Dense nanostructured materials obtained by spark plasma sintering and field activated pressure assisted synthesis starting from mechanically activated powder mixtures

The preparation of highly dense bulk materials with a grain size in the range of a few to a few hundreds nanometers is currently the objective of numerous studies. In our research we have achieved a measure of success in this regard by using the methods of mechanically-activated, field-activated, pressure-assisted synthesis, MAFAPAS, which has been patented, and mechanically-activated spark plasma sintering, MASPS. Both methods, which consist of the combination of a mechanical activation step followed by a consolidation step under the simultaneous influence of an electric field and mechanical pressure, have led to the formation of dense nanostructured ceramics, intermetallics, and composite…

Synthesis of nanocrystalline NbAl3 by mechanical and field activation

Abstract The mechanically-activated, field-activated, and pressure-assisted synthesis (MAFAPAS) process, which combines the simultaneous synthesis and densification of nanophase materials, was utilized to produce nanocrystalline NbAl3 material from Nb+3Al mechanically activated powders. Nb+3Al elemental powders were co-milled for a short time in a specially designed planetary ball mill to obtain nanoscale distributed reactants but to avoid the formation of any product phases. These were then subjected to high AC currents (1500–1650 A) and uniaxial pressures (56–84 MPa). Under these conditions, a reaction is initiated by field activation and completed within a short period of time (3–6 min).…

Electrochemical behavior of nanocrystalline iron aluminide obtained by mechanically activated field activated pressure assisted synthesis

Abstract The corrosion behavior of nanocrystalline iron aluminide obtained by mechanically activated field—activated pressure—assisted synthesis was investigated in sulphuric acid media using potentiodynamic curves. The effect of microstructure on the electrochemical corrosion resistance was investigated by examining samples which were heat treated to effect a change in crystallite size and microdistorsion.

Simultaneous Synthesis and Consolidation of Nanostructured MoSi2

A new process combining electric field activation and the imposition of pressure from mechanically activated powder mixtures is demonstrated as a means to simultaneously synthesize and densify nano-MoSi2 in one step. Nanophase reactants (Mo + 2Si) produced by mechanical activation are reacted by field activation with the simultaneous application of a uniaxial pressure. Mo + 2Si powders were comilled in a specially designed planetary mill to obtain nanometric reactants but to avoid formation of any product phases. These were then subjected to high alternating currents (1600 A) and pressures of 106 MPa. Under these conditions, a reaction is initiated and completed within a short period of tim…

Production of dense nanostructured materials using FAPAS and SPS techniques

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One-Step Synthesis and Consolidation of Nanophase Iron Aluminide

The simultaneous synthesis and densification of nanophase iron aluminide is investigated. Elemental nanophase reactants produced by mechanical activation were reacted by field activation with the simultaneous application of uniaxial pressure. The process was demonstrated in this work by the synthesis of dense nanometric FeAl. Iron and aluminum powders were co-milled in a specially designed planetary mill to obtain nanometric reactants and to avoid formation of any product phases. These powders were then subjected to high AC currents (1250–1500 A) and pressures in the range of 70–106 MPa. Under these conditions, a reaction was initiated and completed within a short period of time (2.5–3.5 mi…

Synthesis of bulk FeAl nanostructured materials by HVOF spray forming and Spark Plasma Sintering

Abstract This paper examines the efficiency of two consolidation processing techniques: High Velocity Oxy-Fuel (HVOF) spray forming and Spark Plasma Sintering (SPS) to obtain bulk nanostructured materials from an Y 2 O 3 reinforced Fe–40Al (at.%) milled powder. The microstructures of the sintered end-products were characterized by Scanning Electron Microscopy (SEM) and Transmission Electron Microscopy (TEM) in order to gain new insights in their microstructure formation mechanisms. HVOF spray forming is more effective to retain fine nanograins, in particular within retained unmelted powder particles. The drawbacks of this technique are that it inevitably leads to a high fraction of porosity…

Investigation of mechanically activated field-activated pressure-assisted synthesis processing parameters for producing dense nanostructured FeAl

The parameters of the mechanically activated field-activated pressure-assisted synthesis (MAFAPAS) process, which were recently developed and patented for producing dense nanostructured materials, were studied in the case of the B2-FeAl intermetallic. Based on x-ray diffraction (XRD) experiments, residual stresses XRD analysis, relative density measurement, and secondary-electron microscopic observations, the optimal synthesis conditions (time, current intensity, and pressure) were studied. Fe + Al powders were comilled in a specially designed planetary mill to obtain a mixture of reactants at the nanoscale without the formation of any product. The milled mixtures were then subjected to a h…

Structure and composition heterogeneity of a FeAl alloy prepared by one-step synthesis and consolidation processing and their influence on grain size characterization.

Abstract This paper aims to characterize a bulk dense FeAl (47 at.%) alloy synthesized and consolidated by one-step current-activated pressure-assisted processing of nanocrystalline elemental powders. The end-product was analyzed using a combination of scanning (SEM) and transmission electron microscopies (TEM), electron back-scattering diffraction (EBSD) as well as electron probe microanalysis (EPMA). Special attention was paid to verify the grain size (32–89 nm) previously determined by X-ray diffraction peak profile analysis. It has been found that this material displays equiaxed grains (0.8–4 μm in size) and contains limited structural defects like subgrains and dislocations. The EPMA r…

Effect of Microstructure on the High Temperature Oxidation and Pesting Behaviour of MoSi<sub>2</sub>

Spark plasma synthesis from mechanically activated powders: a versatile route for producing dense nanostructured iron aluminides

Abstract The possibility of mechanically activated spark plasma sintering (MASPS) to perform simultaneously within a very short period of time the synthesis and the consolidation of nanophase iron aluminide from mechanically activated powders of Fe and Al in two different ratio (Fe53 at.% and Fe60 at.%) were confirmed in this work.