Powder Metallurgy Route to Ultrafine-Grained Refractory Metals

Ultrafine-grained (UFG) refractory metals are promising materials for applications in aerospace, microelectronics, nuclear energy, and many others under extreme environments. Powder metallurgy (PM) allows to produce such materials with well-controlled chemistry and microstructure at multiple length scales and near-net shape manufacturing. However, sintering refractory metals to full density while maintaining a fine microstructure is still challenging due to the high sintering temperature and the difficulty to separate the kinetics of densification versus grain growth. Here an overview of the sintering issues, microstructural design rules, and PM practices towards UFG and nanocrystalline refractory metals are sought to be provided. The previous efforts shall be reviewed to address the processing challenges, including the use of fine/nanopowders, second-phase grain growth inhibitors, and field-assisted sintering techniques. Recently, pressureless two-step sintering has been successfully demonstrated in producing dense UFG refractory metals down to ≈300 nm average grain size with a uniform microstructure and this technological breakthrough shall be reviewed. PM progresses in specific materials systems shall be next reviewed, including elementary metals (W and Mo), refractory alloys (W-Re), refractory high-entropy alloys, and their composites. Last, future developments and the endeavor towards UFG and nanocrystalline refractory metals with exceptionally uniform microstructure and improved properties are outlined.

Novel SrO-Containing Glass-Ceramic Sealants for Solid Oxide Electrolysis Cells (SOEC): Their Design and Characterization under Relevant Conditions

This study presents results on the development of strontium oxide (SrO) containing glass sealants used to join Crofer22APU to yttria-stabilized zirconia (3YSZ), in which the main glass components, that is, silicon oxide (SiO₂), strontium oxide (SrO), calcium oxide (CaO) and aluminum oxide (Al₂O₃), have been varied appropriately. Certain properties, such as the crystallization behavior, the coefficient of thermal expansion, adhesion, and reactivity of the sealants in contact with Crofer22APU, have been reviewed and discussed. The optimized glass composition (with CTE in the 9.8-10.3 × 10^-6 K^-1 range) results in a good joining behavior by hindering the formation of undesirable strontium chromate (SrCrO₄) on contact with the Crofer22APU steel after 1000 h. at 850 °C. High specific resistivity values of about 10⁶ Ohm.cm have been obtained, thus demonstrating good insulating properties at 850 °C under an applied voltage of 1.6 V. A negligible degradation in the electrical resistivity trend was measured during the test up to 1000 h, thus excluding the presence of detrimental reactions of the glass-ceramic sealant in contact with Crofer22APU under a dual atmosphere, as confirmed using SEM-EDS post-mortem analyses.

Conventional, Speed Sintering and High-Speed Sintering of Zirconia: A Systematic Review of the Current Status of Applications in Dentistry with a Focus on Precision, Mechanical and Optical Parameters

The aim of this systematic review was to provide an overview of the technical and clinical outcomes of conventional, speed sintering and high-speed sintering protocols of zirconia in the dental field. Data on precision, mechanical and optical parameters were evaluated and related to the clinical performance of zirconia ceramic. The PICOS search strategy was applied using MEDLINE to search for in vitro and in vivo studies using MeSH Terms by two reviewers. Of 66 potentially relevant studies, 5 full text articles were selected and 10 were further retrieved through a manual search. All 15 studies included in the systematic review were in vitro studies. Mechanical, precision and optical properties (marginal and internal fit, fracture strength and modulus, wear, translucency and opalescence, aging resistance/hydrothermal aging) were evaluated regarding 3-, 4- and 5-YTZP zirconia material and conventional, high- and high-speed sintering protocols. Mechanical and precision results were similar or better when speed or high-speed sintering methods were used for 3-, 4- and 5-YTZP zirconia. Translucency is usually reduced when 3 Y-TZP is used with speed sintering methods. All types of zirconia using the sintering procedures performed mechanically better compared to lithium disilicate glass ceramics but glass ceramics showed better results regarding translucency.

Geopolymer-Based Artificial Aggregates: A Review on Methods of Producing, Properties, and Improving Techniques

The depletion of aggregate-related natural resources is the primary concern of all researchers globally. Recent studies emphasize the significance of recycling and reusing various types of natural or by-product material waste from industry as a result of the building industry's rising demand for aggregate as the primary component in concrete production. It has been demonstrated that the geopolymer system has exceptional features, such as high strength, superior durability, and greater resistance to fire exposure, making it a viable alternative to ordinary Portland Cement (OPC) concrete. This study will examine the present method utilized to generate artificial aggregate-based geopolymers, including their physical and mechanical properties, as well as their characterization. The production process of geopolymer derived from synthetic aggregates will be highlighted. In conjunction with the bonding of aggregates and the cement matrix, the interfacial transition zone (ITZ) is highlighted in this work as an additional important property to be researched in the future. It will be discussed how to improve the properties of geopolymers based on artificial aggregates. It has been demonstrated that cold bonding provides superior qualities for artificial aggregate while conserving energy during production. The creation of ITZ has a significant impact on the bonding strength between artificial aggregates and the cement matrix. Additionally, improvement strategies demonstrate viable methods for enhancing the quality of manufactured aggregates. In addition, other recommendations are discussed in this study for future work.

Improved Mechanical and Corrosion Properties of Powder Metallurgy Austenitic, Ferritic, and Martensitic Stainless Steels by Liquid Phase Sintering

Powder metallurgy (PM) has been widely used to produce various steels in industry, mainly due to its capabilities for manufacturing nearly net-shaped products and mass production. To improve the performances of PM stainless steels, the roles of 0.6 wt% B additive in the microstructures, mechanical properties, and corrosion resistances of PM 304L austenitic, 410L ferritic, and 410 martensitic stainless steels were investigated. The results showed that adding 0.6 wt% B significantly improved the sintered densities of the three kinds of stainless steels due to the liquid phase sintering (LPS) phenomenon. The borides in 304L + 0.6B, 410L + 0.6B, and 410 + 0.6B were rich in B and Cr atoms but deficient in Fe, Ni, or C atoms, as analyzed by electron probe micro-analysis. Furthermore, the B additive contributed to the improved apparent hardness and corrosion resistance of PM stainless steels. In the 410L stainless steel, the 0.6 wt% B addition increased the corrosion voltage from -0.43 V_SCE to -0.24 V_SCE and reduced the corrosion current density from 2.27 × 10^-6 A/cm² to 1.93 × 10^-7 A/cm². The effects of several factors, namely: porosity; the generation of boride; the matrix/boride interfacial areas; Cr depletion; and the microstructure on the corrosion performances are discussed. The findings clearly indicate that porosity plays a predominant role in the corrosion resistances of PM austenitic, ferritic, and martensitic stainless steels.

Colossal Permittivity Characteristics of (Nb, Si) Co-Doped TiO2 Ceramics

(Nb5+, Si4+) co-doped TiO2 (NSTO) ceramics with the compositions (Nb0.5Si0.5)xTi1−xO2, x = 0, 0.025, 0.050 and 0.1 were prepared with a solid-state reaction technique. X-ray diffraction (XRD) patterns and Raman spectra confirmed that the tetragonal rutile is the main phase in all the ceramics. Additionally, XRD revealed the presence of a secondary phase of SiO2 in the co-doped ceramics. Impedance spectroscopy analysis showed two contributions, which correspond to the responses of grain and grain-boundary. All the (Nb, Si) co-doped TiO2 showed improved dielectric performance in the high frequency range (>103 Hz). The sample (Nb0.5Si0.5)0.025Ti0.975O2 showed the best dielectric performance in terms of higher relative permittivity (5.5 × 104) and lower dielectric loss (0.18), at 10 kHz and 300 K, compared to pure TiO2 (1.1 × 103, 0.34). The colossal permittivity of NSTO ceramics is attributed to an internal barrier layer capacitance (IBLC) effect, formed by insulating grain-boundaries and semiconductor grains in the ceramics.

Effects of Bonding Materials on Optical-Thermal Performances and High-Temperature Reliability of High-Power LED

The die-bonding layer between chips and substrate determinates the heat conduction efficiency of high-power LED. Sn-based solder, AuSn20 eutectic, and nano-Ag paste were widely applied to LED interconnection. In this paper, the optical-thermal performances and high-temperature reliability of LED with these bonding materials have systematically compared and studied. The thermal conductivity, electrical resistivity, and mechanical property of these bonding materials were characterized. The LED module packaged with nano-Ag has a minimum working temperature of 21.5 °C. The total thermal resistance of LED packaged with nano-Ag, Au80Sn20, and SAC305 is 4.82, 7.84, and 8.75 K/W, respectively, which is 4.72, 6.14, and 7.84 K/W higher after aging for 500 h. Meanwhile, the junction temperature change of these LEDs increases from 2.33, 3.76, and 4.25 °C to 4.34, 4.81, and 6.41 °C after aging, respectively. The thermal resistance of the nano-Ag, Au80Sn20 and SAC305 layer after aging is 1.5%, 65.7%, and 151.5% higher than before aging, respectively. After aging, the LED bonded with nano-Ag has the better optical performances in spectral intensity and light output power, which indicates its excellent heat dissipation can improve the light efficiency. These results demonstrate the nano-Ag bonding material could enhance the optical-thermal performances and high-temperature reliability of high-power LED.

Machine Learning-Based Void Percentage Analysis of Components Fabricated with the Low-Cost Metal Material Extrusion Process

Additive manufacturing (AM) is a widely used layer-by-layer manufacturing process. Material extrusion (ME) is one of the most popular AM techniques. Lately, low-cost metal material extrusion (LCMME) technology is developed to perform metal ME to produce metallic parts with the ME technology. This technique is used to fabricate metallic parts after sintering the metal infused additively manufactured parts. Both AM and sintering process parameters will affect the quality of the final parts. It is evident that the sintered parts do not have the same mechanical properties as the pure metal parts fabricated by the traditional manufacturing processes. In this research, several machine learning algorithms are used to predict the size of the internal voids of the final parts based on the collected data. Additionally, the results show that the neural network (NN) is more accurate than the support vector regression (SVR) on prediction.

Preparation of Calcium Phosphate Compounds on Zirconia Surfaces for Dental Implant Applications

Titanium is widely used in medical implants despite the release of heavy metal ions over long-term use. Zirconia is very close to the color of teeth; however, its biological inertness hinders bonding with bone tissue. Alkaline treatment and coatings of calcium phosphate can be used to enhance bone regeneration adjacent to dental implants. This study examined the effects of alkaline treatment, calcium phosphate coatings, and sintering, on the physical properties of implant material. Our analysis confirmed that the calcium phosphate species were octacalcium phosphate (OCP). The sintering of calcium phosphate was shown to create B-type HAP, which is highly conducive toward the differentiation of mesenchymal stem cells (MSCs) into osteoblasts for the facilitation of bone integration. Conclusions: This study demonstrated the room-temperature fabrication of dental implants with superhydrophilic surfaces to enhance biocompatibility.

Laser Sintering Approaches for Bone Tissue Engineering

The adoption of additive manufacturing (AM) techniques into the medical space has revolutionised tissue engineering. Depending upon the tissue type, specific AM approaches are capable of closely matching the physical and biological tissue attributes, to guide tissue regeneration. For hard tissue such as bone, powder bed fusion (PBF) techniques have significant potential, as they are capable of fabricating materials that can match the mechanical requirements necessary to maintain bone functionality and support regeneration. This review focuses on the PBF techniques that utilize laser sintering for creating scaffolds for bone tissue engineering (BTE) applications. Optimal scaffold requirements are explained, ranging from material biocompatibility and bioactivity, to generating specific architectures to recapitulate the porosity, interconnectivity, and mechanical properties of native human bone. The main objective of the review is to outline the most common materials processed using PBF in the context of BTE; initially outlining the most common polymers, including polyamide, polycaprolactone, polyethylene, and polyetheretherketone. Subsequent sections investigate the use of metals and ceramics in similar systems for BTE applications. The last section explores how composite materials can be used. Within each material section, the benefits and shortcomings are outlined, including their mechanical and biological performance, as well as associated printing parameters. The framework provided can be applied to the development of new, novel materials or laser-based approaches to ultimately generate bone tissue analogues or for guiding bone regeneration.

The Influence of Nanographite Addition on the Compaction Process and Properties of AISI 316L Sintered Stainless Steel

This paper presents the effect of graphite addition on the pressing process and selected mechanical properties of AISI 316L austenitic stainless steel. The graphite powders used in this study differed in the value of the specific surface area of the particles, which were 15 (micropowder), 350, and 400 m²/g (nanopowder). Mixtures with the addition of lubricants—stearic acid and Kenolube—were also created, for comparison purposes. The scope of the tests included compressibility of blends, measurements of the ejection force while removing the compacts from the die, micro-structural studies, a static tensile test, a three-point bending test, a Kc impact test, Rockwell hardness, and Vickers microhardness measurements. The study demonstrated that the addition of graphite nanopowder to the studied steel acts as a lubricant, providing a significant improvement in lubricity during the pressing process. Moreover, the addition of nanographite allowed for a significant increase in the mechanical properties studied in this work; it was observed that, for the sinters made of mixtures with a higher graphite content and with a large specific surface area of its particles, better values for the tested properties were obtained.

Influence of Diamond Grain Size on the Basic Properties of WC-Co/Diamond Composites Used in Tools for Wood-Based Materials Machining

The paper presents the effect of diamond particle size (varying between 2.5 µm and 20 µm) on the microstructure, density and hardness of WC-Co/diamond composites. The obtained materials contained 30% vol. diamond. The advanced sintering method Pulse Plasma Sintering (PPS) was used for the production of composites. The sintering process was carried out in two stages at a pressure of 50 and 100 MPa and a temperature of 1050 °C. Depending on the size of the diamond particles, composites with a density of 91–99% were obtained. Microstructure studies were performed employing scanning electron microscopy, along with an analysis of the chemical composition in micro-areas. Additionally, the phase composition was investigated by means of X-ray diffraction. In addition, hardness tests were performed. It was found that the size of the diamond particles significantly influenced the microstructure of the tested materials, as well as the density and hardness. As a result of PPS sintering of composites containing the finest diamond particles (2.5–5 µm), the presence of a metastable type of diamond—graphite was found.

Dielectric Properties of Bi2/3Cu3Ti4O12 Ceramics Prepared by Mechanical Ball Milling and Low Temperature Conventional Sintering

In the current study, Bi_2/3Cu₃Ti₄O₁₂ (BCTO) ceramics were prepared by mechanical ball mill of the elemental oxides followed by conventional sintering of the powder without any pre-sintering heat treatments. The sintering temperature was in the range 950-990 °C, which is 100-150 °C lower than the previous conventional sintering studies on BCTO ceramics. All the ceramic samples showed body-centered cubic phase and grain size ≈ 2-6 μm. Sintering temperature in the range 950-975 °C resulted in comparatively lower dielectric loss and lower thermal coefficient of permittivity in the temperature range from -50 to 120 °C. All the BCTO ceramics showed reasonably high relative permittivity. The behavior of BCTO ceramics was correlated with the change in oxygen content in the samples with sintering temperature. This interpretation was supported by the measurements of the energy dispersive x-ray spectroscopy (EDS) elemental analysis and activation energy for conduction and for relaxation in the ceramics.

Green synthesis of novelin situmicro/submicron-Cu paste for semiconductor interconnection

A green method for the synthesis ofin situCu paste is developed. Cu particles are prepared through chemical reduction by selecting a special copper source, reducing agent, and solvent. Then the reaction solution is directly concentrated to obtain anin situCu paste. The synthesis of Cu particles and the preparation of Cu paste are conducted simultaneously, and the process of separation, purification, drying, storage, and re-dispersion of powder are reduced. Particles are not directly exposed to air, thus the oxidation of micro/submicron -Cu is effectively prevented, and the agglomeration of particles caused by drying and dispersion operations is simultaneously reduced. Furthermore, the proposed method has a certain universality, and different types of Cu sources can be used to preparein situpaste with different sizes and morphologies. The entire preparation process is simple, efficient, green, and the yield can reach 99.99%, which breaks through the bottleneck of the application of traditional micro/submicron-Cu materials. Copper acetate-basedin situpaste is sintered for 30 min at 260 °C and 2 MPa in a reducing atmosphere. The shear strength, resistivity, and thermal conductivity reach 55.26 MPa, 4.01 × 10^-8Ω·m, and 92.75 W/(m·K), respectively, which could meet the interconnection application of power semiconductor devices.

Lead-Free Sodium Potassium Niobate-Based Multilayer Structures for Ultrasound Transducer Applications

Thick films with nominal composition (K₀.₅Na₀.₅)₀.₉₉Sr₀.₀₀₅NbO₃ (KNNSr) on porous ceramics with identical nominal composition were investigated as potential candidates for environmentally benign ultrasonic transducers composed entirely of inorganic materials. In this paper, the processing of the multilayer structure, namely, the thick film by screen printing and the porous ceramic by sacrificial template method, is related to their phase composition, microstructure, electromechanical, and acoustic properties to understand the performance of the devices. The ceramic with a homogeneous distribution of 8 μm pores had a sufficiently high attenuation coefficient of 0.5 dB/mm/MHz and served as an effective backing. The KNNSr thick films sintered at 1100 °C exhibited a homogeneous microstructure and a relative density of 97%, contributing to a large dielectric permittivity and elastic constant and yielding a thickness coupling factor k_t of ~30%. The electroacoustic response of the multilayer structure in water provides a centre frequency of 15 MHz and a very large fractional bandwidth (BW) of 127% at -6 dB. The multilayer structure is a candidate for imaging applications operating above 15 MHz, especially by realising focused-beam structure through lenses to further increase the sensitivity in the focal zone.

A review on intense pulsed light process as post-treatment for metal oxide thin films and nanostructures for device application

The intense pulsed light (IPL) post-treatment process has attracted great attention in the device fabrication due to its versatility and rapidity particularly for solution process functional structures in devices, flexible/printed electronics, and continuous manufacturing process. The metal oxide materials inherently have multi-functionality and have been widely used in form of thin films or nanostructures in device application such as thin film transistors, light emitting diodes, solar cells, supercapacitors, etc. The IPL treatment enhances the physical and/or chemical properties of the functional metal oxide through photothermal effects. However, most metal oxides are transparent to most range of visible light and require more energy for post-treatment. In this review, we have summarized the IPL post-treatment processes for metal oxide thin films and nanostructures in device applications. The sintering and annealing of metal oxides using IPL improved the device performances by employing additional light absorbing layer or back-reflector. The IPL process becomes an innovative versatile post-treatment process in conjunction with multi-functional metal oxides in near-future device applications.

Sustainable Biocomposites for Structural Applications with Environmental Affinity

In this work, we report a facile preparation of biocomposites using a chitosan matrix that is reinforced with morphed graphene in amounts from 1 to 5 wt % C. The composites are processed by milling and conventional sintering. The morphed graphene additions show clear improvements in mechanical properties, having a direct correlation with temperature in particular for 180 °C. Higher temperatures are detrimental to chitosan and the properties drop because chitosan degrades. Mechanical properties in the composite such as yield strength and compressive strength increase between 40 and 50% with respect to the pure chitosan samples. The Young's modulus presents a drop of approximately 10%, but the fracture toughness increases up to 3.5 fold. The properties of our sustainable composites are comparable to those seen in polymers such as polyethylene, polypropylene, nylon, and poly(methyl methacrylate), among other commodity or single use plastics. The enhancement in the mechanical properties is attributed to the morphed graphene embedded chitosan matrix that generates a network of intergranular "anchors" that hold the chitosan crystals in place, preventing failure. The composites can be molded into near-net-shape products, machined, or shaped using various methods including laser lithography. These studies demonstrate the feasibility of fabricating biocomposites with different architectures and sizes for disposable structural components. Both chitosan and the composites are compostable and biodegradable with the potential to sustain plant growth when discarded. In addition, morphed graphene and chitosan are produced from byproducts or waste, which may result in a negative carbon footprint on the environment.

The Influence of Sintering Temperature on the Pore Structure of an Alkali-Activated Kaolin-Based Geopolymer Ceramic

Geopolymer materials are used as construction materials due to their lower carbon dioxide (CO₂) emissions compared with conventional cementitious materials. An example of a geopolymer material is alkali-activated kaolin, which is a viable alternative for producing high-strength ceramics. Producing high-performing kaolin ceramics using the conventional method requires a high processing temperature (over 1200 °C). However, properties such as pore size and distribution are affected at high sintering temperatures. Therefore, knowledge regarding the sintering process and related pore structures on alkali-activated kaolin geopolymer ceramic is crucial for optimizing the properties of the aforementioned materials. Pore size was analyzed using neutron tomography, while pore distribution was observed using synchrotron micro-XRF. This study elucidated the pore structure of alkali-activated kaolin at various sintering temperatures. The experiments showed the presence of open pores and closed pores in alkali-activated kaolin geopolymer ceramic samples. The distributions of the main elements within the geopolymer ceramic edifice were found with Si and Al maps, allowing for the identification of the kaolin geopolymer. The results also confirmed that increasing the sintering temperature to 1100 °C resulted in the alkali-activated kaolin geopolymer ceramic samples having large pores, with an average size of ~80 µm³ and a layered porosity distribution.

Study on the difference of osteogenesis and Notch signaling pathway expression in biphasic calcium-phosphorus ceramic granule materials with different microstructure

Different microstructures including micropore diameter, micropore volume, and micropore area of biphasic calcium phosphate (BCP, hydroxyapatite: β-tricalcium phosphate = 8:2) ceramics granules were obtained by varying their sintering temperatures. Sprague-Dawley rat bone marrow-derived stem cells (BMSCs) were co-cultured with BCPs in vitro study and the BMSCs showed different degrees of proliferative activity under the influence of three materials. Cell proliferation and vitality were assessed. Three kinds of BCPs were implanted in the dorsal muscle of beagle dogs. At 1, 2, and 3 months, histological analyses were conducted to estimate the rate of osteogenesis. Expression of Notch pathway genes and osteogenic-related genes were detected by quantitative real-time polymerase chain reaction (q-rtPCR). The proportion of osteogenesis area increased to:48.75 ± 4.20%, 29.48 ± 1.55%, and 26.58 ± 3.86% at 3 months after the implantation (1050, 1150, 1250). Significant differences were observed in the upregulation of Notch pathway genes among different BCPs. BCPs with different micropore diameters have different ectopic osteogenesis effects and led to up-regulation of the Notch signaling pathway genes to different extents.

MgO-ZrO2 Ceramic Composites for Silicomanganese Production

The deterioration of the refractory lining represents a significant problem for the smooth operation in the ferroalloys industry, particularly in the production of silicomanganese, due to the periodic requirements of substitution of the damaged refractory. Within this context, magnesia refractories are commonly employed in the critical zones of the furnaces used in silicomanganese production since the slag involved in the process has a basic character. The behavior of MgO–ZrO₂ ceramic composites with different ZrO₂ nanoparticles (0, 1, 3, and 5 wt.%) contents in the presence of silicomanganese slags is proposed in this manuscript. XPS, XRD and SEM–EDX were used to evaluate the properties of the ceramic composite against the silicomanganese slag. The static corrosion test was used to evaluate the corrosion of the refractory. Results suggest that corrosion is controlled by the change in slag viscosity due to the reaction between CaZrO₃ and the melted slag. Besides, ZrO₂ nanoparticles located at both triple points and grain boundaries act as a barrier for the slag advance within the refractory. The utilization of MgO refractories with ZrO₂ nanoparticles can extend the life of furnaces used to produce silicomanganese.

A Green and Facile Microvia Filling Method via Printing and Sintering of Cu-Ag Core-Shell Nano-Microparticles

In this work, we developed an eco-friendly and facile microvia filling method by using printing and sintering of Cu-Ag core-shell nano-microparticles (Cu@Ag NMPs). Through a chemical reduction reaction in a modified silver ammonia solution with L-His complexing agent, Cu@Ag NMPs with compact and uniform Ag shells, excellent sphericity and oxidation resistance were synthesized. The as-synthesized Cu@Ag NMPs show superior microvia filling properties to Cu nanoparticles (NPs), Ag NPs, and Cu NMPs. By developing a dense refill method, the porosity of the sintered particles within the microvias was significantly reduced from ~30% to ~10%, and the electrical conductivity is increased about twenty-fold. Combing the Cu@Ag NMPs and the dense refill method, the microvias could obtain resistivities as low as 7.0 and 6.3 μΩ·cm under the sintering temperatures of 220 °C and 260 °C, respectively. The material and method in this study possess great potentials in advanced electronic applications.

A Review of Binderless Polycrystalline Diamonds: Focus on the High-Pressure-High-Temperature Sintering Process

Nowadays, synthetic diamonds are easy to fabricate industrially, and a wide range of methods were developed during the last century. Among them, the high-pressure–high-temperature (HP–HT) process is the most used to prepare diamond compacts for cutting or drilling applications. However, these diamond compacts contain binder, limiting their mechanical and optical properties and their substantial uses. Binderless diamond compacts were synthesized more recently, and important developments were made to optimize the P–T conditions of sintering. Resulting sintered compacts had mechanical and optical properties at least equivalent to that of natural single crystal and higher than that of binder-containing sintered compacts, offering a huge potential market. However, pressure–temperature (P–T) conditions to sinter such bodies remain too high for an industrial transfer, making this the next challenge to be accomplished. This review gives an overview of natural diamond formation and the main experimental techniques that are used to synthesize and/or sinter diamond powders and compact objects. The focus of this review is the HP–HT process, especially for the synthesis and sintering of binderless diamonds. P–T conditions of the formation and exceptional properties of such objects are discussed and compared with classic binder-diamonds objects and with natural single-crystal diamonds. Finally, the question of an industrial transfer is asked and outlooks related to this are proposed.

Novel Composite Nitride Nanoceramics from Reaction-Mixed Nanocrystalline Powders in the System Aluminum Nitride AlN/Gallium Nitride GaN/Titanium Nitride TiN (Al:Ga:Ti = 1:1:1)

A study is presented on the synthesis of reaction-mixed nitride nanopowders in the reference system of aluminium nitride AlN, gallium nitride GaN, and titanium nitride TiN (Al:Ga:Ti = 1:1:1) followed by their high-pressure and high-temperature sintering towards novel multi-nitride composite nanoceramics. The synthesis starts with a 4 h reflux in hexane of the mixture of the respective metal dimethylamides, which is followed by hexane evacuation, and reactions of the residue in liquid ammonia at −33 °C to afford a mixed metal amide/imide precursor. Plausible equilibration towards a bimetallic Al/Ga-dimethylamide compound upon mixing of the solutions of the individual metal-dimethylamide precursors containing dimeric {Al[N(CH₃)₂]₃}₂ and dimeric {Ga[N(CH₃)₂]₃}₂ is confirmed by ¹H- and ¹³C{H}-NMR spectroscopy in C₆D₆ solution. The precursor is pyrolyzed under ammonia at 800 and 950 °C yielding, respectively, two different reaction-mixed composite nitride nanopowders. The latter are subjected to no-additive high-pressure and high-temperature sintering under conditions either conservative for the initial powder nanocrystallinity (650 °C, 7.7 GPa) or promoting crystal growth/recrystallization and, possibly, solid solution formation via reactions of AlN and GaN towards Al_0.5Ga_0.5N (1000 and 1100 °C, 7.7 GPa). The sintered composite pellets show moderately high mechanical hardness as determined by the Vicker’s method. The starting nanopowders and resulting nanoceramics are characterized by powder XRD, Raman spectroscopy, and SEM/EDX. It is demonstrated that, in addition to the multi-nitride composite nanoceramics of hexagonal AlN/hexagonal GaN/cubic TiN, under specific conditions the novel composite nanoceramics made of hexagonal Al_0.5Ga_0.5N and cubic TiN can be prepared.

Sintering Behavior of Bi-Material Micro-Component of 17-4PH Stainless Steel and Yttria-Stabilized Zirconia Produced by Two-Component Micro-Powder Injection Molding Process

In this research, we investigated the influence of the sintering temperature on the physical and mechanical properties of micro-sized bi-material components of 17-4PH stainless steel and 3 mol% yttria-stabilized zirconia fabricated using a two-component micro-powder injection molding (2C-μPIM) process. First, 17-4PH and zirconia powders were separately mixed with binders to obtain feedstocks, which were then injection-molded into the dumbbell shape, followed by the binder extraction process. Subsequently, the debound micro-specimens were subjected to sintering between 1250 °C and 1350 °C for 3 h. Per the observations of the microstructures using scanning electron microscopy (SEM), a strong bond between metal and ceramic in micro-sized 17-4PH/zirconia components was formed when the sintering temperature exceeded 1300 °C. The maximum relative density of 99% was achieved when the bi-material micro-part was sintered at 1350 °C. The linear shrinkage increased from 9.6% to 17.4% when the sintering temperature was increased from 1250 °C to 1350 °C. The highest hardness value of 1439.6 HV was achieved at 1350 °C along the bi-material bonding region. Moreover, a maximum tensile strength of 13.7 MPa was obtained at 1350 °C.

Visualization of the Final Stage of Sintering in Nanoceramics with Atomic Resolution

The deep understanding of the sintering mechanism is pivotal to optimizing denser ceramics production. Although several models explain the sintering satisfactorily on the micrometric scale, the extrapolation for nanostructured systems is not trivial. Aiming to provide additional information about the particularities of the sintering at the nanoscale, we performed in situ experiments using high-resolution transmission electron microscopy (HRTEM). We studied the pore elimination process in a ZrO₂ thin film and identified a high anisotropic pore elimination. Interestingly, there is a redistribution of the atoms from the rough surface in the solid-gas surface, followed by the atom attachment in a faceted surface. Finally, we found evidence of the pore acting as a pin, reducing the GB mobility. These findings certainly can contribute to enhance the kinetic models to describe the densification process of systems at the nanoscale.