The Preparation of an Ultrafine Copper Powder by the Hydrogen Reduction of an Ultrafine Copper Oxide Powder and Reduction Kinetics

Ultrafine copper powders were prepared by the air-jet milling of copper oxide (CuO) powders and a subsequent hydrogen (H2) reduction. After milling, the particle size and grain size of CuO powders decreased, while the specific surface area and structural microstrain increased, thereby improving the reaction activity. In a pure H2 atmosphere, the process of CuO reduction was conducted in one step, and followed a pseudo-first-order kinetics model. The smaller CuO powders after milling exhibited higher reduction rates and lower activation energies compared with those without milling. Based on the unreacted shrinking core model, the reduction of CuO powders via H2 was controlled by the interface reaction at the early stage, whereas the latter was limited by the diffusion of H2 through the solid product layer. Additionally, the scanning electron microscopy (SEM) indicated that copper powders after H2 reduction presented a spherical-like shape, and the sintering and agglomeration between particles occurred after 300 °C, which led to a moderate increase in particle size. The preparing parameters (at 400 °C for 180 min) were preferred to obtain ultrafine copper powders with an average particle size in the range of 5.43-6.72 μm and an oxygen content of less than 0.2 wt.%.

Optimization of the Consolidation Parameters for Enhanced Thermoelectric Properties of Gr-Bi2Te2.55Se0.45 Nanocomposites

Hot pressing represents a promising consolidation technique for ball-milled bismuth telluride alloys, yet deep investigations are needed to understand its effect on the thermoelectric properties. This paper studies the effect of hot-pressing parameters (temperature and pressure) on the thermoelectric properties of the n-type Gr-Bi2Te2.55Se0.45 nanocomposite. Ultra-high pressure, up to 1.5 GPa, is considered for the first time for consolidating Bi2(Te,Se)3 alloys. Results from this study show that increasing the temperature leads to changes in chemical composition and causes noticeable grain growth. On the contrary, increasing pressure mainly causes improvements in densification. Overall, increments in these two parameters improve the ZT values, with the temperature parameter having a higher influence. The highest ZT of 0.69 at 160 °C was obtained for the sample hot-pressed at 350 °C and 1 GPa for 5 min, which is indeed an excellent and competitive value when compared with results reported for this n-type Bi2Te2.55Se0.45 composition.

Exploring the Potential of Carbonized Nano-Si within G@C@Si Anodes for Lithium-Ion Rechargeable Batteries

This study presents the synthesis, characterization, and electrochemical performance evaluation of carbon@silicon (C@Si) and graphite@carbon@silicon (G@C@Si) nanocomposites as potential anode materials for lithium-ion batteries (LIBs). Employing a combination of mechanical milling and carbonization using citric acid, we developed nanocomposites exhibiting unique core-shell structures, as confirmed by detailed SEM and TEM analysis. The G@C@Si nanocomposite displayed superior electrochemical performance, delivering an initial discharge capacity of 1724 mAh g-1 and a high initial Coulombic efficiency of 87.37%. The nanocomposite demonstrated remarkable cycling durability with a discharge capacity of 1248 mAh g-1 over 200 cycles and an average Coulombic efficiency of 99.1% and high-capacity retention of about 83%. Notably, a high capacity of 1325 mAh g-1 was observed at a high 3C rate, and the electrode showed excellent resilience by rapidly recovering to a discharge capacity of 1637 mAh g-1 when the C rate was reduced back to 0.5C. Electrochemical impedance spectra revealed a reduced charge transfer resistance of approximately 43 Ω in the G@C@Si nanocomposite as compared to that of C@Si (∼56 Ω) and nano-Si (105 Ω), indicating enhanced lithium-ion diffusion due to the integration of graphite. Postcycle electrode analysis revealed excellent structural integrity, with minimized volume changes in both C@Si and G@C@Si. XPS studies revealed a thinner SEI layer formation in the G@C@Si electrode compared to C@Si. The C@Si core-shell formation through the citric acid treatment of nano-Si and integration of graphite by mechanical milling significantly boosts the electrochemical performance of the G@C@Si nanocomposite. These findings suggest that the G@C@Si nanocomposite offers immense potential for utilization in high-capacity and high-efficiency LIBs.

Synthesis of Tungsten Carbides in a Copper Matrix by Spark Plasma Sintering: Microstructure Formation Mechanisms and Properties of the Consolidated Materials

In this study, the synthesis of tungsten carbides in a copper matrix by spark plasma sintering (SPS) is conducted and the microstructure formation mechanisms of the composite materials are investigated. The reaction mixtures were prepared by the high-energy mechanical milling (MM) of W, C and Cu powders. The influence of the MM time and SPS temperature on the tungsten carbide synthesis in an inert copper matrix was analyzed. It was demonstrated that the milling duration is a critical factor for creating the direct contacts between the W and C reactants and increasing the reactive transformation degree. A WC-W2C-Cu composite was fabricated from the W-C-3Cu powder mixture milled for 10 min and subjected to SPS at a temperature of 980 °C for 5 min. The formation of unconventional microstructures with Cu-rich regions is related to inter-particle melting during SPS. The WC-W2C-Cu composite showed a promising combination of mechanical and functional properties: a hardness of 300 HV, an electrical conductivity of 24% of the International Annealed Copper Standard, a residual porosity of less than 5%, a coefficient of friction in pair with a WC-6Co counterpart of 0.46, and a specific wear rate of the material of 0.52 × 10-5 mm3 N-1 m-1.

Review on Generation and Characterization of Copper Particles and Copper Composites Prepared by Mechanical Milling on a Lab-Scale

This review aims to expose mechanical milling as an alternative method for generating copper-based particles (copper particles (CuP) and copper composites (CuC)); more specifically, via a top-down or bottom-up approach, on a lab-scale. This work will also highlight the different parameters that can affect the size distribution, the type, and the morphology of the obtained CuP or CuC, such as the type of mechanical mill, ball-to-powder ratios (BPR), the milling speed, milling time, and the milling environment, among others. This review analyzes various papers based on the Cu-based particle generation route, which begins with a pretreatment step, then mechanical milling, its approach (top-down or bottom-up), and the post-treatment. Finally, the characterization methods of the resulting CuP and CuC through mechanical milling are also discussed.

Fabrication of Copper of Harmonic Structure: Mechanical Property-Based Optimization of the Milling Parameters and Fracture Mechanism

A severe plastic deformation process for the achievement of favorable mechanical properties for metallic powder is mechanical milling. However, to obtain the highest productivity while maintaining reasonable manufacturing costs, the process parameters must be optimized to achieve the best mechanical properties. This study involved the use of response surface methodology to optimize the mechanical milling process parameters of harmonic-structure pure Cu. Certain critical parameters that affect the properties and fracture mechanisms of harmonic-structure pure Cu were investigated and are discussed in detail. The Box-Behnken design was used to design the experiments to determine the correlation between the process parameters and mechanical properties. The results show that the parameters (rotation speed, mechanical milling time, and powder-to-ball ratio) affect the microstructure characteristics and influence the mechanical performance, including the fracture mechanisms of harmonic-structure pure Cu specimens. The best combination values of the ultimate tensile strength (UTS) and elongation were found to be 272 MPa and 46.85%, respectively. This combination of properties can be achieved by applying an optimum set of process parameters: a rotation speed of 200 rpm; mechanical milling time of 17.78 h; and powder-to-ball ratio of 0.065. The superior UTS and elongation of the harmonic-structure pure Cu were found to be related to the delay of void and crack initiation in the core and shell interface regions, which in turn were controlled by the degree of strength variation between these regions.

Discoloration Improvement by Mechanically-Milled Binary Oxides as Radiopacifier for Mineral Trioxide Aggregates

Mineral trioxide aggregates (MTA) have been widely used in endodontic treatments, but after some time, patients suffer tooth discoloration due to the use of bismuth oxide (Bi2O3) as a radiopacifier. Replacement of Bi2O3 with high energy ball-milled single (zirconia ZrO2; hafnia, HfO2; or tantalum pentoxide, Ta2O5) or binary oxide powder was attempted, and corresponding discoloration improvement was investigated in the present study. Bi2O3-free MTA is expected to exhibit superior discoloration. The radiopacity, diametral tensile strength, and discoloration of MTA-like cements prepared from the as-milled powder were investigated. Experimental results showed that MTA-like cements prepared using Ta2O5 exhibited a slightly higher radiopacity than that of HfO2 but had a much higher radiopacity than ZrO2. Milling treatment (30 min to 3 h) did not affect the radiopacities significantly. These MTA-like cements exhibited superior color stability (all measured ΔE00 < 1.0) without any perceptible differences after UV irradiation. MTA-like cements prepared using ZrO2 exhibited the best color stability but the lowest radiopacity, which can be improved by introducing binary oxide. Among the investigated samples, MTA-like cement using (ZrO2)50(Ta2O5)50 exhibited excellent color stability and the best overall performance with a radiopacity of 3.25 mmAl and a diametral tensile strength of 4.39 MPa.

Properties of Fe-Si Alloy Anode for Lithium-Ion Battery Synthesized Using Mechanical Milling

Silicon (Si)-based anode materials can increase the energy density of lithium (Li)-ion batteries owing to the high weight and volume capacity of Si. However, their electrochemical properties rapidly deteriorate due to large volume changes in the electrode resulting from repeated charging and discharging. In this study, we manufactured structurally stable Fe–Si alloy powders by performing high-energy milling for up to 24 h through the reduction of the Si phase size and the formation of the α-FeSi₂ phase. The cause behind the deterioration of the electrochemical properties of the Fe–Si alloy powder produced by over-milling (milling for an increased time) was investigated. The 12 h milled Fe–Si alloy powder showed the best electrochemical properties. Through the microstructural analysis of the Fe–Si alloy powders after the evaluation of half/full coin cells, powder resistance tests, and charge/discharge cycles, it was found that this was due to the low electrical conductivity and durability of β-FeSi₂. The findings provide insight into the possible improvements in battery performance through the commercialization of Fe–Si alloy powders produced by over-milling in a mechanical alloying process.

Enhanced Room-Temperature Ionic Conductivity of NaCB11H12 via High-Energy Mechanical Milling

The body-centered cubic (bcc) polymorph of NaCB₁₁H₁₂ has been stabilized at room temperature by high-energy mechanical milling. Temperature-dependent electrochemical impedance spectroscopy shows an optimum at 45-min milling time, leading to an rt conductivity of 4 mS cm^-1. Mechanical milling suppresses an order-disorder phase transition in the investigated temperature range. Nevertheless, two main regimes can be identified, with two clearly distinct activation energies. Powder X-ray diffraction and ²³Na solid-state NMR reveal two different Na⁺ environments, which are partially occupied, in the bcc polymorph. The increased number of available sodium sites w.r.t. ccp polymorph raises the configurational entropy of the bcc phase, contributing to a higher ionic conductivity. Mechanical treatment does not alter the oxidative stability of NaCB₁₁H₁₂. Electrochemical test on a symmetric cell (Na|NaCB₁₁H₁₂|Na) without control of the stack pressure provides a critical current density of 0.12 mA cm^-2, able to fully charge/discharge a 120 mA h g^-1 specific capacity positive electrode at the rate of C/2.

Effect of the Processing Parameters on the Porosity and Mechanical Behavior of Titanium Samples with Bimodal Microstructure Produced via Hot Pressing

Commercially pure (c.p.) titanium grade IV with a bimodal microstructure is a promising material for biomedical implants. The influence of the processing parameters on the physical, microstructural, and mechanical properties was investigated. The bimodal microstructure was achieved from the blends of powder particles with different sizes, while the porous structure was obtained using the space-holder technique (50 vol.% of ammonium bicarbonate). Mechanically milled powders (10 and 20 h) were mixed in 50 wt.% or 75 wt.% with c.p. titanium. Four different mixtures of powders were precompacted via uniaxial cold pressing at 400 MPa. Then, the specimens were sintered at 750 °C via hot pressing in an argon gas atmosphere. The presence of a bimodal microstructure, comprised of small-grain regions separated by coarse-grain ones, was confirmed by optical and scanning electron microscopies. The samples with a bimodal microstructure exhibited an increase in the porosity compared with the commercially available pure Ti. In addition, the hardness was increased while the Young's modulus was decreased in the specimens with 75 wt.% of the milled powders (20 h).

Influence of Powder Milling and Annealing Parameters on the Formation of Cubic Li7La3Zr2O12 Compound

Li-ion batteries are widely used as energy storage devices due to their excellent electrochemical performance. The cubic Li₇La₃Zr₂O₁₂ (c-LLZO) compound is regarded as a promising candidate as a solid-state electrolyte for lithium-ion batteries due to its high bulk Li-ion conductivity, excellent thermal performance, and chemical stability. The standard manufacturing procedure involves the high-temperature and lengthy annealing of powders. However, the formation of the tetragonal modification of LLZO and other undesired side phases results in the deterioration of electrochemical properties. The mechanical milling of precursor powders can enhance the powders’ reactivity and can result in an easier formation of c-LLZO. The aim of this work was to study the influence of selected milling and annealing parameters on c-LLZO compound formation. The starting powders of La(OH)_3, Li₂CO₃, and ZrO₂ were subjected to milling in various ball mills, under different milling conditions. The powders were then annealed at various temperatures for different lengths of times. These studies showed that the phase transformation processes of the powders were not very sensitive to the milling parameters. On the other hand, the final phase composition and microstructure strongly depended on heat treatment conditions. Low temperature annealing (750 °C) for 3 h produced 90% of c-LLZO in the powder structure.

Effect of Tantalum Pentoxide Addition on the Radiopacity Performance of Bi2O3/Ta2O5 Composite Powders Prepared by Mechanical Milling

Among the various phases of bismuth oxide, the high temperature metastable face-centered cubic δ phase attracts great attention due to its unique properties. It can be used as an ionic conductor or an endodontic radiopacifying material. However, no reports concerning tantalum and bismuth binary oxide prepared by high energy ball milling and serving as a dental radiopacifier can be found. In the present study, Ta₂O₅-added Bi₂O₃ composite powders were mechanically milled to investigate the formation of these metastable phases. The as-milled powders were examined by X-ray diffraction and scanning electron microscopy to reveal the structural evolution. The as-milled composite powders then served as the radiopacifier within mineral trioxide aggregates (i.e., MTA). Radiopacity performance, diametral tensile strength, setting times, and biocompatibility of MTA-like cements solidified by deionized water, saline, or 10% calcium chloride solution were investigated. The experimental results showed that subsequent formation of high temperature metastable β-Bi_7.8Ta_0.2O_12.2, δ-Bi₂O₃, and δ-Bi₃TaO₇ phases can be observed after mechanical milling of (Bi₂O₃)₉₅(Ta₂O₅)₅ or (Bi₂O₃)₈₀(Ta₂O₅)₂₀ powder mixtures. Compared to its pristine Bi₂O₃ counterpart with a radiopacity of 4.42 mmAl, long setting times (60 and 120 min for initial and final setting times) and 84% MG-63 cell viability, MTA-like cement prepared from (Bi₂O₃)₉₅(Ta₂O₅)₅ powder exhibited superior performance with a radiopacity of 5.92 mmAl (the highest in the present work), accelerated setting times (the initial and final setting time can be shortened to 25 and 40 min, respectively), and biocompatibility (94% cell viability).

The Role of Sintering Temperature and Dual Metal Substitutions (Al3+, Ti4+) in the Development of NASICON-Structured Electrolyte

The aim of this study is to synthesize Li1+xAlxTixSn2-2x(PO4) sodium super ion conductor (NASICON) -based ceramic solid electrolyte and to study the effect of dual metal substitution on the electrical and structural properties of the electrolyte. The performance of the electrolyte is analyzed based on the sintering temperature (550 to 950 °C) as well as the composition. The trend of XRD results reveals the presence of impurities in the sample, and from Rietveld Refinement, the purest sample is achieved at a sintering temperature of 950 °C and when x = 0.6. The electrolytes obey Vegard's Law as the addition of Al3+ and Ti4+ provide linear relation with cell volume, which signifies a random distribution. The different composition has a different optimum sintering temperature at which the highest conductivity is achieved when the sample is sintered at 650 °C and x = 0.4. Field emission scanning electron microscope (FESEM) analysis showed that higher sintering temperature promotes the increment of grain boundaries and size. Based on energy dispersive X-ray spectroscopy (EDX) analysis, x = 0.4 produced the closest atomic percentage ratio to the theoretical value. Electrode polarization is found to be at maximum when x = 0.4, which is determined from dielectric analysis. The electrolytes follow non-Debye behavior as it shows a variety of relaxation times.

Modified Li7P3S11 Glass-Ceramic Electrolyte and Its Characterization

Li₇P₃S₁₁ glass ceramics have high conductivities competitive with liquid electrolytes, making them good candidates as solid-state electrolytes for all-solid-state lithium-ion batteries. However, the metastable nature and performance of Li₇P₃S₁₁ glass ceramics remain mysterious. Herein, modified Li₇P₃S₁₁ glass ceramics with compositions of 70Li₂S-30P₂S₅ were prepared via two-step mechanical milling and thermal annealing. Li₇P₃S₁₁ glass ceramics synthesized using the conventional method (mechanical milling and thermal annealing) were again ball-milled to obtain amorphous 70Li₂S-30P₂S₅ with a peculiar glass structure. Further thermal annealing was carried out to crystallize the glass. The obtained crystalline phase was analogous to the original Li₇P₃S₁₁ phase, but the conductivity was enhanced by a factor of 1.7. Based on ³¹P solid-state nuclear magnetic resonance (NMR) spectroscopy, the Li₇P₃S₁₁ phase contained an additional PS₄^3- unit. A rational deconvolution procedure for the ³¹P solid-state NMR spectra based on crystalline Li₇P₃S₁₁ was developed and applied to the samples. The analysis can resolve the additional crystalline PS₄^3- unit in the Li₇P₃S₁₁ structure. Based on two-dimensional double-quantum ³¹P NMR spectroscopy, the additional PS₄^3- unit is located adjacent to the P₂S₇^4- unit, suggesting that P₂S₇^4- is divided into two PS₄^3- units in the Li₇P₃S₁₁ phase. The flip motion of Li⁺ was also investigated based on the ⁷Li spin-lattice relaxation time. The independent activation energy of spin-lattice relaxation with respect to temperature in the Li₇P₃S₁₁ phase was attributed to a conduction path between the two PS₄^3- units. The findings provide a synthetic route that can be used to develop metastable solid-state electrolytes.

Statistical and Microstructural Analyses of Al-C-Cu Composites Synthesized Using the State Solid Route

Aluminum powder with different C and C–Cu mixtures powders were fabricated by powder metallurgy, using high-energy mechanical milling as a pre-treatment of powders. To evaluate the combined effect of the C–Cu mixture and the process conditions, such as sintering temperature/time and milling time, on the yield stress and hardness, two experimental designs were carried out. The results were analyzed with Minitab Statistical Software using contour plots. From the results, better mechanical properties were found at a Cu/C ratio of 0.33 and samples with high C content (3 wt. %). In samples subject to long sintering time (3 h), the mechanism of precipitation of the second phase was mainly present, resulting in an improvement in mechanical properties. From the difference found between the elastic limit and the microhardness tests, it was found that there was an inefficient sintering process affecting the elastic limit test results. Additionally, X-ray analyses using the Rietveld program, were used for microstructural characterization and mechanical parameters of yield strength and ultimate tensile strength.

Bimodal Microstructure in an AlZrTi Alloy Prepared by Mechanical Milling and Spark Plasma Sintering

The aim of this study was to prepare a low porosity bulk sample with a fine-grained structure from an AlZrTi alloy. Nanostructured powder particles were prepared by mechanical milling of gas atomized powder. The mechanically milled powder was consolidated using spark plasma sintering technology at 475 °C for 6 min using a pressure of 100 MPa. Sintering led to a low porosity sintered sample with a bimodal microstructure. The sintered sample was revealed to be composed of non-recrystallized grains with an approximate size of about 100 nm encompassed by distinct clusters of coarser, micrometer-sized grains. Whereas the larger grains were found to be lean on second phase particles, a high density of second phase particles was found in the areas of fine grains. The microhardness of the milled powder particles was established to be 163 ± 15 HV0.01, which decreased to a slightly lower value of 137 ± 25 HV0.01 after sintering.

Magnetic Properties of SmCo5 + 10 wt% Fe Exchange-Coupled Nanocomposites Produced from Recycled SmCo5

Nanostructured alloy powders of SmCo₅ + 10 wt% Fe obtained using recycled material were studied for the first time. The SmCo₅ precursor was obtained from commercial magnets recycled by hydrogen decrepitation. The results were compared with identically processed samples obtained using virgin SmCo₅ raw material. The samples were synthesized by dry high-energy ball-milling and subsequent heat treatment. Robust soft/hard exchange coupling was observed—with large coercivity, which is essential for commercial permanent magnets. The obtained energy products for the recycled material fall between 80% and 95% of those obtained when using virgin SmCo₅, depending on milling and annealing times. These results further offer viability of recycling and sustainability in production. These powders and processes are therefore candidates for the next generation of specialized and nanostructured exchange-coupled bulk industrial magnets.

Room-Temperature Stable Inorganic Halide Perovskite as Potential Solid Electrolyte for Chloride Ion Batteries

Solid electrolytes have attracted considerable interest in rechargeable batteries because of their potential high safety, inhibition of electrode dissolution, and large electrochemical window. However, their development in some new battery concepts such as room-temperature halide ion batteries has been scarce. Herein, we develop the inorganic halide perovskite of CsSnCl₃ prepared by mechanical milling and subsequent mild heat treatment as the potential solid electrolyte for chloride ion batteries (CIB). Benefiting from its high structural stability against a phase transformation to monoclinic structure at room temperature, the as-prepared cubic CsSnCl₃ achieves an impressive electrochemical performance with the highest ionic conductivity of 3.6 × 10^-4 S cm^-1 and a large electrochemical window of about 6.1 V at 298 K. These values are much higher than 1.2 × 10^-5 S cm^-1 and 4.25 V of the previously reported solid polymer electrolyte for CIBs. Importantly, the chloride ion transfer of the as-prepared CsSnCl₃ electrolyte is demonstrated by employing the electrode couples of SnCl₂/Sn and BiCl₃/Bi.

Top-Down Synthesis of Silicon/Carbon Composite Anode Materials for Lithium-Ion Batteries: Mechanical Milling and Etching

Lithium-ion batteries (LIBs) providing high energy and power densities as well as long cycle life are in high demand for various applications. Benefitting from its high theoretical specific charge capacity of ≈4200 mAh g^-1 and natural abundance, Si is nowadays considered as one of the most promising anode candidates for high-energy-density LIBs. However, its huge volume change during cycling prevents its widespread commercialization. Si/C-based electrodes, fabricated through top-down mechanical-milling technique and etching, could be particularly promising since they can adequately accommodate the Si volume expansion, buffer the mechanical stress, and ameliorate the interface/surface stability. In this Review, the current progresses in the top-down synthesis of Si/C anode materials for LIBs from inexpensive Si sources via the combination of low-cost, simple, scalable, and efficient ball-milling and etching processes are summarized. Various Si precursors as well as etching routes are highlighted in this Review. This review would be a guide for fabricating high-performance Si-based anodes.

Effects of Milling Time, Zirconia Addition, and Storage Environment on the Radiopacity Performance of Mechanically Milled Bi2O3/ZrO2 Composite Powders

Mineral trioxide aggregate (MTA) typically consists of Portland cement (75 wt.%), bismuth oxide (20 wt.%), and gypsum (5 wt.%) and is commonly used as endodontic cement. Bismuth oxide serving as the radiopacifying material reveals the canal filling effect after clinical treatment. In the present study, bismuth/zirconium oxide composite powder was prepared by high energy ball milling of (Bi₂O₃)_100−x (ZrO₂)_x (x = 5, 10, 15, and 20 wt.%) powder mixture and used as the radiopacifiers within MTA. The crystalline phases of the as-milled powders were examined by the X-ray diffraction technique. The radiopacities of MTA-like cements prepared by using as-milled composite powders (at various milling stages or different amount of zirconia addition) were examined. In addition, the stability of the as-milled powders stored in an ambient environment, an electronic dry box, or a glove box was investigated. The experimental results show that the as-milled powder exhibited the starting powder phases of Bi₂O₃ and ZrO₂ and the newly formed δ-Bi_7.38Zr_0.62O_2.31 phase. The longer the milling time or the larger the amount of the zirconia addition, the higher the percentage of the δ-Bi_7.38Zr_0.62O_2.31 phase in the composite powder. All the MTA-like cements prepared by the as-milled powder exhibited a radiopacity higher than 4 mmAl that is better than the 3 mmAl ISO standard requirement. The 30 min as-milled (Bi₂O₃)₉₅(ZrO₂)₅ composite powder exhibited a radiopacity of 5.82 ± 0.33 mmAl and degraded significantly in the ambient environment. However, storing under an oxygen- and humidity-controlled glove box can prolong a high radiopacity performance. The radiopacity was 5.76 ± 0.08 mmAl after 28 days in a glove box that was statistically the same as the original composite powder.

Effect of Oxygen Concentration and Tantalum Addition on the Formation of High Temperature Bismuth Oxide Phase by Mechanochemical Reaction

High-temperature face-centered cubic bismuth oxide phase is a material of great interest given its unique properties. In the present study, α-Bi₂O₃ and tantalum powders were used as the starting powders for the formation of high-temperature bismuth oxide phase via mechanochemical synthesis by high energy ball milling. (Bi₂O₃)₈₀(Ta)₂₀ and (Bi₂O₃)₉₅(Ta)₅ in weight concentrations were milled in either an oxygen-free argon-filled glove box environment or an ambient atmosphere to investigate the effects of oxygen concentration and tantalum addition. The as-milled powders were examined using X-ray diffraction, scanning electron microscopy with energy-dispersive spectroscopy, and differential scanning calorimetry to reveal the structural evolution. The experimental results showed that for (Bi₂O₃)₉₅(Ta)₅ powder mixtures milled within the glove box, tantalum gradually reacted with the α-Bi₂O₃ phase and formed a β-Bi_7.8Ta_0.2O_12.2 phase. For (Bi₂O₃)₈₀(Ta)₂₀ milled under the same conditions, Ta and α-Bi₂O₃ mechanochemically reacted to form δ-Bi₃TaO₇ and bismuth after 10 min of high energy ball milling, whereas milling (Bi₂O₃)₈₀(Ta)₂₀ under the ambient atmosphere with a much higher oxygen concentration accelerated the mechanochemical reaction to less than five minutes of milling and resulted in the formation of high-temperature δ-Bi₃TaO₇ phase.

Synthesis of Nanocrystalline AZ91 Magnesium Alloy Dispersed with 15 vol.% Submicron SiC Particles by Mechanical Milling

The development of a magnesium matrix composite with a high content of dispersions using conventional liquid-phase process is a great challenge, especially for nanometer/submicron particles. In this work, mechanical milling was employed to prepare nanocrystalline AZ91 dispersed with 15 vol.% submicron SiC particles (SiCp/AZ91). AZ91 with no SiCp was applied as a comparative study with the same mechanical milling. In order to investigate the mechanism of dispersing, the morphology evolution of powders and the corresponding SiCp distribution were observed. As the scanning electron microscope (SEM) analysis exhibited, the addition of SiCp accelerated the smashing of AZ91 particles, which promoted the dispersion of SiCp in AZ91. Thus, after mechanical milling, 15 vol.% SiCp, which was smashed from 800 to 255 nm, got uniformly distributed in the Mg matrix. Based on X-ray diffraction (XRD) results, part of the Mg₁₇Al₁₂ precipitate got dissolved, and an Al-supersaturated Mg solid solution was formed. The transmission electron microscopy (TEM) results showed that the ultimate Mg grain (32 nm) of milled SiCp/AZ91 was much smaller than that of milled AZ91 (64 nm), which can be attributed to a pinning effect of submicron SiCp. After mechanical milling, the hardness of SiCp/AZ91 reached 185 HV, which was 185% higher than the original AZ91 and 33% higher than milled AZ91, due to fine Mg grain and submicron dispersions.

Microstructure and Properties of Mg-Zn-Y Alloy Powder Compacted by Equal Channel Angular Pressing

Mg₉₇Zn₁Y₂ (at %) alloy with a long period stacking ordered (LPSO) phase has attracted a great deal of attention due to its excellent mechanical properties. It has been reported that this alloy could be fabricated by warm extrusion of rapid solidified alloy powders. In this study, an alternative route combining mechanical milling and equal channel angular pressing (ECAP) was selected to produce the bulk Mg₉₇Zn₁Y₂ alloy. Microstructural characterization, mechanical properties and corrosion behavior of the ECAP-compacted alloys were studied. The as-cast alloy contained α-Mg and LPSO-Mg₁₂Zn₁Y₁ phase. In the as-milled powder, the LPSO phase decomposed and formed Mg₂₄Y₅ phase. The ECAP-compacted alloy had identical phases to those of the as-milled sample. The compacted alloy exhibited a hardness of 120 HV and a compressive yield strength of 308 MPa, which were higher than those of the as-cast counterpart. The compacted alloy had better corrosion resistance, which was attributed to the reduced volume fraction of the secondary phase resulting in lower microgalvanic corrosion in the compacted alloy. The increase in Y content in the α-Mg matrix also contributed to the improvement of corrosion resistance.

Mechanical Milling-Assisted Spark Plasma Sintering of Fine-Grained W-Ni-Mn Alloy

Fine-grained W-6Ni-4Mn alloys were fabricated by spark plasma sintering (SPS) using mechanical milling W, Ni and Mn composite powders. The relative density of W-6Ni-4Mn alloy increases from 71.56% to 99.60% when it is sintered at a low temperature range of 1000–1200 °C for 3 min. The spark plasma sintering process of the alloy can be divided into three stages, which clarify the densification process of powder compacts. As the sintering temperature increases, the average W grain size increases but remains at less than 7 µm and the distribution of the binding phase is uniform. Transmission electron microscopy (TEM) observation reveals that the W-6Ni-4Mn alloy consists of the tungsten phase and the γ-(Ni, Mn, W) binding phase. As the sintering temperature increases, the Rockwell hardness and bending strength of alloys initially increases and then decreases. The optimum comprehensive hardness and bending strength of the alloy are obtained at 1150 °C. The main fracture mode of the alloys is W/W interface fracture.

The Influence of Milling and Spark Plasma Sintering on the Microstructure and Properties of the Al7075 Alloy

The compact samples of an Al7075 alloy were prepared by a combination of gas atomization, high energy milling, and spark plasma sintering. The predominantly cellular morphology observed in gas atomized powder particles was completely changed by mechanical milling. The continuous-like intermetallic phases present along intercellular boundaries were destroyed; nevertheless, a small amount of Mg(Zn,Cu,Al)₂ phase was observed also in the milled powder. Milling resulted in a severe plastic deformation of the material and led to a reduction of grain size from several µm into the nanocrystalline region. The combination of these microstructural characteristics resulted in abnormally high microhardness values exceeding 300 HV. Consolidation through spark plasma sintering (SPS) resulted in bulk samples with negligible porosity. The heat exposition during SPS led to precipitation of intermetallic phases from the non-equilibrium microstructure of both gas atomized and milled powders. SPS of the milled powder resulted in a recrystallization of the severely deformed structure. An ultra-fine grained structure (grain size close to 500 nm) with grains divided primarily by high-angle boundaries was formed. A simultaneous release of stored deformation energy and an increase in the grain size caused a drop of microhardness to values close to 150 HV. This value was retained even after annealing at 425 °C.

Nanocrystalline Al7075 + 1 wt % Zr Alloy Prepared Using Mechanical Milling and Spark Plasma Sintering

The microstructure, phase composition, and microhardness of both gas-atomized and mechanically milled powders of the Al7075 + 1 wt % Zr alloy were investigated. The gas-atomized powder exhibited a cellular microstructure (grain size of a few µm) with layers of intermetallic phases along the cell boundaries. Mechanical milling (400 revolutions per minute (RPM)/8 h) resulted in a grain size reduction to the nanocrystalline range (20 to 100 nm) along with the dissolution of the intermetallic phases. Milling led to an increase in the powder's microhardness from 97 to 343 HV. Compacts prepared by spark plasma sintering (SPS) exhibited negligible porosity. The grain size of the originally gas-atomized material was retained, but the continuous layers of intermetallic phases were replaced by individual particles. Recrystallization led to a grain size increase to 365 nm in the SPS compact prepared from the originally milled powder. Small precipitates of the Al₃Zr phase were observed in the SPS compacts, and they are believed to be responsible for the retainment of the sub-microcrystalline microstructure during SPS. A more intensive precipitation in this SPS compact can be attributed to a faster diffusion due to a high density of dislocations and grain boundaries in the milled powder.

Phosphorus-Rich CuP2 Embedded in Carbon Matrix as a High-Performance Anode for Lithium-Ion Batteries

Phosphorus-rich CuP₂ and its carbon composites have been investigated as an anode material for lithium-ion batteries. Through a facile, low-cost mechanochemical reaction, microsized composites composed of active CuP₂ particles uniformly embedded in the carbon matrix have been successfully synthesized. Combined structural and electrochemical characterizations show that phosphorus-rich CuP₂ undergoes irreversible reaction with lithium, giving metal-rich Cu₃P and amorphous phosphorus at the end of the first cycle. Both Cu₃P and phosphorus are reversibly formed in subsequent cycles, contributing to a high reversible capacity of >1000 mA h g^-1. By controlling the carbon content, the electrochemical reversibility and stability of CuP₂ are greatly improved. The carbon composite demonstrates a remarkable lithium-storage capability in terms of a stable capacity of >720 mA h g^-1 over 100 cycles at 200 mA g^-1, a high initial Coulombic efficiency of ∼83%, and a good rate capability with a capacity of >637 mA h g^-1 at 1.6 A g^-1. The performance improvement is mainly associated with the formation of the conductive carbon network that offers high conductivity and fast reaction kinetics, as well as enhanced structural stability of CuP₂ anode.

Spark Plasma Co-Sintering of Mechanically Milled Tool Steel and High Speed Steel Powders

Hot work tool steel (AISI H13) and high speed steel (AISI M3:2) powders were successfully co-sintered to produce hybrid tool steels that have properties and microstructures that can be modulated for specific applications. To promote co-sintering, which is made difficult by the various densification kinetics of the two steels, the particle sizes and structures were refined by mechanical milling (MM). Near full density samples (>99.5%) showing very fine and homogeneous microstructure were obtained using spark plasma sintering (SPS). The density of the blends (20, 40, 60, 80 wt % H13) was in agreement with the linear rule of mixtures. Their hardness showed a positive deviation, which could be ascribed to the strengthening effect of the secondary particles altering the stress distribution during indentation. A toughening of the M3:2-rich blends could be explained in view of the crack deviation and crack arrest exerted by the H13 particles.

High-Performance Zn-TiC-C Nanocomposite Alloy Anode with Exceptional Cycle Life for Lithium-Ion Batteries

A Zn-based nanocomposite has been prepared through a facile, low-cost high-energy mechanochemical process and employed as an anode material for lithium-ion batteries. Structural characterization reveals that the micrometer-sized Zn-TiC-C nanocomposite is composed of Zn nanocrystals uniformly dispersed in a multifunctional TiC and conductive carbon matrix with a tap density of 1.3 g cm(-3). The Zn-TiC-C nanocomposite exhibits high reversible volumetric capacity (468 mA h cm(-3)), excellent cyclability over 800 cycles (79.2% retention), and good rate performance up to 12.5C (75% of its capacity at 0.25C rate). The enhanced electrochemical performance is mainly due to the presence of the well-mixed TiC+C matrix that plays an important role in providing high conductivity as well as mechanical buffer that mitigates the huge volume expansion and contraction during prolonged cycling. In addition, it prevents the particle growth by uniformly dispersing nanosized Zn within itself during cycling, maintaining high utilization (∼100%) and fast reaction kinetics of Zn anode.

Matrix Structure Evolution and Nanoreinforcement Distribution in Mechanically Milled and Spark Plasma Sintered Al-SiC Nanocomposites

Development of homogenous metal matrix nanocomposites with uniform distribution of nanoreinforcement, preserved matrix nanostructure features, and improved properties, was possible by means of innovative processing techniques. In this work, Al-SiC nanocomposites were synthesized by mechanical milling and consolidated through spark plasma sintering. Field Emission Scanning Electron Microscope (FE-SEM) with Energy Dispersive X-ray Spectroscopy (EDS) facility was used for the characterization of the extent of SiC particles’ distribution in the mechanically milled powders and spark plasma sintered samples. The change of the matrix crystallite size and lattice strain during milling and sintering was followed through X-ray diffraction (XRD). The density and hardness of the developed materials were evaluated as function of SiC content at fixed sintering conditions using a densimeter and a digital microhardness tester, respectively. It was found that milling for 24 h led to uniform distribution of SiC nanoreinforcement, reduced particle size and crystallite size of the aluminum matrix, and increased lattice strain. The presence and amount of SiC reinforcement enhanced the milling effect. The uniform distribution of SiC achieved by mechanical milling was maintained in sintered samples. Sintering led to the increase in the crystallite size of the aluminum matrix; however, it remained less than 100 nm in the composite containing 10 wt.% SiC. Density and hardness of sintered nanocomposites were reported and compared with those published in the literature.

Mechanically activated catalyst mixing for high-yield boron nitride nanotube growth

Boron nitride nanotubes (BNNTs) have many fascinating properties and a wide range of applications. An improved ball milling method has been developed for high-yield BNNT synthesis, in which metal nitrate, such as Fe(NO3)3, and amorphous boron powder are milled together to prepare a more effective precursor. The heating of the precursor in nitrogen-containing gas produces a high density of BNNTs with controlled structures. The chemical bonding and structure of the synthesized BNNTs are precisely probed by near-edge X-ray absorption fine structure spectroscopy. The higher efficiency of the precursor containing milling-activated catalyst is revealed by thermogravimetric analyses. Detailed X-ray diffraction and X-ray photoelectron spectroscopy investigations disclose that during ball milling the Fe(NO3)3 decomposes to Fe which greatly accelerates the nitriding reaction and therefore increases the yield of BNNTs. This improved synthesis method brings the large-scale production and application of BNNTs one step closer.