Mechanical Alloying and Milling

492 Pages·2004·6.15 MB·English

by  Cury Suryanarayana

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Mechanical Alloying
and Milling
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MATERIALS ENGINEERING
1. Modern Ceramic Engineering: Properties, Processing, and Use in Design. Second Edition,
Revised and Expanded, David W. Richerson
2. Introduction to Engineering Materials: Behavior, Properties, and Selection,
G. T. Murray
3. Rapidly Solidified Alloys: Processes • Structures • Applications,
edited by Howard H. Liebermann
4. Fiber and Whisker Reinforced Ceramics for Structural Applications,
David Belitskus
5. Thermal Analysis of Ceramics, Robert F. Speyer
6. Friction and Wear of Ceramics, edited by Said Jahanmir
7. Mechanical Properties of Metallic Composites, edited by Shojiro Ochiai
8. Chemical Processing of Ceramics, edited by Burtrand I. Lee
and Edward J. A. Pope
9. Handbook of Advanced Materials Testing,
edited by Nicholas P. Cheremisinoff and Paul N. Cheremisinoff
10. Ceramic Processing and Sintering, M. N. Rahaman
11. Composites Engineering Handbook, edited by P. K. Mallick
12. Porosity of Ceramics, Roy W. Rice
13. Intermetallic and Ceramic Coatings, edited by Narendra B. Dahotre
and T. S. Sudarshan
14. Adhesion Promotion Techniques: Technological Applications,
edited by K. L. Mittal and A. Pizzi
15. Impurities in Engineering Materials: Impact, Reliability, and Control,
edited by Clyde L. Briant
16. Ferroelectric Devices, Kenji Uchino
17. Mechanical Properties of Ceramics and Composites: Grain
and Particle Effects, Roy W. Rice
18. Solid Lubrication Fundamentals and Applications, Kazuhisa Miyoshi
19. Modeling for Casting and Solidification Processing,
edited by Kuang-O (Oscar) Yu
20. Ceramic Fabrication Technology, Roy W. Rice
21. Coatings of Polymers and Plastics, edited by Rose A. Ryntz
and Philip V. Yaneff
22. Mechanical Alloying and Milling,C. Suryanarayana
Additional Volumes in Preparation
Micromechatronics, Kenji Uchino and Jayne Giniewicz
Ceramic Processing and Sintering: Second Edition, Mohamed N. Rahaman
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Mechanical
Alloying
and
Milling
C. Suryanarayana
MarcelDekker NewYork
4103-X_Suryanarayana_Prelims_R1_071504
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4103-X_Suryanarayana_Foreword_R1_071504
Foreword
Chemists sometimes talk of ‘brute force methods’ and of ‘soft chemistry’, with a
clear preference for the latter. At first sight, hurling small samples of metallic
powder violently between hard grinding balls would seem the apotheosis of brute-
force methods, and yet that process (called ‘mechanical alloying’ or ‘mechanical
milling’,accordingtothenatureofthepowder)hasattractedever-growingnumbers
of metallurgical researchers in the past two decades. Several kinds of metastable
structures, crystalline or amorphous, can be prepared in a wide range of composi-
tions, and the literature has burgeoned.
ProfessorSuryanarayana,knowntoallhismanyfriendsandadmirersasSurya
forshort,hasbeeninvolvedwiththistypeofresearchsincethebeginning,andhasan
unequalled familiarity with the entire literature. In this book, he has exploited this
expertise to present the most thorough treatment of the field to see the light of day.
I commend it cordially to the metallurgical profession.
Robert W. Cahn, FRS
(UniversityofCambridge)
iii
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MD: SURYANARAYANA, JOB:03320,PAGE: iv
4103-X_Suryanarayana_Preface_R2_080304
Preface
Mechanical alloying and milling continues to be a fascinating field of investigation
for nearly four decades. Originally developed in the late 1960’s for the production
of oxide dispersion strengthened (ODS) nickel-base superalloys, the technique of
mechanical alloying has now branched out to the synthesis of a variety of
equilibrium and non-equilibrium alloy phases, including solid solutions, intermetal-
lics,quasicrystals,amorphousalloys,andbulkmetallicglasses.Nanostructuredma-
terials, hydrogen storage materials, and even exotic materials are being synthesized
using this simple, inexpensive, and scaleable technique. It is a continually growing
field with over 500 research papers being published annually. It is also an accepted
industrial processing method with varied applications for these materials.
Several dedicated conferences have been held on this topic and their Proceed-
ingshavebeenpublished.Afewmonographshavealsobeenpublishedonthistopic.
But, in majority of these, the treatment has been rather cursory, with focus on
selectedtopicsandnotallthetopicshavebeencovered.Thepurposeofthispresent
bookistoserveasaresourceforbothstudentsandresearcherswhorequireatimely
and comprehensive treatment of the subject.
The present book surveys the vast field of Mechanical Alloying (MA) (and the
relatedtechniques)fromascientificandtechnologicalpointofview.Theorganization
of the book progresses logically from the historical perspective of the technique,
through a description of the process, different metastable effects produced, mecha-
nismsofphaseformation,toapplicationsofmechanicallyalloyedproducts.Thebook
comprises19chapters.Chapter1presentsanoverviewofthedifferentnon-equilibrium
processingtechniquespresentlyavailabletosynthesizeadvancedmaterialsandsetsthe
tonefortherestofthebook.Abriefhistoricalintroductionofthedevelopmentofthe
technique of MA is presented in Chapter 2 followed by introduction of the different
variants of MA in Chapter 3. A detailed description of the mills and the effect of
processvariablesonphaseconstitutionarediscussedinChapters4and5,respectively.
Chapter 6 describes the mechanismofalloying in different typesof powdercombina-
tions. A detailed description of the techniques to measure particle size, lattice strain,
phase constitution, and microstructure of the as-milled powder and consolidated
productsispresentedinChapter7.Thetemperatureriseduringmillingisdiscussedin
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4103-X_Suryanarayana_Preface_R2_080304
vi Preface
Chapter 8. The next four Chapters deal with the metastable constitutional effects
achievedinthemilledpowdersofdifferentalloysystems.TheseincludeSolidSolutions
(Chapter 9), Intermetallics (including Quasicrystals) (Chapter 10), Disordering of
Intermetallics (Chapter 11), and Amorphous Alloys (Chapter 12). Formation of
nanostructures and nanocomposites, their properties, and potential applications are
describedinChapter13.Synthesisofalloyphases,purificationofmetalsbyexchange
reactions,preparation ofrefractorycompounds,etc.by mechanochemical methodsis
discussedinChapter14.Theubiquitousproblemofpowdercontaminationandways
ofavoiding/minimizingitarepresentedinChapter15.Chapter16brieflyexplainsthe
different modeling attempts that have been undertaken to-date and their current
limitations. The existing and potential applications of the mechanically alloyed
productsaredescribedinChapter17.Safetyhazardsassociatedwithpowderhandling
are outlined in Chapter 18 and the last Chapter makes some concluding remarks on
the present status of mechanical alloying and milling.
This book is primarily intended for use by graduate students and research
personnel involved with this technique of powder processing. Industry personnel
connected with the production and characterization of mechanically alloyed prod-
ucts, and wishing to exploit these materials for potential applications will also find
this book very useful in understanding the basic scientific features. Scientists begin-
ning their research work in this area can also find this book helpful from the clear
introduction to the several different topics (the mills, process variables, methods of
characterization of mechanically alloyed powders, types of phases that could be
produced, etc.) and also the detailed explanations of the various aspects associated
withthistechnique.Personsinvolvedinthenon-equilibriumprocessingofmaterials
in general will also benefit from a comparison of this technique with other tech-
niques. Because of these attractive features, this book could also be of use for a
graduate level course in processing of materials.
I have strived to make the discussion of topics as comprehensive and self-
containedaspossible.Forthisreason,Ihaveincludedunusuallyextensive(andmost
comprehensive at the time of writing) listing of the results of different metastable
effectsobtainedinvariousalloysystems.Extensivelistsofreferences havealsobeen
providedattheendofeachChapter.Theseareimportantfeaturesofthisbook.Be-
causeofthis,thebookcouldbeanexcellentsourceofreferencesfortheliteratureon
MA.
Thetreatmentofthesubjectmatterhasbeensimpleandhasbeenpresentedin
an easy to understand manner. However, the scientific accuracy has not been com-
promised. The most recent literature has also been cited, including several papers
published in 2003! The ISMANAM conference proceedings have been very good
sources of the most recent literature, in addition to the archival journals in which
research papers have been published.
The field of Mechanical Alloying has become quite diversified with active
contributions from materials scientists, chemists, physicists, and engineers. There-
fore, in surveying such a diverse field, it is possible that some errors have crept in.
Iwouldbemostpleasedifthediscerningreaders,whospotanymistakes,bringthem
to my notice at [email protected].
C. Suryanarayana
Orlando, October 2003
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4103-X_Suryanarayana_Acknowledgements_R2_071504
Acknowledgements
Inwritinganybookitisunlikelythattheauthorhasworkedentirelyinisolationand
withoutassistancefromcolleaguesandfriends.Iamcertainlynotanexceptionandit
is with great pleasure that I acknowledge those people that have contributed, in
various ways, to the successful completion of this book.
In my long journey in the field of non-equilibrium processing, I had the good
fortune to interact with a great number of colleagues, from all of whom I have
learned immensely and benefited greatly in understanding the complexities of meta-
stable phases. In alphabetical order, they are T.R. Anantharaman, R.W. Cahn,
A. Inoue, E. Ivanov, C.C. Koch, E.J. Lavernia, T. Masumoto, J.J. Moore, P.
Ramachandrarao, S. Ranganathan, and R. Sundaresan. I am particularly thankful
to Professors T.R. Anantharaman, R.W. Cahn, T. Masumoto, and J.J. Moore for
theirguidanceandadviceatdifferentstagesinmyprofessionalcareer.Iamgrateful
to them for sharing with me the excitement of working in the general field of non-
equilibrium processing of materials. Particular mention may be made of E. Ivanov,
C.C. Koch, E.J. Lavernia, and R. Sundaresan for collaborating with me at various
stagesinworkinginthefieldofmechanicalalloyingandsharingtheirexpertisewith
me. I was also fortunate to work with many talented undergraduate and graduate
students and I am thankful to them for their dedicated efforts in joining me in
pushing the frontiers of mechanical alloying farther. I hope that they have learned
from me at least a fraction of what I have learnt from them.
Alargenumberoffriendshavehelped meby supplyingfiguresthathavebeen
included in different Chapters of the book. I am thankful to them. Additionally,
manystudentshavehelpedinthearduoustaskofdrawingsomeofthefigures.They
are Chandrasen Rathod, Bhaskar Srivastava, Ms. Honey Dandwani, Soon-Jik
Hong,andK.V.KrishnaMurthy.Iamparticularlyindebtedtothemfortheirhelp.
The aesthetics of the figures are mostly due to their efforts.
Parts of the book were written while the author was a Guest Scientist at the
GKSS Research Center in Geesthacht, Germany, during the summers of 2002 and
2003. I am deeply obliged to Thomas Klassen and Ru¨diger Bormann for providing
kindhospitalityandfortheseveralusefuldiscussionsduringthepost-lunchwalksin
the woods. Thomas Klassen has also read some Chapters and made constructive
vii
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