Plasma preparation and low-temperature sintering of spherical TiC–Fe composite powder

A spherical Fe matrix composite powder containing a high volume fraction (82vol%) of fine TiC reinforcement was produced us-ing a novel process combining in situ synthesis and plasma techniques. The composite powder exhibited good sphericity and a dense struc-ture, and the fine sub-micron TiC particles were homogeneously distributed in theα-Fe matrix. A TiC–Fe cermet was prepared from the as-prepared spherical composite powder using powder metallurgy at a low sintering temperature;the product exhibited a hardness of HRA 88.5 and a flexural strength of 1360 MPa. The grain size of the fine-grained TiC and special surface structure of the spherical powder played the key roles in the fabrication process.     

TiC/Fe cermet coating by plasma cladding using asphalt as carbonaceous precursor

A new Ti-Fe-C compound powder for plasma cladding was prepared by heating a mixture powder of ferrotitaniurn and asphalt pyro- lyzed as a carbonaceous precursor. The carbon by the pyrolysis of the asphalt acts as a reactive constituent as well as a binder in the compound powder. The TiC/Fe cermet coatings were prepared by plasma cladding with the compound powder. Results show that the Ti-Fe-C compound powder has a very tight structure, which can avoid the problem of the reactive constituent particles being separated during cladding. The TiC/Fe cermet coating presents a typical morphology of plasma cladding coatings with two different laminated layers： one is the composite layer in which the round fine TiC particles （〈500 nm） are dispersed within a Fe matrix, the other is the paragentic layer of TiC and Ti2O3. The coating shows high hardness and excellent wear resistance. The surface hardness of the coating is 68 ± 5（HR30N）. In the same fretting conditions, the wear area of Ni60 coating is about Ⅱ times as much as the TiC/Fe cermet coating.     

A TiCx reinforced Fe (Al) matrix composite using in-situ reaction

A new Fe matrix composite reinforced by the in-situ generated TiCx grains was prepared using the element Fe and Ti3AlC2 powders as the starting materials.Several hot-pressing temperatures were tried for exploring the phase transformation behavior from Ti3AlC2 to TiC x.Microstructures of the hot-pressed product were observed and analyzed.A tensile test was carried out for the new composite material,and the fracture face was analyzed.The results showed that the starting Ti3AlC2 was wholly decomposed and transformed into submicron TiC x grains at the hotpressing temperature above 1100℃.Most of the Al ions escaped from Ti3AlC2 were aggregated at the grain boundary of Fe grains,but a small amount of Al ions could be absorbed by Fe and formed Fe(Al) alloy around the surface of Fe grains.The prepared material exhibited a higher tensile strength of about 660 MPa and a uniform deformation of about 7%.     

PTA clad (Cr,Fe)7C3/γ-Fe in situ ceramal composite coating

A wear-resistant (Cr, Fe)₇C₃/γ-Fe in situ ceramal composite coating was fabricated on the substrate of 0.45wt%C carbon steel by a plasma-transferred arc cladding process using the Fe-Cr-C elemental powder blends. The microstructure, microhardness, and dry-sliding wear resistance of the coating were evaluated. The results indicate that the microstructure of the coating, which was composed of (Cr, Fe)₇C₃ primary phase uniformly distributed in the γ-Fe, and the (Cr, Fe)₇C₃ eutectic matrix was metallurgically bonded to the 0.45wt%C carbon steel substrate. From substrate to coating, the microstructure of the coating exhibited an evident epitaxial growth character. The coating, indehiscent and tack-free, had high hardness and appropriate gradient. It had excellent wear resistance under the dry sliding wear test condition.     

Novel Carboxylic Acid Solvolysis Route to Synthesis Electrode-active Nanostructured Spinel-Li_4Ti_5O_(12) for Lithium Batteries and Hybrid Capacitors

1 Results Nanostructured spinel-type Li4Ti5O12 (LTO) was prepared using Lewis acid base reaction technique involving a mixture of titanium β-diketonate and lithium nitrate as starting materials in the presence of aqueous citric acid as a solvolysis agent. The above method yielded a simple single step process without involving sol to gel conversion. The phase purity of the synthesized product after calcining at 800 ℃ for 24 h in air showed a spinel structure without any residual impurities. The nanostructure of the final product (both as prepared and calcined) was confirmed by High-resolution TEM (HRTEM) analysis. This process yielded very uniform spherical nanoparticles of ≈3 nm in size. The LTO product was tested as anode-active material in lithium containing half cells, Li4Ti5O12/Li at room temperature. It was found that the composite anode exhibited a working voltage of 1.55 V vs. Li/Li with a first discharge capacity of 160 mAh·g-1.     

Preparation of Cu-SiO<Subscript>2</Subscript> composite aerogel by ambient drying and the influence of synthesizing conditions on the structure of the aerogel

A copper-doped silica composite aerogel with high specific surface area was prepared using a sol-gel method at ambient pressure. A drying control chemical additive (DCCA) N,N-dimethylformamide (DMF) was introduced to the composite sol of tetraethyl orthosilicate (TEOS) and copper nitrate (Cu(NO3)2·3H2O) during the synthesizing process. The influence of the preparation conditions including Cu loading, catalyst concentration and heat treatment on the structure of copper-doped silica was investigated. The results showed that the obtained aerogel particles were uniformly distributed. The pore diameter was in a range of 2 to 15 nm. Heavier Cu loading benefited the formation of CuO crystalline, and reduced the specific surface area and pore diameter. When the catalyst concentration was high, the aggregation of Si-O network was reduced with the increase of it. The composite aerogel exhibited a good thermal stability after the heat treatment at high temperature.     

Spheroidization of molybdenum powder by radio frequency thermal plasma

To control the morphology and particle size of dense spherical molybdenum powder prepared by radio frequency (RF) plasma from irregular molybdenum powder as a precursor, plasma process parameters were optimized in this paper. The effects of the carrier gas flow rate and molybdenum powder feeding rate on the shape and size of the final products were studied. The molybdenum powder morphology was examined using high-resolution scanning electron microscopy. The powder phases were analyzed by X-ray diffraction. The tap density and apparent density of the molybdenum powder were investigated using a Hall flow meter and a Scott volumeter. The optimal process parameters for the spherical molybdenum powder preparation are 50 g/min powder feeding rate and 0.6 m3/h carrier gas rate. In addition, pure spherical molybdenum powder can be obtained from irregular powder, and the tap density is enhanced after plasma processing. The average size is reduced from 72 to 62 μm, and the tap density is increased from 2.7 to 6.2 g/cm3. Therefore, RF plasma is a promising method for the preparation of high-density and high-purity spherical powders.     

A New Process for Preparing Fine-ceramic-containing Composite Coatings──Flame Spray Synthesis

Flame spray synthesis (FSS), a combination of the flame spray technology and Self-propagation High-temperature Synthesis (SHS) was developed for preparing fine-ceramic-containing composite coatings. It can simplify the preparations of powder to synthesize and deposit the desired materials in one step. The preliminary results obtained from TiC-Fe cermet coatings by FSS process are reported. The peculiar microstructure of the composite coatings, which contains very fine (<1μm) and round TiC and alternate TiC-rich (Hv=11-13 GPa) and TiC-poor layers (Hv=3.0-6.0 GPa), is expected to play an important role in their tribological properties.     

Fabrication and character ization of electrospun TiO2/CuS micro–nano-scaled composite fibers

A process to fabricate a kind of novel micro–nano scaled TiO2/CuS composite fibers by electrospinning technique and chemical precipitation method was developed in the present study. The microstructures and photoelectronic properties of the fibers were characterize d using SEM, FT-IR, UV–vis and fluorescence spectroscopy. The results revealed that the TiO2 portion in the composite fibers was a mixture rutile and anatase phases while TiO2 and CuS had been fully composite. The fibers had smooth surface with a diameter of 50–300 nm. Comparing with pure TiO2 fiber, the TiO2/CuS micro–nano-scaled composite fibers exhibited a strong absorption in the visible light region and the efficiency of photo-induced charge separation were enhanced. This composite system is of widely potential applications in the areas such as solar cells, supercapacity, photocatalysis, etc.     

Pseudo-capacitance of ruthenium oxide/carbon black composites for electrochemical capacitors

Hydrous ruthenium oxide was formed by a new process. The precursor was obtained by mixing the aqueous solutions of RuCl₃·xH₂O and NaHCO₃. The addition of NaHCO₃ led to the formation of an oxide with extremely fine RuO₂ particles forming a porous network structure in the oxide electrode. Polyethylene glycol was added as a controller to partly inhibit the sol-gel reaction. The rate capacitance of 530 F·g-1 was measured for the powder formed at an optimal annealing temperature of 210℃. Several details concerning this new material, including crystal structure, particle size as a function of temperature, and electrochemical properties, were also reported. In addition, the rate capacitance of the composite electrode reached 800 F·g-1 after carbon black was added. By using the modified electrode of a RuO₂/carbon black composite electrode, the electrochemical capacitor exhibits high energy density and stable power characteristics. The values of specific energy and maximum specific power of 24 Wh·kg-1 and 4 kW·kg-1, respectively, are demonstrated for a cell voltage between 0 and 1 V.     

Microstructure and mechanical properties of SiC-particle-strengthening tri-metal Al/Cu/Ni composite produced by accumulative roll bonding process

In this study, a multilayer Al/Ni/Cu composite reinforced with SiC particles was produced using an accumulative roll bonding (ARB) process with different cycles. The microstructure and mechanical properties of this composite were investigated using optical and scanning microscopy and hardness and tensile testing. The results show that by increasing the applied strain, the Al/Ni/Cu multilayer composite converted from layer features to near a particle-strengthening characteristic. After the fifth ARB cycle, a composite with a uniform distribution of reinforcements (Cu, Ni, and SiC) was fabricated. The tensile strength of the composite increased from the initial sandwich structure to the first ARB cycle and then decreased from the first to the third ARB cycle. Upon reaching five ARB cycles, the tensile strength of the composite increased again. The variation in the elongation of the composite exhibited a tendency similar to that of its tensile strength. It is observed that with increasing strain, the microhardness values of the Al, Cu, and Ni layers increased, and that the dominant fracture mechanisms of Al and Cu were dimple formation and ductile fracture. In contrast, brittle fracture in specific plains was the main characteristic of Ni fractures.     

Injection processing and foaming behaviors of polypropylene composite foams

A volume-adjustable cavity of molding machine for polymer foaming was fabricated with renovation of an ordinary injection molding machine. Polypropylene （PP） composite foams were prepared by chemical foaming method via the volume-adjustable cavity of the molding machine. The decompressing and short shot processes in preparing the samples were carded out to adjust the cell structure of the foamed samples. The structures that foamed insufficiently, moder- ately, and excessively were observed in these two foaming processes. The foamed PP composite samples generated in decompressing pro- cess have more desirable cell s~cture than those generated by short shot process, specifically, the cell structure with the cell size of 46.97 IJxn, cell density of 3.18x 106 cell/cm3, and cell size dispersion of 10.76 ~m was achieved in the decompressing process. A controlled foaming process was realized through the decompressing process using the injection foaming equipment with a volume-adjustable cavity. The foamed PP composite has the insufficient, moderate, and excessive foamed structures in these two foaming processes.     

Enhanced dielectric properties of polypropylene based composite using Bi2S3 nanorod filler

A novel two-phase composite system using polypropylene(PP) as matrix and semiconductor bismuth sulfide(Bi_2S_3) as filler,was prepared by a simple process.Surfactant KH550 was chosen to modify the interface between inorganic fillers and organic PP matrix.The variations of dielectric properties of the Bi_2S_3/PP composites with the volume fraction of Bi_2S_3,frequency and temperature were discussed.The results reveal a percolative behavior of the composites with the threshold of 0.08.The composite is demo...     

Influence of particle structure on electrochemical character of composite graphite

The natural graphite has been used as the anode material for Lithium-Ion batteries, because of its low cost, chemical stability and excellent reversibility for Li+ insertion. However, the slow diffusion rate of lithium ion and poor compatibility with electrolyte solutions make it difficult to use in some conditions. In order to solve these problems, an epoxy-coke/graphite composite has been manufactured. The particle of composite carbonaceous material coated on non-graphitizable (hard) carbon matrix. Due to the disordered structure, the diffusion rate of lithium species in the non-graphitzable carbon is remarkably fast and less anisotropic. The process for preparing a composite carbon powder provides a promising new anode material with superior electrochemical properties for Li-ion batteries. The unique structure of epoxy-coke/graphite composite electrodes results in much better kinetics, also better recharge ability and initial charge/discharge efficiency.     

Effect of vacuum annealing on the characteristics of composite pellets containing DBSA-doped polyaniline and Fe nanoparticles

The DBSA-PANI-Fe composite powder with 50wt% of Fe nanoparticles was prepared by mechanically mixing the DBSA-doped polyaniline powder and Fe nanoparticles. The composite powder was compacted to pellets and the pellets were annealed in vacuum at 443,493,543, and 593 K for 60 and 120 min. The conductivity of the pellet increases markedly with increasing the annealing temperature up to 493 K, and then decreases with further increasing the annealing temperature. When the pellet was annealed at 493 K for 60 min, the increment of conductivity reaches a maximum value, and the conductivity is 2.6 times as large as that of the pellet unannealed. The conductivities of the pellets annealed under the conditions of 543 K/120 min, 593 K/60 min, and 593 K/120 min are lower than the conductivity of the pellet unannealed. For all the pellets, the variation in conductivity with temperature reveals that the charge transport mechanism can be considered to be 1-D variable-range-hopping (1-D VRH). The composite pellet shows a magnetic hysteresis loop independent of the annealing condition. The saturation magnetization is about 5.4×104 emu/kg. The saturation field and the coercivity are estimated to be 4.38×105 and 3.06×104 A/m, respectively. The crystalline structure ofFe nanoparticles in the composites does not change with the annealing condition. The annealing condition cannot destroy the polymer backbones.     

Preparation of fine copper powders and their application in BME-MLCC

The preparation of fine copper powders by chemical reduction method was investigated. The reaction of [Cu(NH₃)₄]2+ complex with hydrazine hydrate gives spherical monodispersed fine copper powders. The spherical copper powder with a uniform size of 3.5 ± 0.5 μm was processed to obtain flake copper powder having a uniform size of 8-10 μm, excellent dispersibility and uniform shape. The spherical copper powder of 2.5 ± 0.3 μm in size, flake copper, glass frit and vehicle were mixed to prepare copper paste, which was fired in 910-920°C to obtain BME-MLCC (base metal multilayer ceramic capacitor) with a dense surface of end termination, high adhesion and qualified electrical behavior. Polarized light photo and SEM were employed to observe the copper end termination of BME-MLCC. The rough interface from the interfacial reaction between glass and chip gives high adhesion.     

A study of interparticulate strain in a hot-extruded SiCp/2014 Al composite

We report a correlative study of strain distribution and grain structure in the Al matrix of a hot-extruded SiC particulate-reinforced Al composite (SiC_p/2014 Al). Finite element method (FEM) simulation and microstructure characterization indicate that the grain structure of the Al matrix is affected by the interparticulate strain distribution in the matrix during the process. Both electron-backscattered diffraction (EBSD) and selected-area electron diffraction (SAED) indicated localized misorientation in the Al matrix after hot extrusion. Scanning transmission electron microscopy (STEM) revealed fine and recrystallized grains adjacent to the SiC particulate and elongated grains between the particulates. This result is explained in terms of recrystallization under an interparticulate strain distribution during the hot extrusion process.     

Preparation of graphene and TiO2 layer by layer composite with highly photocatalytic efficiency

A process for fabricating graphene and TiO2 layer by layer composite was introduced to improve the photocatalytic activity by controlling the layers, thickness and the mass ratio between graphene and TiO2. The graphene oxide (GO) was synthesized from natural graphite pow der by the modified Hummers met hod. Large-area uniform GO and TiO2 thin films were made by a spin-coating process in turn. After exposure of the TiO2/GO multilayer film to UV light irradiation which allows the reduction of GO to graphene, a novel photocatalyt ic structure as graphene and TiO2 layer by layer composite was synthesized. The cross-sectional SEM image showed that a clear layer by layer microstructure with a single layer thickness of graphene or TiO2 was in the range of about 50 nm. The total thickness of the film was around 5 μm which was varied according to the layer number of spin coating process. Raman spectra revealed th at significant structural changes occurred through UV light irradiation. Photodegrada tion for methylene blue (MB) exhibited that the layer by layer com posite is of higher photocatalytic activity than the pure TiO2 layer.     

Stainless steel binder for the development of novel TiC-reinforced steel cermets

Steel reinforced TiC composites are an attractive choice for wear resistance and corrosion resistance applications. TiC-reinforced 17-4PH maraging stainless matrix composites were processed by conventional powder metallurgy (P/M). TiC-reinforced maraging stainless steel composites with >97% of theoretical density were fabricated. The microstructure, mechanical and wear properties of the composites were evaluated. The microstructure of these composites consisted of spherical and semi-spherical TiC particles.A few microcracks appeared in the composites, showing the presence of tensile stress in the composites produced during sintering.Typical properties, namely, hardness and bend strength were reported for the sintered composites. After heat treatment and aging, the increase of hardness was observed. The increase of hardness was attributed to the aging reaction in the 17-4PH stainless steel. The precipitates appeared in the microstructure and were responsible for the increase in hardness. The specific wear behavior of the composites was strongly dependent on the content of TiC particles, the interparticle spacing, and the presence of hard precipitates in the binder phase.     

Hydroxyapatite/alumina nanocrystalline composite powders synthesized by sol-gel process for biomedical applications

Hydroxyapatite/alumina nanocrystalline composite powders needed for various biomedical applications were successfully synthesized by sol-gel process. Structural and morphological investigations of the prepared composite powders were performed using X-ray diffractometer (XRD), scanning electron microscopy (SEM), X’Pert HighScore software, and Clemex Vision image analysis software. The results show that the crystallite size of the obtained composite powders is in the range of 25 to 90 nm. SEM evaluation shows that the obtained composite powders have a porous structure, which is very useful for biomedical applications. The spherical nanoparticles in the range of 60 to 800 nm are embedded in the agglomerated clusters of the prepared composite powders.