using the conventional metallurgy. In this study, a Nb-Al intermetallic compound was prepared by multi-layered roll-bonding of elemental Nb and Al foils. The process consisted of the accumulative roll-bonding (ARB) for making a laminated Nb/Al sheet and the subsequent heat treatment promoting a solid-phase reaction in the laminated Nb/Al sheet. Accumulated foils were roll-bonded at 573 K. The rolling reduction at 1 pass was ~50%, and the final rolling reduction at 4 passes was ~94%. A pulsed electric current sintering (PECS) process was used for the subsequent heat treatment. The microstructures produced at each processing stage were characterized by X-ray diffraction (XRD), optical microscopy and scanning electron microscopy (SEM) equipped with energy-dispersive X-ray spectroscopy (EDS). A homogeneous intermetallic compound of Nb3Al could be obtained after the subsequent heat treatment for 1.8 ks at 873 K and for 0.9 ks at 1673 K.

Abstract: Crack-healing effectiveness of nano-Ni+SiC co-dispersed Al2O3 hybrid materials by heat treatment was studied as well as oxidation behavior. The starting powder mixture was prepared by drying slurry consisting of distilled water, Al2O3, SiC powder and nickel nitrate. After reduction, the powder mixture was densified by pulsed electric current sintering. Cracks were introduced by a Vickers indenter. Specimens were exposed into air at temperature ranging from 1000 and 1300°C for 1 and 48 h. Thickness of oxidized zone in SiC+nano-Ni/Al2O3 thinner than nano-Ni/Al2O3. Cracks of SiC+nano-Ni/Al2O3 disappeared completely, for example, by oxidation at 1200°C for 6 h, as same as nano-Ni/Al2O3. Bending strength of crack-disappeared SiC+nano-Ni/Al2O3 showed 519 MPa and was comparable with that of as-sintered one. SiC+nano-Ni/Al2O3 pocesses crack-healing effectiveness with improved high-temperature oxidation resistance.

Abstract: Densification and sample temperature of alumina (Al2O3) powder during pulsed electric current sintering with different pulse power generators, inverter type and pulsed direct current type were investigated. The sample temperature for inverter generator was higher than that for pulsed direct current generator in same die temperature ranging form 800 to 1400oC. The relative density increased with increasing of the sample temperature.

Abstract: Iron aluminides exhibit good resistance to high-temperature oxidizing and sulphidizing environments and have potential for structural applications at high temperatures under corrosive environments. In this study, an Fe-Al intermetallic compound was prepared by multi-layered roll-bonding of elemental Fe and Al foils. The process consisted of the accumulative roll-bonding (ARB) for making a laminated Fe/Al sheet and the subsequent heat treatment promoting a solid-phase reaction in the laminated Fe/Al sheet. Accumulated foils were rolled and bonded at room temperature or 573 K. A pulsed electric current sintering (PECS) process was used for the subsequent heat treatment. The microstructures produced at each processing stage were characterized by optical microscopy and scanning electron microscopy (SEM) equipped with energy-dispersive X-ray spectroscopy (EDS). Vickers microhardness testing was used for hardness determination. A homogeneous intermetallic compound of Fe3Al or FeAl could be obtained after the subsequent heat treatment for 1.8 ks at 873 K and for 3.6 ks at 1173 K.

Abstract: Pulsed electric current sintering (PECS) was applied to the bonding of W (tungsten) to Cu (copper) using Nb or Ni powder as an intermediate layer. The influence of the intermediate layer on the bond strength of the joint was investigated by observation of the microstructure. The bonding process was carried out at carbon-die temperatures of 1073 and 1173 K for 1.8 ks at a bonding pressure of 130 MPa. The bond strength of the joint with an intermediate layer of Ni powder was 250 MPa. This joint fractured in the Cu base during the tensile test. SEM observations of the joint with an intermediate layer of Ni revealed that a diffusion layer formed at the joint interface.

Abstract: To make the tungsten and copper joint, several methods has been tried using the diffusion bonding system. When the thin plating Ni layer was used as the interlayer on tungsten surface, it bonded with copper under low bonding temperature and short holding duration by the pulse electric current sintering (PECS) machine. The effects of bonding temperature, bonding duration time, bonding pressure and the difference of specimen shape on the bonding strength were investigated. The tensile strength of joints depended on these factors. Highest strength attained to the copper tensile strength.