Printing, Debinding and Sintering of 15-5PH Stainless Steel Components by Fused Deposition Modeling Additive Manufacturing

Metal FDM technology overcomes the problems of high cost, high energy consumption and high material requirements of traditional metal additive manufacturing by combining FDM and powder metallurgy and realizes the low-cost manufacturing of complex metal parts. In this work, 15-5PH stainless steel granules with a powder content of 90% and suitable for metal FDM were developed. The flowability and formability of the feedstock were investigated and the parts were printed. A two-step (solvent and thermal) debinding process is used to remove the binder from the green part. After being kept at 75 °C in cyclohexane for 24 h, the solvent debinding rate reached 98.7%. Following thermal debinding, the material's weight decreased by slightly more than 10%. Sintering was conducted at 1300 °C, 1375 °C and 1390 °C in a hydrogen atmosphere. The results show that the shrinkage of the sintered components in the X-Y-Z direction remains quite consistent, with values ranging from 13.26% to 19.58% between 1300 °C and 1390 °C. After sintering at 1390 °C, the material exhibited a relative density of 95.83%, a hardness of 101.63 HRBW and a remarkable tensile strength of 770 MPa. This work realizes the production of metal parts using 15-5PH granules' extrusion additive manufacturing, providing a method for the low-cost preparation of metal parts. And it provides a useful reference for the debinding and sintering process settings of metal FDM. In addition, it also enriches the selection range of materials for metal FDM.

Testing for Abrasion Resistance of WC-Co Composites for Blades Used in Wood-Based Material Processing

Commonly used tool materials for machining wood-based materials are WC-Co carbides. Although they have been known for a long time, there is still much development in the field of sintered tool materials, especially WC-Co carbides and superhard materials. The use of new manufacturing methods (such as FAST-field-assisted sintering technology), which use pulses of electric current for heating, can improve the properties of the materials used for cutting tools, thereby increasing the cost-effectiveness of machining. The ability to increase tool life without the downtime associated with tool wear allows significant cost savings, particularly in mass production. This paper presents the results of a study of the effect of grain size and cobalt content of carbide tool sinters on the tribological properties of the materials studied. The powders used for consolidation were characterised by irregular shape and formed agglomerates of different sizes. Tribological tests were carried out using the T-01 (ball-on-disc) method. In order to determine the wear kinetics, the entire friction path was divided into 15 cycles of 200 m and the weight loss was measured after each stage. In order to determine the mechanism and intensity of wear of the tested materials under technically dry friction conditions, the surface of the tested sinters was observed before the test and after 5, 10, and 15 cycles. The conclusions of the study indicate that the predominant effect of surface cooperation at the friction node is abrasion due to the material chipping that occurs during the process. The results confirm the influence of sintered grain size and cobalt content on durability. In the context of the application of the materials in question for cutting tools, it can be pointed out that sintered WC(0.4)_4 has the highest potential for use in the manufacture of cutting tools.

Laser-Based Manufacturing of Ceramics: A Review

Ceramics are widely used in microelectronics, semiconductor manufacturing, medical devices, aerospace, and aviation, cutting tools, precision optics, MEMS and NEMS devices, insulating components, and ceramic molds. But the fabrication and machining of the ceramic-based materials by conventional processes are always difficult due to their higher hardness and mechanical properties. Therefore, advanced manufacturing techniques are being preferred for these advanced materials, and out of that, laser-based processes are widely used. The benefits of laser fabrication and machining of ceramics include high precision, reduced thermal damage, non-contact processing, and the ability to work with complex geometries. Laser technology continues to advance, enabling even more intricate and diverse applications for ceramics in a wide range of industries. This paper explains various laser based ceramic processing techniques, such as selective laser sintering and melting, and laser machining techniques, such as laser drilling, etc. Identifying and optimizing the process parameters that influence the output quality of laser processed parts is the key technique to improving the quality, which is also focused on in this paper. It aims to facilitate the researchers by providing knowledge on laser-based manufacturing of ceramics and their composites to establish the field further.

Corrigendum: Additive manufacturing of Al2O3 ceramics with MgO/SiC contents by laser powder bed fusion process

[This corrects the article DOI: 10.3389/fchem.2023.1034473.].

Optimizing Li1.3Al0.3Ti1.7(PO4)3 Particle Sizes toward High Ionic Conductivity

NASICON-type Li_1.3Al_0.3Ti_1.7(PO₄)₃ (LATP) has attracted a lot of attention because of its high ionic conductivity and stability to air and moisture. However, the size effect of LATP primary particles on ionic conductivity is ignored. In this study, different sizes of LATP particles are prepared to investigate the morphology, relative density, and ionic conductivity of the LATP solid electrolyte. The influences of particle size and sintering temperature on the microstructure, phase composition, and electrical properties of LATP ceramics were systematically studied. The medium-sized LATP particle (2 μm) presents a great microstructure with a high relative density of over 97%, the highest ionic conductivity of 6.7 × 10^-4 S cm^-1, and an activation energy of 0.418 eV. The Li-Li symmetric cells and Li-LFP batteries delivering good electrochemical performance were fabricated with highly conductive LATP ceramics. These results make significant strides in elucidating the relationship between the particle sizes of LATP and its electrochemical performance.

Effect of dual sintering with laser irradiation and thermal treatment on printed copper nanoparticle patterns

The dual sintering of copper (Cu) nanoparticles (NPs) was introduced to produce conductive patterns suitable for flexible electronics applications. In this method, laser irradiation using a Nd:YAG laser with a wavelength of 1064 nm was performed at laser powers of 400, 600, and 800 mJ. The laser irradiation time was 15 and 30 s for each laser power. After laser irradiation, all of the Cu NP patterns were thermally sintered under formic acid (FA) vapors. The temperature and time for thermal sintering were selected as 260 °C and 15 min, respectively. The resultant physical, chemical, electrical and mechanical properties were evaluated and compared considering the six different dual sintering conditions. The Cu NP patterns sintered using 800 mJ for 30 s showed increased necking and coalescence compared to the other patterns and featured a microstructure with increased density. Despite being oxidized, the Cu NP patterns sintered with 800 mJ for 30 s showed the lowest electrical resistivity of 11.25 μΩ·cm. The surface of every sintered Cu pattern was oxidized, and mechanical hardness increased with increasing laser power. The Cu NP pattern sintered with 800 mJ for 30 s demonstrated the highest hardness of 48.64 N/mm2. After sintering using the six different conditions, the Cu NP patterns exhibited a weight loss of 0.02-3.87 wt%, and their roughness varied in the range of 26.15-74.08 nm. This can be attributed to the effective removal of organic residues and the degree of particle agglomeration. After performing folding tests up to 50 cycles, Cu NP patterns showed an upward trend in resistance with increasing laser power and time. The highest and lowest resistance ratios were observed as 3.97 and 17.24 for the patterns sintered at 400 mJ for 15 s and 800 mJ for 30 s, respectively.

Effect of Thermal Treatments and Ion Substitution on Sintering and Crystallization of Bioactive Glasses: A Review

Bioactive glasses (BGs) are promising materials for bone regeneration due to their ability to bond with living bone tissue. However, thermal stability and mechanical properties of BGs need improvement for better clinical performance. In this paper, we present an overview of the influence of different ions on the sintering and crystallization of BGs. Specifically, this review focuses on the impact of thermal treatments on the crystallization of 45S5 and other significant BG compositions. Potential applications of these thermally treated BGs, such as scaffolds, BG-based composites, and thermally sprayed coatings, are explored. Moreover, the substitution of ions has been investigated as a method to enhance the thermal properties of BGs. Notably, zinc, potassium, and strontium have been studied extensively and have demonstrated promising effects on both the thermal and the mechanical properties of BGs. However, it is important to note that research on ion inclusion in BGs is still in its early stages, and further investigation is necessary to fully comprehend the effects of different ions on sintering and crystallization. Therefore, future studies should focus on optimizing the ion substitution method to improve the thermal, mechanical, and even biological properties of BGs, thereby enhancing their potential for various biomedical applications.

Design of Ti64/Ta Hybrid Materials by Powder Metallurgy Mimicking Bone Structure

This work reports on the fabrication of a novel two-layer material composed of a porous tantalum core and a dense Ti6Al4V (Ti64) shell by powder metallurgy. The porous core was obtained by mixing Ta particles and salt space-holders to create large pores, the green compact was obtained by pressing. The sintering behavior of the two-layer sample was studied by dilatometry. The interface bonding between the Ti64 and Ta layers was analyzed by SEM, and the pore characteristics were analyzed by computed microtomography. Images showed that two distinct layers were obtained with a bonding achieved by the solid-state diffusion of Ta particles into Ti64 during sintering. The formation of β-Ti and α' martensitic phases confirmed the diffusion of Ta. The pore size distribution was in the size range of 80 to 500 µm, and a permeability value of 6 × 10^-10 m² was close to the trabecular bones one. The mechanical properties of the component were dominated mainly by the porous layer, and Young's modulus of 16 GPa was in the range of bones. Additionally, the density of this material (6 g/cm³) was much lower than the one of pure Ta, which helps to reduce the weight for the desired applications. These results indicate that structurally hybridized materials, also known as composites, with specific property profiles can improve the response to osseointegration for bone implant applications.

The Study of Copper Powder Sintering for Porous Wick Structures with High Capillary Force

The porosity, permeability, and capillary force of porous sintered copper were examined in relation to the effects of copper powder size, pore-forming agent, and sintering conditions. Cu powder with particle sizes of 100 and 200 μm was mixed with pore-forming agents ranging from 15 to 45 weight percent, and the mixture was sintered in a vacuum tube furnace. Copper powder necks were formed at sintering temperatures higher than 900 °C. The porosity, as determined by the Archimedes measurement method, and the permeability performance of the sintered body displayed higher values when the Cu powder size was uniform or small. To investigate the capillary force of the sintered foam, a test was conducted using a raised meniscus test device. As more forming agent was added, the capillary force increased. It was also higher when the Cu powder size was larger and the size of the powders was not uniform. The result was discussed in relation to porosity and pore size distribution.

Recent Advances in Processing of Titanium and Titanium Alloys through Metal Injection Molding for Biomedical Applications: 2013-2022

Metal injection molding (MIM) is one of the most widely used manufacturing processes worldwide as it is a cost-effective way of producing a variety of dental and orthopedic implants, surgical instruments, and other important biomedical products. Titanium (Ti) and Ti alloys are popular modern metallic materials that have revamped the biomedical sector as they have superior biocompatibility, excellent corrosion resistance, and high static and fatigue strength. This paper systematically reviews the MIM process parameters that extant studies have used to produce Ti and Ti alloy components between 2013 and 2022 for the medical industry. Moreover, the effect of sintering temperature on the mechanical properties of the MIM-processed sintered components has been reviewed and discussed. It is concluded that by appropriately selecting and implementing the processing parameters at different stages of the MIM process, defect-free Ti and Ti alloy-based biomedical components can be produced. Therefore, this present study could greatly benefit future studies that examine using MIM to develop products for biomedical applications.

A Novel Method for the Fabrication of Antibacterial Stainless Steel with Uniform Silver Dispersions by Silver Nanoparticle/Polyethyleneimine Composites

Only a few studies have so far focused on the addition of silver to SS316L alloys by conventional sintering methods. Unfortunately, the metallurgical process of silver-containing antimicrobial SS is greatly limited due to the extremely low solubility of silver in iron and its tendency to precipitate at the grain boundaries, resulting in an inhomogeneous distribution of the antimicrobial phase and loss of antimicrobial properties. In this work, we present a novel approach to fabricate antibacterial stainless steel 316L by functional polyethyleneimine-glutaraldehyde copolymer (PEI-co-GA/Ag catalyst) composites. PEI is a highly branched cationic polymer, which makes it exhibit very good adhesion on the surface of the substrate. Unlike the effect of the conventional silver mirror reaction, the introduction of functional polymers can effectively improve the adhesion and distribution of Ag particles on the surface of 316LSS. It can be seen from the SEM images that a large number of silver particles are retained and well dispersed in 316LSS after sintering. PEI-co-GA/Ag 316LSS exhibits excellent antimicrobial properties and does not release free silver ions to affect the surrounding environment. Furthermore, the probable mechanism for the influence of the functional composites on the enhancement of adhesion is also proposed. The formation of a large number of hydrogen bonds and van der Waals forces, as well as the negative zeta potential of the 316LSS surface, can effectively enable the formation of a tight attraction between the Cu layer and the surface of 316LSS. These results meet our expectations of designing passive antimicrobial properties on the contact surface of medical devices.

Signal-Decay Based Approach for Visualization of Buried Defects in 3-D Printed Ceramic Components Imaged with Help of Optical Coherence Tomography

We propose the use of Optical Coherence Tomography (OCT) as a tool for the quality control of 3-D-printed ceramics. Test samples with premeditated defects, namely single- and two-component samples of zirconia, titania, and titanium suboxides, were printed by stereolithography-based DLP (Digital Light Processing) processes. The OCT tomograms obtained on the green samples showed the capability of the method to visualize variations in the layered structure of the samples as well as the presence of cracks and inclusions at depths up to 130 µm, as validated by SEM images. The structural information was visible in cross-sectional images as well as in plan-view images. The optical signal measured from the printed zirconia oxide and titanium oxide samples showed strong attenuation with depth and could be fit with an exponential decay curve. The variations of the decay parameter correlated very well with the presence of defects and material variation. When used as an imaging quantity, the decay parameter projects the position of the defects into 2-D (X,Y) coordinates. This procedure can be used in real time, it reduces the data volume up to 1000 times, and allows for faster subsequent data analysis and transfer. Tomograms were also obtained on sintered samples. The results showed that the method can detect changes in the optical properties of the green ceramics caused by sintering. Specifically, the zirconium oxide samples became more transparent to the light used, whereas the titanium suboxide samples became entirely opaque. In addition, the optical response of the sintered zirconium oxide showed variations within the imaged volume, indicating material density variations. The results presented in this study show that OCT provides sufficient structural information on 3-D-printed ceramics and can be used as an in-line tool for quality control.

Does Cluster Encapsulation Inhibit Sintering? Stabilization of Size-Selected Pt Clusters on Fe3O4(001) by SMSI

The metastability of supported metal nanoparticles limits their application in heterogeneous catalysis at elevated temperatures due to their tendency to sinter. One strategy to overcome these thermodynamic limits on reducible oxide supports is encapsulation via strong metal-support interaction (SMSI). While annealing-induced encapsulation is a well-explored phenomenon for extended nanoparticles, it is as yet unknown whether the same mechanisms hold for subnanometer clusters, where concomitant sintering and alloying might play a significant role. In this article, we explore the encapsulation and stability of size-selected Pt5, Pt10, and Pt19 clusters deposited on Fe3O4(001). In a multimodal approach using temperature-programmed desorption (TPD), X-ray photoelectron spectroscopy (XPS), and scanning tunneling microscopy (STM), we demonstrate that SMSI indeed leads to the formation of a defective, FeO-like conglomerate encapsulating the clusters. By stepwise annealing up to 1023 K, we observe the succession of encapsulation, cluster coalescence, and Ostwald ripening, resulting in square-shaped crystalline Pt particles, independent of the initial cluster size. The respective sintering onset temperatures scale with the cluster footprint and thus size. Remarkably, while small encapsulated clusters can still diffuse as a whole, atom detachment and thus Ostwald ripening are successfully suppressed up to 823 K, i.e., 200 K above the Hüttig temperature that indicates the thermodynamic stability limit.

Glass-Ceramic Coating on Silver Electrode Surface via 3D Printing

Silver electrodes are commonly used as a conductive layer for electromagnetic devices. It has the advantages of good conductivity, easy processing, and good bonding with a ceramic matrix. However, the low melting point (961 °C) results in a decrease in electrical conductivity and migration of silver ions under an electric field when it works at high temperatures. Using a dense coating layer on the silver surface is a feasible way to effectively prevent the performance fluctuation or failure of the electrodes without sacrificing its wave-transmitting performance. Calcium-magnesium-silicon glass-ceramic (CaMgSi₂O₆) is a diopside material that has been widely used in electronic packaging materials. However, CaMgSi₂O₆ glass-ceramics (CMS) are facing tough challenges, such as high sintering temperature and insufficient density after sintering, which significantly confine its applications. In this study, CaO, MgO, B₂O₃, and SiO₂ were used as raw materials to manufacture a uniform glass coating on the silver and Al₂O₃ ceramics surface via 3D printing technology followed by high-temperature sintering. The dielectric and thermal properties of the glass/ceramic layer prepared with various CaO-MgO-B₂O₃-SiO₂ components were studied, and the protective effect of the glass-ceramic coating on the silver substrate at high temperatures were evaluated. It was found that the viscosity of the paste and the surface density of the coating increase with the increase of solid contents. The 3D-printed coating shows well-bonded interfaces between the Ag layer, the CMS coating, and the Al₂O₃ substrate. The diffusion depth was 2.5 μm, and no obvious pores and cracks can be detected. According to the high density and well-bonded glass coating, the silver was well protected from the corrosion environment. Increasing the sintering temperature and extending the sintering time is beneficial to form the crystallinity and the densification effect. This study provides an effective method to manufacture a corrosive-resistant coating on an electrically conductive substrate with outstanding dielectric performances.

Preparation of Nanostructured Sn/Ti Oxide Hybrid Films with Terpineol/PEG-Based Nanofluids: Perovskite Solar Cell Applications

Tin oxide (SnO₂) and titanium dioxide (TiO₂) are recognized as attractive energy materials applicable for lead halide perovskite solar cells (PSCs). Sintering is one of the effective strategies for improving the carrier transport of semiconductor nanomaterials. Using the alternative metal-oxide-based ETL, nanoparticles are often used in a way that they are dispersed in a precursor liquid prior to their thin-film deposition. Currently, the creation of PSCs using nanostructured Sn/Ti oxide thin-film ETL is one of the topical issues for the development of high-efficiency PSCs. Here, we demonstrate the preparation of terpineol/PEG-based fluid containing both tin and titanium compounds that can be utilized for the formation of a hybrid Sn/Ti oxide ETL on a conductive substrate (F-doped SnO₂ glass substrate: FTO). We also pay attention to the structural analysis of the Sn/Ti metal oxide formation at the nanoscale using a high-resolution transmission electron microscope (HR-TEM). The variation of the nanofluid composition, i.e., the concentration of tin and titanium sources, was examined to obtain a uniform transparent thin film by spin-coating and sintering processes. The maximum power conversion efficiency was obtained for the concentration condition of [SnCl₂·2H₂O]/[titanium tetraisopropoxide (TTIP)] = 25:75 in the terpineol/PEG-based precursor solution. Our method for preparing the ETL nanomaterials provides useful guidance for the creation of high-performance PSCs using the sintering method.

Fabrication of 3D Printed Ceramic Part Using Photo-Polymerization Process

Ceramics are high-strength and high-temperature resistant materials that are used in various functional parts. However, due to the high strength and brittleness properties, there are many difficulties in the fabrication of complex shapes. Therefore, there are many studies related to the fabrication of ceramic parts using 3D printing technology optimized for complex shapes. Among them, studies using photo-polymerization (PP) 3D printing technology with excellent dimensional accuracy and surface quality have received the most widespread attention. To secure the physical properties of sintered ceramic, the content and distribution of materials are important. This study suggests a novel 3D printing process based on a high-viscosity composite resin that maximizes the content of zirconia ceramics. For reliable printing, the developed 3D printers that can adjust the process environment were used. To minimize warpage and delamination, the divided micro square pattern images were irradiated in two separate intervals of 1.6 s each while maintaining the internal chamber temperature at 40 °C. This contributed to improved stability and density of the sintered structures. Ultimately, the ceramic parts with a Vickers hardness of 12.2 GPa and a relative density of over 95% were able to be fabricated based on a high-viscosity resin with 25,000 cps.

The effects of heating rate and sintering time on the biaxial flexural strength of monolithic zirconia ceramics

The strength of zirconia ceramic materials used in restorations is dependent upon sintering. Varying sintering protocols may affect the biaxial flexural strength of zirconia materials. This in vitro study was conducted to investigate the effects of sintering parameters on the biaxial flexural strength of monolithic zirconia. Two different monoblock zirconia ceramics were used. Following coloration, samples of both types of ceramics were divided into groups according to whether or not biaxial flexural strength testing was performed directly after sintering or following thermocycling. Biaxial flexural strength data was analysed with a Shapiro Wilk normality test, followed by 1-way ANOVA, Tukey post hoc tests for inter-group comparisons, and paired samples t-tests for intra-group comparisons. A significant difference was found between the biaxial flexural strengths of Zircon X and Upcera ceramics before thermocycling (p<0.05). In both Zircon X and Upcera ceramic groups, the thermocycling process created a significant difference in the biaxial flexural strength values of the ceramic samples in Group 6 (p<0.05) which had the slowest heating rate and longest holding time. The zirconia ceramics have higher BFS at higher heating rates either before or after thermocycling. The holding time has significant effects on thermocycling and flexural strength. The zirconia achieved its optimum strength when it sintered at longer time regardless of heating rates.

Application of U-FAST Technology in Sintering of Submicron WC-Co Carbides

This article presents the microstructure, hardness, fracture toughness coefficient K_IC and phase composition of submicron WC-4Co carbides. The carbides were sintered using the innovative U-FAST (Upgraded Field Assisted Sintering Technology) method, from mixtures of WC-Co powders with an average WC grain size of 0.4 µm and 0.8 µm. The obtained sinters were characterized by a relative density above 99% of the theoretical density. The hardness of the obtained composites was above 2000 HV30, while the K_IC coefficient was about 8 MPa m^1/2.

Processing and Properties of Garnet-Type Li7 La3 Zr2 O12 Ceramic Electrolytes

Garnet-type solid electrolyte Li₇ La₃ Zr₂ O₁₂ (LLZO) is widely considered as one of the most promising candidates for solid state batteries (SSBs) owing to its high ionic conductivity and good electrochemical stability. Since its discovery in 2007, great progress has been made in terms of crystal chemistry, chemical and electrochemical properties, and battery application. Nonetheless, reliable and controllable preparation of LLZO ceramics with desirable properties still remains as big challenges. Herein, this review summarizes various synthetic routes of LLZO ceramics and examines the influence of various key processing parameters on the chemical and electrochemical properties. Focusing on correlation of processing parameters and properties, this review aims to provide new insights on a reliable and controllable production of high-quality LLZO ceramic electrolytes for SSB application.

Corrosion Resistance of Nickel-Aluminum Sinters Produced by High-Pressure HPHT/SPS Method

As part of extensive research on the properties of nickel-aluminum alloys, corrosion tests of sintered materials produced by the innovative HPHT/SPS (high pressure, high temperature/spark plasma sintering) method were performed in 0.1 molar H₂SO₄ acid. The hybrid, unique device used for this purpose (one of only two such devices operating in the world) is equipped with a Bridgman chamber, which allows heating with high-frequency pulsed current and sintering of powders under high pressure in the range of 4-8 GPa and at temperatures up to 2400 °C. Using this device for the production of materials contributes to the generation of new phases not obtainable by classical methods. In this article, the first test results obtained for the nickel-aluminum alloys never before produced by this method are discussed. Alloys containing 25 at.% Al, 37 at.% Al and 50 at.% Al were produced. The alloys were obtained by the combined effect of the pressure of 7 GPa and the temperature of 1200 °C generated by the pulsed current. The time of the sintering process was 60 s. The electrochemical tests, such as OCP (open circuit potential), polarization tests and EIS (electrochemical impedance spectroscopy), were carried out for the newly produced sinters and the results were compared with the reference materials, i.e., nickel and aluminum. The corrosion tests showed good corrosion resistance of the produced sinters, with corrosion rates of 0.091, 0.073 and 0.127 mm per year, respectively. It leaves no doubt that the good resistance of materials synthesized by powder metallurgy is due to the proper selection of the manufacturing process parameters, ensuring a high degree of material consolidation. This was further confirmed by the examinations of microstructure (optical microscopy and scanning electron microscopy) and the results of density tests (hydrostatic method). It has been shown that the obtained sinters were characterized by a compact, homogeneous and pore-free structure, though at the same time differentiated and multi-phase, while the densities of individual alloys reached a level close to the theoretical values. The Vickers hardness of the alloys was 334, 399 and 486 HV10, respectively.

Physicochemical, mechanical, dielectric, and biological properties of sintered hydroxyapatite/barium titanate nanocomposites for bone regeneration

Bone implants fabricated using nanocomposites containing hydroxyapatite (HA) and barium titanate (BT) show osteoconductive, osteoinductive, osteointegration, and piezoelectricity properties for bone regeneration applications. In our present study, HA and BT nanopowders were synthesized using high-energy ball-milling-assisted solid-state reaction with precursors of calcium carbonate and ammonium dihydrogen phosphate, and barium carbonate and titanium oxide powder mixtures, respectively. Hexagonal HA and tetragonal BT phases were formed after calcination at 700 and 1000 °C, respectively. Subsequently, hydroxyapatite/barium titanate (HA/BT) nanocomposites with different weight percentages of HA and BT were prepared by ball-milling, then compacted and sintered at two different temperatures to endow these bioceramics with better mechanical, dielectric, and biological properties for bone regeneration. Microstructure, crystal phases, and molecular structure characterizations of these sintered HA/BT nanocomposite compacts (SHBNCs) were performed using field-emission scanning electron microscopy, x-ray diffraction, and Fourier-transform infrared spectroscopy, respectively. Bulk density was evaluated using the Archimedes method. HA/BT nanocomposites with increased BT content showed enhanced dielectric properties, and the dielectric constant (ϵ_r) value for 5HA/95BT was ∼182 at 100 Hz. Mechanical properties such as Vicker's hardness, fracture toughness, yield strength, and diametral tensile strength were also investigated. The hemolysis assay of SHBNCs exhibited hemocompatibility. The effect of these SHBNCs as implants on thein vitrocytocompatibility and cell viability of MG-63 osteoblast-like cells was assessed by MTT assay and live/dead staining, respectively. 15HA/85BT showed increased metabolic activity with a higher number of live cells than BT after the culture period. Overall, the SHBNCs can be used as orthopedic implants for bone regeneration applications.

Combustion Synthesis and Reactive Spark Plasma Sintering of Non-Equiatomic CoAl-Based High Entropy Intermetallics

The present work reports the direct production of a high-entropy (HE) intermetallic CoNi_0.3Fe_0.3Cr_0.15Al material with a B2 structure from mechanically activated elemental powder mixtures. Fast and efficient combustion synthesis (CS), spark plasma sintering (SPS), and reactive SPS (RSPS) methods were used to synthesize the HE powders and bulks. The formation of the main B2 phase along with some amounts of secondary BCC and FCC phases are reported, and L12 intermetallic (CS scheme) and BCC based on Cr (CS + SPS and RSPS schemes at 1000 °C) were observed in all samples. The interaction between the components during heating to 1600 °C of the mechanically activated mixtures and CS powders has been studied. It has been shown that the formation of the CoNi_0.3Fe_0.3Cr_0.15Al phase occurs at 1370 °C through the formation of intermediate intermetallic phases (Al₉Me₂, AlCo, AlNi₃) and their solid solutions, which coincidences well with thermodynamic calculations and solubility diagrams. Compression tests at room and elevated temperatures showed that the alloy obtained by the RSPS method has enhanced mechanical properties (σ_p = 2.79 GPa, σ_0.2 = 1.82 GPa, ε = 11.5% at 400 °C) that surpass many known alloys in this system. High mechanical properties at elevated temperatures are provided by the B2 ordered phase due to the presence of impurity atoms and defects in the lattice.

Additive manufacturing of Al2O3 ceramics with MgO/SiC contents by laser powder bed fusion process

Laser powder bed fusion is a laser-based additive manufacturing technique that uses a high-energy laser beam to interact directly with powder feedstock. LPBF of oxide ceramics is highly desirable for aerospace, biomedical and high-tech industries. However, the LPBF of ceramics remains a challenging area to address. In this work, a new slurry-based approach for LPBF of ceramic was studied, which has some significant advantages compared to indirect selective laser sintering of ceramic powders. LPBF of Al2O3 was fabricated at different MgO loads up to 80 wt%. Several specimens on different laser powers (70 W-120 W) were printed. The addition of magnesia influenced the microstructure of the alumina ceramic significantly. The findings show that when the laser power is high and the magnesia load is low, the surface quality of the printing parts improves. It is feasible to produce slurry ceramic parts without binders through LPBF. Furthermore, the effects of SiC and MgO loads on the microstructure and surface morphology of alumina are compared and analysed.

Metal Nanocatalyst Sintering Interrogated at Complementary Length Scales

Metal nanoparticle (NP) sintering is a prime cause of catalyst degradation, limiting its economic lifetime and viability. To date, sintering phenomena are interrogated either at the bulk scale to probe averaged NP properties or at the level of individual NPs to visualize atomic motion. Yet, "mesoscale" strategies which bridge these worlds can chart NP populations at intermediate length scales but remain elusive due to characterization challenges. Here, a multi-pronged approach is developed to provide complementary information on Pt NP sintering covering multiple length scales. High-resolution scanning electron microscopy (HRSEM) and Monte Carlo simulation show that the size evolution of individual NPs depends on the number of coalescence events they undergo during their lifetime. In its turn, the probability of coalescence is strongly dependent on the NP's mesoscale environment, where local population heterogeneities generate NP-rich "hotspots" and NP-free zones during sintering. Surprisingly, advanced in situ synchrotron X-ray diffraction shows that not all NPs within the small NP sub-population are equally prone to sintering, depending on their crystallographic orientation on the support surface. The demonstrated approach shows that mesoscale heterogeneities in the NP population drive sintering and mitigation strategies demand their maximal elimination via advanced catalyst synthesis strategies.

Improved Mechanical Properties of Alumina Ceramics Using Plasma-Assisted Milling Technique

In order to improve the mechanical properties of alumina ceramics, dielectric barrier discharge plasma-assisted milling (DBDPM) was employed to activate alumina powder. The effect of the plasma-assisted milling technique on the grinding behavior of alumina powder, as well as the microstructure and properties of fabricated alumina ceramic, was investigated in detail. Attributed to the great thermal stress induced via plasma heating, DBDPM showed significantly higher grinding efficiency than the common vibratory milling technique. Moreover, the lattice distortion of alumina grains occurred with the application of plasma, leading to an improved sintering activity of the produced alumina powders. Therefore, compared with the common vibratory milling technique, the fabricated alumina ceramics exhibited smaller grain sizes and improved mechanical properties when using alumina powder produced via the DBDPM method as the starting material.