Mechanical Alloying, Second Edition: Nanotechnology, Materials Science and Powder Metallurgy

340 Pages·2015·56.12 MB·English

by  M. Sherif El-Eskandarany

Mechanical Alloying
Mechanical Alloying
Nanotechnology, Materials Science
and Powder Metallurgy
Second Edition
M. Sherif El-Eskandarany
Kuwait Institute for Scientific Research
Kuwait
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Dedication
To Egypt, Japan, and Kuwait
How do I say thank you when “Thank You” isn’t enough?
To My Professor Kenji Suzuki
You have taught me how to enjoy the experiments
and how to be a creative researcher.
To My Lovely Family; Mitsuko, Osama, and Nasser El-Eskandarany
I owe a debt of gratitude that I cannot entirely repay!
About the author
M. Sherif El-Eskandarany is a full professor of Materials Science and
Nanotechnology, gained his Master’s and Doctoral degrees at Tohoku University,
Japan. He worked as professor at Institute for Materials Research, Tohoku
University, Japan, and professor at Faculty of Engineering, Al-Azhar University,
Egypt. Until 2007, he worked as First-Under-Secretary of Egyptian Minster of
Higher Education and Scientific Research, and the former Vice-President of the
Academy of Scientific Research and Technology of Egypt. He has joined Kuwait
Institute for Scientific Research as Senior Research Scientist in 2007. Since 2007,
he works as Senior Research Scientist and Program Manager of Nanotechnology
and Advanced Materials. He has published more than 250 peer-reviewed papers in
highly cited international scientific journals in the field of materials science,
nanoscience, and nanotechnology and more than 200 papers in the proceedings of
several international conferences. He is the author of six scientific books and
received many national and international awards, one of them given by the Former
EgyptianPresident.
Preface
The mechanical alloying (MA) process, using ball-milling and/or rod-milling tech-
niques, has received much attention as a powerful tool for the fabrication of several
advanced materials including equilibrium, nonequilibrium (e.g., amorphous parti-
cles, quasicrystals, nanocrystalline materials, etc.), and nanocomposite materials. In
addition, it has been employed for reducing some metallic oxides by milling the
oxide powders with metallic reducing agents at room temperature. The MA is a
unique process in that a solid-state reaction takes place between the fresh powder
surfaces of the reactant materials at room temperature. Consequently, it has been
employed to produce alloys and compounds that are difficult or impossible to
obtainbytheconventionalmeltingandcastingtechniques.
This book is intended primarily to serve as an introduction to the MA process,
including a general description of the process, starting material requirements, the
equipment, characterizations of the milled powders, consolidation techniques, and
utilizations of the mechanically alloyed/milled powder for surface protective coat-
ingapplications.
The book contains several examples of selected advanced materials that have
been fabricated by MA during the last three decades. This book aims at the scien-
tists on materials, nanoscience, nanotechnology, powder metallurgy, and metallur-
gists in industry. Researchers, senior undergraduate and graduate students may also
benefitfromthisbook.
Chapter 1 gives a brief introduction about the approaches used for preparations
of advanced materials via mechanically and thermally assisted approaches. A brief
history of the usage of ball milling for fabrications of wide spectrum of advanced
andnewmaterialswithinthelast40yearsispresentedinChapter2.Inthischapter,
the types of ball mills used in MA are also presented. Chapter 3 discusses in more
detail the factors affecting the MA, mechanical milling, andmechanical disordering
processes.Chapter4presentstheapplicationsofball-millingtechniqueinnanotech-
nology for fabrication of nanocrystalline materials via top-down approach. The
chapter gives several typical examples of the nanocrystalline systems fabricated by
ball milling and how they can be consolidated into bulk nanocrystalline materials
usingadvancedconsolidationtechniques.
In Chapter 5, we shall discuss the mechanism of synthesizing nanocrystalline
metalcarbides,usinghigh-energyball-millingtechnique.Chapter6givessometyp-
ical examples of employing the ball-milling method for reduction of metal oxides
by milling with metallic reducing agents. Employing of mechanical mixing for fab-
rication of nanocomposite powders is discussed in Chapter 7. Reactive ball milling
xiv Preface
techniqueforsynthesizingofmetalnitrides andmetalhydrides atroomtemperature
isdiscussedindetailinChapters8and9,respectively.
Chapter 10 presents the solid-state amorphization reactions for fabrication of
amorphous and metallic glassy powders. Finally, in Chapter 11, we shall discuss
one of the most vital applications of mechanically alloyed and ball-milled powders
intheareaofsurfaceprotectivecoating,usingadvancedsprayingtechnology.
M.SherifEl-Eskandarany
Kuwait
April2015
Acknowledgment
The continual support and encouragement of Dr. Naji Al-Mutairi, the Director
General, Kuwait Institute for Scientific Research, the Energy and Building
Research Center, Kuwait Institute of Scientific Research, and the Government of
Kuwaitaredeeplyandsincerelyappreciated.
1
Introduction
Thecapabilityofanysocietiesalongthehumanhistoryondevelopingandinstigatingofnew
materialsthatfittheirneedshasledtotheadvancementoftheirperformanceandranking
worldwide.Thegapdifferencesonthe“leveloflife,”indexedbytheprogressmadeon
health,education,industry,economic,culture,etc.,betweenacountrytocountryandregion
toanotherarealwaysattributedtotheman’sabilityfordevelopingmaterialsand
manufacturingequipmentanddevisesusedformaterialsfabricationsandcharacterizations.
However,therearemanyapproachesandtechniquesusedforproducingtheadvanced
materials;mechanicalalloyinghasbeenreceivinggreatattentionsandconsiderationsasa
uniqueprocessforsynthesizingofnewadvancedmaterialsfamiliesthatcannotbeobtained
byanyothertechniques.Nanostructuredmaterials,nanoparticles,nanocomposites,carbon
nanotubes,amorphousandmetallicglassyandalloysaresomeofthosenewengineering
materialsthatcanbesuccessfullyobtainedbysucharoomtemperaturewayoffabrication.
Thefigureshowsanimageofhighresolutiontransmissionelectronmicroscope(HRTEM)
forasinglewallcarbonnanotube(SWCNT)preparedbytheauthor,usingachemicalvapor
deposition(CVD)equipmenthousedintheNanotechnologyLaboratory,Energyand
BuildingResearchCenter(EBRC),KuwaitInstituteforScientificResearch(KISR).
1.1 Advanced materials
Life in the current twenty-first century cannot be depending on limited groups of
materials, instead it is dependent on unlimited families of advanced materials.
MechanicalAlloying.DOI:http://dx.doi.org/10.1016/B978-1-4557-7752-5.00001-2
©2015ElsevierInc.Allrightsreserved.
2 MechanicalAlloying
Space
industry
Sports
Textiles
goods
Metallic glasses
Reenneewrgayble Semiconductors RS MA CVD Nanomaterials Food
Advanced
Medicine LA materials PECVD Agriculture
Auintodmusotrbyile setisopmocona ALD EBPVD PVD slairetamoiB Health care
N
Smart materials
Environment Military
Electronics
Figure1.1 Advancedmaterials,suchasmetallicglasses,nanomaterials,biomaterials,smart
materials,nanocomposites,semiconductors,etc.,thatareusedindifferentindustrial,medical,
electronic,andmanyothersectorsarepreparedbywidevarietyofmaterialsprocessing.
Laptop computers, digital cameras, smart cell phones, nanosensors, microwave
ovens, computerized cars, bio-microelectromechanics, thin film photovoltaics,
and many other intelligent devices and instruments used in many sectors require
special type of materials that have superior properties. In spite of the traditional
categories of materials (metals and metal alloys, ceramics, polymer, and compo-
sites) that do not match well with the whole modern industries’ requirements, a
newcomer so-called “advanced materials” has found an important space in the
functional classifications of the materials. However, the advanced materials can
be defined in numerous ways based on their properties and usages, and we can
define them as those materials that show advances over the traditional materials
and used for manufacturing of high-tech products. Thus, the advanced materials
refertoallnewmaterialsandtheirdevelopmenttotheexistingmaterialstoobtain
superior, unique, and high performance in one or more properties. Amorphous
and metallic glasses, nanomaterials and nanocomposites, biomaterials, semicon-
ductors, and smart or so-called intelligent materials are some types of the
advanced materials used in differentsectors (Figure 1.1).