Mechanical Alloying for Fabrication of Advanced Engineering Materials

254 Pages·2001·4.87 MB·English

by  M. Sherif El-Eskandarany

MECHANICAL ALLOYING FOR
FABRICATION OF ADVANCED
ENGINEERING MATERIALS
by
M. Sherif El-Eskandarany
Al Azhar University
Cairo, Egypt
NOYES PUBLICATIONS
WILLIAM ANDREW PUBLISHING
Norwich, New York, U.S.A.
JMR 3-Jul-01
Copyright © 2001 by Noyes Publications
No part of this book may be reproduced or
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Library of Congress Catalog Card Number:
ISBN: 0-8155-1462-X
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Library of Congress Cataloging-in-Publication Data
El-Eskandarany, M. Sherif.
Mechanical alloying for fabrication of advanced engineering materials /
Dr. M. Sherif El-Eskandarany.
p. cm.
Includes index.
ISBN 0-8155-1462-X (alk. paper)
1. Mechanical alloying. I. Title
TN698 .E44 2001
669'.95--dc21 2001032983
MATERIALS SCIENCE AND PROCESS TECHNOLOGY SERIES
Series Editors
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DIAMOND CHEMICAL VAPOR DEPOSITION: by Huimin Liu and David S. Dandy
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Other Related Titles
ADVANCED CERAMIC PROCESSING AND TECHNOLOGY, Volume 1: edited by Jon G. P.
Binner
CEMENTED TUNGSTEN CARBIDES: by Gopal S. Upadhyaya
CERAMIC CUTTING TOOLS: edited by E. Dow Whitney
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David E. Clark and Bruce K. Zoitos
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HANDBOOK OF ANALYTICAL TECHNIQUES IN CONCRETE SCIENCE AND TECHNOLOGY;
Principles, Techniques, and Applications: edited by V. S. Ramachandran and James J.
Beaudoin
HANDBOOK OF CERAMIC GRINDING AND POLISHING: edited by Ioan D. Marinescu, Hans
K. Tonshoff, and Ichiro Inasaki
HANDBOOK OF HYDROTHERMAL TECHNOLOGY: edited by K. Byrappa and Masahiro
Yoshimura
HANDBOOK OF INDUSTRIAL REFRACTORIES TECHNOLOGY: by Stephen C. Carniglia
and Gordon L. Barna
HANDBOOK OF PHYSICAL VAPOR DEPOSITION (PVD) PROCESSING: by Donald M. Mattox
MECHANICAL ALLOYING FOR FABRICATION OF ADVANCED ENGINEERING MATERIALS:
by M. Sherif El-Eskandarany
SHOCK WAVES FOR INDUSTRIAL APPLICATIONS: edited by Lawrence E. Murr
SOL-GEL TECHNOLOGY FOR THIN FILMS, FIBERS, PREFORMS, ELECTRONICS AND
SPECIALTY SHAPES: edited by Lisa C. Klein
SOL-GEL SILICA: by Larry L. Hench
SPECIAL MELTING AND PROCESSING TECHNOLOGIES: edited by G. K. Bhat
SUPERCRITICAL FLUID CLEANING: edited by John McHardy and Samuel P. Sawan
JMR- 3-Jul-01
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that he can meet all applicable safety and health standards.
To Professor Kenji Suzuki
You have taught me how to enjoy the experiments
and how to be a creative researcher. I owe a debt of
gratitude that I cannot entirely repay.
Acknowledgment
The continual support and encouragement of my family is
deeply and sincerely appreciated.
Contents
1 Introduction..............................................................................1
1.1 BACKGROUND.................................................................................1
1.2 HISTORY OF STORY OF MECHANICAL ALLOYING....................2
1.3 MILLING ............................................................................................5
1.3.1 Factors Affecting the Mechanical Alloying ...........................6
1.3.1.1 Types of Mills...........................................................7
1.3.1.2 Effect of Ball-to-Powder Weight Ratio................ 14
1.3.1.3 Effect of Milling Atmosphere............................... 16
1.4 MECHANISM OF MECHANICAL ALLOYING............................ 16
1.4.1 Ball-Powder-Ball Collision................................................. 16
1.5 NECESSITY OF MECHANICAL ALLOYING................................ 19
REFERENCES.......................................................................................... 19
2 Fabrication of ODS Alloys....................................................22
2.1 INTRODUCTION AND BACKGROUND....................................... 22
2.2 APPLICATIONS AND EXAMPLES................................................ 24
2.2.1 ODS Ni-Base Superalloys and Fe-Base
High-Temperature Alloys..................................................... 24
2.2.1.1 INCONEL MA 754................................................ 25
2.2.1.2 INCONEL MA 6000.............................................. 25
2.2.1.3 INCOLOY MA 956................................................ 27
REFERENCES.......................................................................................... 33
xi
xii Mechanical Alloying
3 Fabrication of Nanophase Materials.................................... 34
3.1 INTRODUCTION.............................................................................34
3.2 INFLUENCE OF NANOCRYSTALLINITY ON MECHANICAL
PROPERTIES: STRENGTHENING BY GRAIN SIZE
REDUCTION ................................................................................... 35
3.3 FORMATION OF NANOCRYSTALLINE MATERIALS BY
BALL MILLING TECHNIQUE....................................................... 36
3.3.1 Mechanism(s)........................................................ 37
3.3.2 Selected Examples.................................................38
3.4 CONSOLIDATION OF THE NANOCRYSTALLINE MILLED
POWDERS ......................................................................................41
REFERENCES..........................................................................................43
4 Fabrication of Nanocomposite Materials............................. 45
4.1 INTRODUCTION AND BACKGROUND.......................................45
4.2 FABRICATION OF SiCp/Al COMPOSITES BY MECHANICAL
SOLID STATE MIXING...................................................................47
4.3 PROPERTIES OF MECHANICALLY SOLID-STATE FABRICATED
SiCp/Al COMPOSITES ....................................................................48
4.3.1 X-Ray Analysis.....................................................................48
4.3.2 Morphology and Metallography........................................... 49
4.3.3 TEM Observations................................................................ 52
4.3.4 Consolidation.......................................................................53
4.3.5 Properties.............................................................................56
4.4 MECHANISM OF FABRICATION..................................................58
4.4.1 Formation of Agglomerates Coarse Composite
SiCp/Al Powder Particles..................................................... 58
4.4.2 Disintegration of the Agglomerates Composite
SiCp/Al Powder Particles..................................................... 59
4.4.3 Formation of Nanocomposite SiCp/Al Powder
Particles................................................................................59
4.4.4 Consolidation of Nanocomposite SiCp/Al Powder
Particles................................................................................59
REFERENCES..........................................................................................60
5 Mechanically Induced Solid State Carbonization................62
5.1 INTRODUCTION.............................................................................62
5.2 DIFFICULTIES OF PREPARATIONS.............................................. 64
Contents xiii
5.3 FABRICATION OF NANOCRYSTALLINE TiC BY
MECHANICAL ALLOYING METHOD ......................................... 65
5.4 PROPERTIES OF MECHANICALLY SOLID-STATE
REACTED TiC POWDERS............................................................. 68
5.4.1 Structural Changes with the Milling Time ........................... 68
5.4.2 Morphology.......................................................................... 76
5.4.3 Consolidation....................................................................... 78
5.4.4 Mechanism of Fabrication................................................... 83
5.5 OTHER CARBIDES PRODUCED BY MECHANICAL
ALLOYING...................................................................................... 86
5.5.1 Fabrication of β-SiC Powders.............................................. 86
5.5.2 Fabrication of Nanocrystalline WC Powders...................... 88
5.5.3 Fabrication of Nanocrystalline ZrC Powders...................... 89
REFERENCES.......................................................................................... 93
6 Mechanically Induced Gas-Solid Reaction ..........................94
6.1 INTRODUCTION............................................................................. 95
6.2 FABRICATION OF NANOCRYSTALLINE TiN BY
REACTIVE BALL MILLING........................................................... 95
6.3 PROPERTIES OF REACTED BALL MILLED TiN POWDERS.... 96
6.3.1 Structural Changes with the Milling Time ........................... 96
6.3.2 Morphology.......................................................................... 98
6.4 MECHANISM OF FABRICATION................................................108
6.4.1 RBM Technique for Preparing TiN Powders.....................108
6.5 OTHER NITRIDES PRODUCED BY RBM..................................109
6.6 FABRICATION OF NANOCRYSTALLINE SOLID
SOLUTION NiTiH BY REACTIVE BALL MILLING................... 113
REFERENCES........................................................................................ 117
7 Mechanically Induced Solid-State Reduction....................118
7.1 INTRODUCTION........................................................................... 119
7.2 REDUCTION OF CuO WITH Ti BY ROOM
2
TEMPERATURE ROD MILLING................................................. 119
7.3 PROPERTIES OF ROD MILLED POWDERS..............................120
7.3.1 Structural Changes with the Milling Time .........................120
7.3.2 Metallography.....................................................................125
7.3.3 DTA Measurements............................................................126
7.4 MECHANISM OF MSSR ..............................................................126