mechanical alloying for fabrication of advanced engineering materials

254 Pages·2006·4.87 MB·English

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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Stephen M. Rossnagel, IBM Thomas J. Watson Research Center
Rointan F. Bunshah, University of California, Los Angeles (1927–1999), founding editor
Electronic Materials and Process Technology
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CHEMICAL VAPOR DEPOSITION OF TUNGSTEN AND TUNGSTEN SILICIDES: by John E.
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CONTACTS TO SEMICONDUCTORS: edited by Leonard J. Brillson
DIAMOND CHEMICAL VAPOR DEPOSITION: by Huimin Liu and David S. Dandy
DIAMOND FILMS AND COATINGS: edited by Robert F. Davis
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v
vi Series
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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
CERAMIC FILMS AND COATINGS: edited by John B. Wachtman and Richard A. Haber
CORROSION OF GLASS, CERAMICS AND CERAMIC SUPERCONDUCTORS: edited by
David E. Clark and Bruce K. Zoitos
FIBER REINFORCED CERAMIC COMPOSITES: edited by K. S. Mazdiyasni
FRICTION AND WEAR TRANSITIONS OF MATERIALS: by Peter J. Blau
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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in this publication should satisfy himself as to such suitability, and
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