Self-assembly process under a solid-state reaction of β-Si3N4/austenitic stainless-steel composites: stirring conditions and material texture

In the self-assembly process of β-Si3N4 (SN)/316L stainless-steel (SUS316L) composite materials tailored via sintering of powder mixtures, the formation of a SN agglomerate resulting from condensation–dispersion reactions during the stirring of SN/SUS316L was found to play an important role in improving the thermal conductivity. Moreover, the obtained SN secondary particle groups connected to form a network through diffusion-limited aggregation. In particular, it was shown that the sample prepared at the milling speed of 150 r/min has a similar particle group area (about 1.38 μm2) to that at 120 r/min, but a higher κ (increased from 9.5 W m−1 K−1 to 11.5 W m−1 K−1). To quantitatively evaluate the microstructural morphology of the texture of the self-assembled composite material, global parameters τ( q) and D q and local parameters α( q) and f( α) were determined via multifractal analysis. These characteristics of the anisotropy, dispersion, and cohesiveness of the particle network in the material texture could be analyzed together with the capacity dimension D0, information dimension D1 (configuration entropy), correlation dimension D2, and α( q) (related to internal energy). The results suggest that α( q) reflects the differences in the cohesion of the additive particle agglomeration that constitutes the self-assembly process under the solid-state reaction.

Effect of temperature, time, and shear force on the morphology and size of dendrites in A356-Al2O3 composites

Dendrite arm spacing (DAS) plays a vital role in determining mechanical properties of aluminum casting composites. In this study, the effects of three different methods of gravity sand casting, squeeze casting, and semi-solid compo-casting with different electromagnetic stirring currents and times on the microstructural morphology of A356-Al2O3 composites were investigated. In order to investigate effects of shear forces on the formation of the globular-like structure, samples with different stirring electric current and times were produced by compo-casting in semi-solid state and analyzed. Optical emission microscopy was used to study the microstructure and DAS of nanocomposites. Quantitative analysis of microstructure was performed by utilizing an image analysis system. In this study, the optimum temperature for composite fabrication for this type of composite was calculated to obtain the most appropriate morphology and size of the microstructure. Also, the appropriate time to keep this composite at this temperature was obtained, and finally the relevant microstructures were fully discussed.

Development and Characterization of Field Structured Magnetic Composites

Polymer composites containing ferromagnetic fillers are promising for applications relating to electrical and electronic devices. In this research, the authors modified an ultraviolet light (UV) curable prepolymer to additionally cure upon heating and validated a permanent magnet-based particle alignment system toward fabricating anisotropic magnetic composites. The developed dual-cure acrylate-based resin, reinforced with ferromagnetic fillers, was first tested for its ability to polymerize through UV and heat. Then, the magnetic alignment setup was used to orient magnetic particles in the dual-cure acrylate-based resin and a heat curable epoxy resin system in a polymer casting approach. The alignment setup was subsequently integrated with a material jetting 3D printer, and the dual-cure resin was dispensed and cured in-situ using UV, followed by thermal post-curing. The resulting magnetic composites were tested for their filler loading, microstructural morphology, alignment of the easy axis of magnetization, and degree of monomer conversion. Magnetic characterization was conducted using a vibrating sample magnetometer along the in-plane and out-of-plane directions to study anisotropic properties. This research establishes a methodology to combine magnetic field induced particle alignment along with a dual-cure resin to create anisotropic magnetic composites through polymer casting and additive manufacturing.

On Novel Copper Based Alloys Development via Friction Stir Alloying

Friction stir alloying (FSA) of commercially pure Cu with Ni, Zn, and Mg is implemented in the current study. Mechanical and microstructural aspects of the successfully fabricated alloy structure have been examined. Energy dispersive X-ray spectroscopy revealed a uniform distribution of alloying elements and coalescence at the atomic level. The compositional and grain size heterogeneity is managed in the stir zone, allowing for microstructural control with FSA. Thus, the present study is essential for the development of novel materials whose fabrication requires temperature well below the melting point of base metals. The alloying process is found to be accompanied by ultra-refined grains, with the smallest grain size being ~0.44 μm. The fabricated alloy managed to retain the FCC phase, and no brittle intermetallic compounds formed, according to X-ray diffraction. The fabricated alloy exhibits maximum and average microhardness enhancements of 18.4% and 6%, respectively. Tensile properties have also been investigated and correlated with microstructural morphology. A shift toward grain bimodality has also been documented, which is a highly sought-after property nowadays, especially to overcome the strength-ductility trade-off.