An official website of the United States government
A boron-rich boron–carbide material (B4+δC) was synthesized by spark plasma sintering of a ball-milled mixture of high-purity boron powder and graphitic carbon at a pressure of 7 MPa and a temperature of 1930 °C. This high-pressure, high-temperature synthesized material was recovered and characterized by X-ray diffraction, X-ray photoelectron spectroscopy, Raman spectroscopy, Vickers hardness measurements, and thermal oxidation studies. The X-ray diffraction studies revealed a single-phase rhombohedral structure (space group R-3m) with lattice parameters in hexagonal representation as a = 5.609 ± 0.007 Å and c = 12.082 ± 0.02 Å. The experimental lattice parameters result in a value of δ = 0.55, or the composition of the synthesized compound as B4.55C. The high-resolution scans of boron binding energy reveal the existence of a B-C bond at 188.5 eV. Raman spectroscopy reveals the existence of a 386 cm−1 vibrational mode representative of C-B-B linear chain formation due to excess boron in the lattice. The measured Vickers microhardness at a load of 200 gf shows a high hardness value of 33.8 ± 2.3 GPa. Thermal gravimetric studies on B4.55C were conducted at a temperature of 1300 °C in a compressed dry air environment, and its behavior is compared to other high-temperature ceramic materials such as high-entropy transition metal boride. The high neutron absorption cross section, high melting point, high mechanical strength, and thermal oxidation resistance make this material ideal for applications in extreme environments.
more »
« less
Selective laser melting of Ti6Al4V-B4C-BN in situ reactive composites
An increasing desire for higher application temperatures and complex geometries for metallic materials has spurred significant development in additive manufacturing (AM) of metal-ceramic composites; however, limited process-microstructure-properties relationships exist for these materials and processing strategies. Herein we investigate the processing window and high-temperature oxidation performance of an in situ reactive, oxidation-resistant titanium metal-matrix composite reinforced with boron nitride (BN) and boron carbide (B4C) via selective laser melting (SLM) to understand the effects of processing parameters on the in situ reactive characteristics and their effects on build reliability and high-temperature oxidation performance. SLM processing required a 50% decrease in overall energy density relative to titanium's optimal parameters to avoid processing failure due to the high in situ reactivity and exothermic reaction between feedstock materials. A precise balance was necessary to combine decreasing the input energy to avoid cracking due to in situ reactivity while simultaneously providing enough input energy to keep the bulk density as high as possible to limit porosity that contributes to processing inconsistencies at low input energy. Process optimization resulted in composites with as high as 98.3% relative density, comparable to some of the best composites reported in the literature, and high-temperature oxidation testing revealed a 39% decrease in oxidation mass gain compared to Ti6Al4V, owing directly to ceramic reinforcement. Our results indicate that control of SLM processing parameters can yield advanced composites with enhanced properties and characteristics compared to the base material, revealing an array of design possibilities for researchers and engineers in many fields.
more »
« less
- Award ID(s):
- 1934230
- PAR ID:
- 10354350
- Date Published:
- Journal Name:
- Journal of materials research and technology
- Volume:
- 18
- ISSN:
- 2214-0697
- Page Range / eLocation ID:
- 2654-2671
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
-
-
Abstract Although ceramic particle‐metal matrix materials (i.e., cermets) can offer superior performance, manufacturing these materials via conventional means is difficult compared to the manufacturing of metal alloys. This study leverages the laser powder bed fusion (LPBF) process to additively manufacture dense tungsten carbide (WC)‐17 wt.% nickel (Ni) composite specimens using novel spherical, sintered‐agglomerated composite powder. A range of processing parameters yielding high‐density specimens was discovered using a sequential series of experiments comprised of single bead, multi‐layer, and cylindrical builds. Cylinders with a relative density >99% were fabricated and characterized in terms of microstructure, chemical composition, and hardness. Scanning electron microscopy images show favorable wetting between the Ni binder and carbide particles without any phase segregation and laser processing increased the average carbide particle size. Energy dispersive X‐ray and X‐ray diffraction analyses detected traces of secondary products after laser processing. For samples processed at high energy densities, complex carbides and carbon agglomerate phases were detected. The maximum hardness of 60.38 Rockwell C is achieved in the printed samples. The successful builds in this study open the way for LPBF of dense WC‐Ni parts with a large workable laser power‐laser velocity processing window.more » « less
-
The cold sintering process (CSP) is a low-temperature consolidation method used to fabricate materials and their composites by applying transient solvents and external pressure. In this mechano-chemical process, the local dissolution, solvent evaporation, and supersaturation of the solute lead to “solution-precipitation” for consolidating various materials to nearly full densification, mimicking the natural pressure solution creep. Because of the low processing temperature (<300°C), it can bridge the temperature gap between ceramics, metals, and polymers for co-sintering composites. Therefore, CSP provides a promising strategy of interface engineering to readily integrate high-processing temperature ceramic materials (e.g., active electrode materials, ceramic solid-state electrolytes) as “grains” and low-melting-point additives (e.g., polymer binders, lithium salts, or solid-state polymer electrolytes) as “grain boundaries.” In this minireview, the mechanisms of geomimetics CSP and energy dissipations are discussed and compared to other sintering technologies. Specifically, the sintering dynamics and various sintering aids/conditions methods are reviewed to assist the low energy consumption processes. We also discuss the CSP-enabled consolidation and interface engineering for composite electrodes, composite solid-state electrolytes, and multi-component laminated structure battery devices for high-performance solid-state batteries. We then conclude the present review with a perspective on future opportunities and challenges.more » « less
-
Abstract Controlling the thermal expansion of ceramic materials is important for many of their applications that involve high-temperature processing and/or working conditions. In this study, we investigate the thermal expansion properties of additively manufactured alumina that is reinforced with boron nitride nanotubes (BNNTs) over a broad temperature range, from room temperature to 900 °C. The coefficient of thermal expansion (CTE) of the BNNT-alumina nanocomposite increases with temperature but decreases with an increase in BNNT loading. The introduction of 0.6% BNNTs results in an approximate 16% reduction in the CTE of alumina. The observed significant CTE reduction of ceramics is attributed to the BNNT’s low CTE and ultrahigh Young’s modulus, and effective interfacial load transfer at the BNNT-ceramic interface. Micromechanical analysis, based onin situRaman measurements, reveals the transition of thermal-expansion-induced interface straining of nanotubes, which shifts from compression to tension inside the ceramic matrix under thermal loadings. This study provides valuable insights into the thermomechanical behavior of BNNT-reinforced ceramic nanocomposites and contributes to the optimal design of ceramic materials with tunable and zero CTE.more » « less
-
Abstract Boron nitride nanotubes (BNNTs) are the perfect candidate for nanofillers in high-temperature multifunctional ceramics due to their high thermal stability, oxidation resistance, good mechanical properties, high thermal conductivity, and radiation shielding. In this paper, 3D printed ceramic nanocomposite with 0.1 wt% of BNNT was prepared by fusing it at high temperatures. Samples were built with three different print directions to study the effect of print layers on mechanical performance along with BNNT addition. Dynamic mechanical analysis is performed to study the length effect of nanoscale reinforcements on the mechanical properties of the printed ceramic composites reporting significant improvements up to 55% in bending strength and 72% in bending modulus with just 0.1 wt% BNNT addition. A 63% thermal diffusivity improvement of ceramic by adding BNNTs is observed using laser flash analysis. The bridging and pull-out effect of nanotubes with a longer aspect ratio was observed with high-resolution microscopy. Such composites’ modeling and simulation approaches are crucial for virtual testing and industrial applications. Understanding the effect of nanoscale synthetic fillers for 3D printed high-temperature ceramics can revolutionize future extreme environment structures.more » « less
- Free Publicly Accessible Full Text
-
Accepted Manuscript1.0
- Journal Article:
- https://doi.org/doi.org/10.1016/j.jmrt.2022.03.092
