Oxidation behavior and atomic structural transition of size-selected coalescence-resistant tantalum nanoclusters

Herein a series of size-selected TaN(N = 147, 309, 561, 923, 1415, 2057, 6525, 10 000, 20 000) clusters are generated using a gas-phase condensation cluster beam source equipped with a lateral time-of-flight mass-selector. Aberration-corrected scanning transmission electron microscopy (AC-STEM) imaging reveals good thermal stability of TaNclusters in this study. The oxidation-induced amorphization is observed from AC-STEM imaging and further demonstrated through x-ray photoelectron spectroscopy and energy-dispersive spectroscopy. The oxidized Ta predominantly exists in the +5 oxidation state and the maximum spontaneous oxidation depth of the Ta cluster is observed to be 5 nm under prolonged atmosphere exposure. Furthermore, the size-dependent sintering and crystallization processes of oxidized TaNclusters are observed with anin situheating technique, and eventually, ordered structures are restored. As the temperature reaches 1300 °C, a fraction of oxidized Ta309clusters exhibit decahedral and icosahedral structures. However, the five-fold symmetry structures are absent in larger clusters, instead, these clusters exhibit ordered structures resembling those of the crystalline Ta2O5films. Notably, the sintering and crystallization process occurs at temperatures significantly lower than the melting point of Ta and Ta2O5, and the ordered structures resulting from annealing remain well-preserved after six months of exposure to ambient conditions.

Concurrent Crystallization Mechanism Leading to Low Temperature Percolation of LAGP Glass-Ceramic Electrolyte

Sintering of ceramic electrolytes (CE) is the most efficient way to obtain a dense, all ceramic solid-state battery with oxide-based materials. However, the high temperature required for this process leads to detrimental reactivity between CE and the active material. Crystalline ceramics are necessary for highly conductive oxide materials. Still, thermomechanical properties of glass-phase materials can be used to obtain a denser and more conductive CE. Glass-phase CE can be produced with Nasicon-type CE. Here, Li1.5Al0.5Ge1.5(PO4)3 (LAGP) glass is used as a model to investigate the formability, densification, and conduction properties upon crystallization. A complete study of the crystallization mechanism is first performed to fully understand how a high conductivity of 6.3 × 10-5 S·cm-1 at 30 °C with 92% relative density is obtained at a sintering temperature of only 550 °C without pressure. This is approximately 200 °C below the usual sintering temperature of LAGP. X-ray diffraction is then used to calculate the amount of crystalline phase as a function of time. A combined study of reaction kinetics and conductivity evolution reveals an autocatalytic nucleation effect, which produces an early crystallization pathway. Density is studied to quantify the ability of the glass to flow during the crystallization process.

In-situ heating-and-electron tomography for materials research: from 3D (in-situ 2D) to 4D (in-situ 3D)

In-situ observation has expanded the application of transmission electron microscopy (TEM) and has made a significant contribution to materials research and development for energy, biomedical, quantum, etc. Recent technological developments related to in-situ TEM have empowered the incorporation of three-dimensional observation, which was previously considered incompatible. In this review article, we take up heating as the most commonly used external stimulus for in-situ TEM observation and overview recent in-situ TEM studies. Then, we focus on the electron tomography (ET) and in-situ heating combined observation by introducing the authors' recent research as an example. Assuming that in-situ heating observation is expanded from two dimensions to three dimensions using a conventional TEM apparatus and a commercially available in-situ heating specimen holder, the following in-situ heating-and-ET observation procedure is proposed: (i) use a rapid heating-and-cooling function of a micro-electro-mechanical system holder; (ii) heat and cool the specimen intermittently and (iii) acquire a tilt-series dataset when the specimen heating is stopped. This procedure is not too technically challenging and can have a wide range of applications. Essential technical points for a successful 4D (space and time) observation will be discussed through reviewing the authors' example application.

Optimization of a tunable process for rapid production of calcium phosphate microparticles using a droplet-based microfluidic platform

Calcium phosphate (CaP) biomaterials are amongst the most widely used synthetic bone graft substitutes, owing to their chemical similarities to the mineral part of bone matrix and off-the-shelf availability. However, their ability to regenerate bone in critical-sized bone defects has remained inferior to the gold standard autologous bone. Hence, there is a need for methods that can be employed to efficiently produce CaPs with different properties, enabling the screening and consequent fine-tuning of the properties of CaPs towards effective bone regeneration. To this end, we propose the use of droplet microfluidics for rapid production of a variety of CaP microparticles. Particularly, this study aims to optimize the steps of a droplet microfluidic-based production process, including droplet generation, in-droplet CaP synthesis, purification and sintering, in order to obtain a library of CaP microparticles with fine-tuned properties. The results showed that size-controlled, monodisperse water-in-oil microdroplets containing calcium- and phosphate-rich solutions can be produced using a flow-focusing droplet-generator microfluidic chip. We optimized synthesis protocols based on in-droplet mineralization to obtain a range of CaP microparticles without and with inorganic additives. This was achieved by adjusting synthesis parameters, such as precursor concentration, pH value, and aging time, and applying heat treatment. In addition, our results indicated that the synthesis and fabrication parameters of CaPs in this method can alter the microstructure and the degradation behavior of CaPs. Overall, the results highlight the potential of the droplet microfluidic platform for engineering CaP microparticle biomaterials with fine-tuned properties.

On-Substrate Fabrication of CsPbBr3 Single-Crystal Microstructures via Nanoparticle Self-Assembly-Assisted Low-Temperature Sintering

The growth of all-inorganic perovskite single-crystal microstructures on substrates is a promising approach for constructing photonic and electronic microdevices. However, current preparation methods typically involve direct control of ions or atoms, which often depends on specific lattice-matched substrates for epitaxial growth and other stringent conditions that limit the mild preparation and flexibility of device integration. Herein, we present the on-substrate fabrication of CsPbBr3 single-crystal microstructures obtained via a nanoparticle self-assembly assisted low-temperature sintering (NSALS) method. Sintering guided by self-assembled atomically oriented superlattice embryos facilitated the formation of single-crystal microstructures under mild conditions without substrate dependence. The as-prepared on-substrate microstructures exhibited a consistent out-of-plane orientation with a carrier lifetime of up to 82.7 ns. Photodetectors fabricated by using these microstructures exhibited an excellent photoresponse of 9.15 A/W, and the dynamic optical response had a relative standard deviation as low as 0.1831%. The discrete photosensor microarray chip with 174000 pixels in a 100 mm2 area showed a response difference of less than 6%. This method of nanoscale particle-controlled single crystal growth on a substrate offers a perspective for mild-condition preparation and in situ repair of crystals of various types. This advancement can propel the flexible integration and widespread application of perovskite devices.

Surface Embedded Metal Nanowire-Liquid Metal-Elastomer Hybrid Composites for Stretchable Electronics

Both liquid metal (LM) and metallic filler-based conductive composites are promising stretchable conductors. LM alloys exhibit intrinsically high deformability but present challenges for patterning on polymeric substrates due to high surface tension. On the other hand, conductive composites comprising metallic fillers undergo considerable decrease in electrical conductivity under mechanical deformation. To address the challenges, we present silver nanowire (AgNW)-LM-elastomer hybrid composite films, where AgNWs and LM are embedded below the surface of an elastomeric matrix, using two fabrication approaches, sequential and mixed. We investigate and understand the process-structure-property relationship of the AgNW-LM-elastomer hybrid composites fabricated using two approaches. Different weight ratios of AgNWs and LM particles provide tunable electrical conductivity. The hybrid composites show more stable electromechanical performance than the composites with AgNWs alone. In particular, 1:2.4 (AgNW:LMP w/w) sequential hybrid composite shows electromechanical stability similar to that of the LM-elastomer composite, with a resistance increase of 2.04% at 90% strain. The sequential approach is found to form AgIn2 intermetallic compounds which along with Ga-In bonds, imparts large deformability to the sequential hybrid composite as well as mechanical robustness against scratching, cutting, peeling, and wiping. To demonstrate the application of the hybrid composite for stretchable electronics, a laser patterned stretchable heater on textile and a stretchable circuit including a light-emitting diode are fabricated.

Two-Photon Polymerization of Nanocomposites for Additive Manufacturing of Transparent Magnesium Aluminate Spinel Ceramics

Transparent polycrystalline magnesium aluminate (MAS) spinel ceramics are of great interest for industry and academia due to their excellent optical and mechanical properties. However, shaping of MAS is notoriously challenging especially on the microscale requiring hazardous etching methods. Therefore, a photochemically curable nanocomposite is demonstrated that can be structured using high-resolution two-photon lithography. The printed nanocomposites are converted intro transparent MAS by subsequent debinding, sintering, and hot isostatic pressing. The resulting transparent spinel ceramics exhibit a surface roughness Sq of only 10 nm and can be shaped with minimum feature sizes of down to 13 µm. This technology will be important for the production of microstructured ceramics used for optics, photonics, or photocatalysis.

Room-Temperature Liquid Metals for Flexible Electronic Devices

Room-temperature gallium-based liquid metals (RT-GaLMs) have garnered significant interest recently owing to their extraordinary combination of fluidity, conductivity, stretchability, self-healing performance, and biocompatibility. They are ideal materials for the manufacture of flexible electronics. By changing the composition and oxidation of RT-GaLMs, physicochemical characteristics of the liquid metal can be adjusted, especially the regulation of rheological, wetting, and adhesion properties. This review highlights the advancements in the liquid metals used in flexible electronics. Meanwhile related characteristics of RT-GaLMs and underlying principles governing their processing and applications for flexible electronics are elucidated. Finally, the diverse applications of RT-GaLMs in self-healing circuits, flexible sensors, energy harvesting devices, and epidermal electronics, are explored. Additionally, the challenges hindering the progress of RT-GaLMs are discussed, while proposing future research directions and potential applications in this emerging field. By presenting a concise and critical analysis, this paper contributes to the advancement of RT-GaLMs as an advanced material applicable for the new generation of flexible electronics.

Reversible and Irreversible Structural Changes in Cu/ZnO/ZrO2 Catalysts during Methanol Synthesis

The structure and chemical state of heterogeneous catalysts are closely related to their operational stability. Knowing these relationships as precisely as possible is thus essential for further catalyst development. This work focuses on the deactivation of a Cu/ZnO/ZrO2-type catalyst for methanol synthesis. Experiments were performed in a parallel setup, with which time-dependent changes in the catalyst material can be observed. Elucidation of potential deactivation pathways is described for catalyst aging at different times on stream (0, 50, 935 h). Data from X-ray absorption spectroscopy, X-ray photoelectron spectroscopy, N2 physisorption, and transmission electron microscopy measurements reveal that sintering of Cu0 domains and restructuring within ZnO domains mainly contribute to deactivation. Subsequent reactivation by reduction (in H2/N2) reverts the observed structural changes only to a limited extent. Moreover, this work highlights the participation of ZrO2 as a promoter and reveals redispersion of zirconia after initial reduction.

Photoluminescence and thermoluminescence dosimetry properties of Ag/Y co-doped ZnO nanophosphor for radiation measurements

This work explores the thermoluminescence (TL) and photoluminescence (PL) properties of Ag/Y co-doped zinc oxide (ZnO) nanophosphor. The proposed dosimeter was prepared by the coprecipitation method and sintered at temperatures from 400°C to 1000°C in an air atmosphere. Raman spectroscopy was studied to investigate the structural features of this composition. The new proposed dosimeter revealed two peaks at 150°C and 175°C with a small shoulder at high temperature (225°C). The PL spectrum showed strong green emissions between 500 to 550 nm. The Raman spectrum showed many bands related to the interaction between ZnO, silver (Ag), and yttrium oxide (Y2 O3 ). The rising sintering temperature enhanced the TL glow curve intensity. The Ag/Y co-doped ZnO nanophosphor showed an excellent linearity index within a dose from 1 to 4 Gy. The minimum detectable dose (MDD) of the Ag/Y co-doped ZnO nanopowder (pellets) equaled 0.518 mGy. The main TL properties were achieved in this work as follows: thermal fading (37% after 45 days at 1 and 4 Gy), optical fading (53% after 1 h and 68% after 6 h by exposure to sunlight), effective atomic number (27.6), and energy response (flat behavior from 0.1 to 1.3 MeV). Finally, the proposed material shows promising results nominated to be used for radiation measurements.

Ligand Decomposition Differences during Thermal Sintering of Oleylamine-Capped Gold Nanoparticles in Ambient and Inert Environments: Implications for Conductive Inks

Gold nanoparticles (GNPs) are essential in creating conductive inks vital for advancing printable electronics, sensing technologies, catalysis, and plasmonics. A crucial step in fabricating useful GNP-based devices is understanding the thermal sintering process and particularly the decomposition pathways of ligands in different environments. This study addresses a gap in the existing research by examining the sintering of oleylamine (OA)-capped GNPs in both ambient (air) and inert (N2) environments. Through a series of analyses including TGA/MS, Raman spectroscopy, and XPS, distinctive OA decomposition behaviors were identified in air and nitrogen environments. The research delineates two OA decomposition pathways resulting in different porosity, microstructure, and electrical conductivity of GNP films sintered in air and nitrogen environments. The study offers some insights that can steer the sintering and utilization of the GNP sintering process and promises to aid the future development of nanoparticle-based printable electronics.

The Effect of Sintering on Zirconia Manufactured via Suspension-Enclosing Projection Stereolithography for Dental Applications: An In Vitro Study

BACKGROUND

Zirconia is a widely used material in the dental industry due to its excellent mechanical and aesthetic properties. Recently, a new 3D printing process called suspension-enclosing projection stereolithography (SEPS) was introduced to fabricate zirconia dental restorations. However, the effect of the sintering time and temperature on the properties of zirconia produced via SEPS has not been fully investigated.

METHODS

Zirconia slurries were prepared with varying percentages of zirconia powders and 3D printing resins, and 5Y-TZP (5 mol% yttria-stabilized zirconia) (n = 40) and 3Y-TZP (3 mol% yttria-stabilized zirconia) (n = 40) bar specimens were fabricated via SEPS manufacturing. The specimens were sintered at different temperatures and dwell times, and their flexural strength, density, and phase composition were measured. The viscosity of the slurries was also measured. Statistical analysis was performed using Welch's ANOVA and Kruskal-Wallis tests to evaluate the impact of the sintering conditions.

RESULTS

Significant differences in flexural strength (p < 0.01) were observed between the 5Y-TZP samples, with those sintered at 1530 °C for 120 min showing an average strength of 268.34 ± 44.66 MPa, compared to 174.16 ± 42.29 MPa for those sintered at 1450 °C for 120 min. In terms of density, significant differences (p < 0.01) were noted for the 3Y-TZP specimens, with an average density of 6.66 ± 0.49 g/cm3 for samples sintered at 1530 °C for 120 min, versus 5.75 ± 0.55 g/cm3 for those sintered at 1530 °C for 10 min. X-ray diffraction confirmed the presence of a predominantly tetragonal phase in both materials.

CONCLUSIONS

Zirconia printed via SEPS manufacturing can be sintered at a higher temperature with shorter dwell times, thereby producing high density samples. Different sintering conditions can be used to fully sinter 3D-printed zirconia for potential dental applications.

In Situ Sintering of CdSe/CdS Nanocrystals under Electron Beam Irradiation

Colloidal semiconductor nanocrystals have attracted widespread attention due to their tremendous electrical and optical properties. Nanoparticles exhibit a strong tendency to aggregate and sinter in a short period of time during processing or use due to their large surface area-to-volume ratio, which may lead to significant changes in their required performance. Therefore, it is of great significance to conduct in-depth research on the sintering process and mechanism of nanoparticles to maintain their stability. Here, the sintering process of CdSe/CdS core/shell nanocrystals under continuous electron beam irradiation was studied using in situ transmission electron microscopy (TEM). In the early stages of sintering, CdSe/CdS nanocrystals approached each other at a distance of approximately 1-2 nm. As the exposure time to the electron beam increased, the movement of surface atoms on the nanocrystals led to contact between them. Subsequently, the atoms on the contact surfaces underwent rapid motion, resulting in the rapid formation of the neck between the particles. The neck formation between adjacent particles provides strong evidence of a sintering mechanism dominated by surface atom diffusion rather than Ostwald ripening. Further research in this area could lead to the development of improved methods to prevent sintering and enhance the stability of nanocrystals, ultimately contributing to the advancement of nanomaterial-based devices and materials with long-lasting performance.

Effect of sintering on the translucency of CAD-CAM lithium disilicate restorations: A comparative in vitro study

PURPOSE

The available independent data on the translucency of novel pre and fully sintered chairside computer-aided design and computer-aided manufacturing (CAD-CAM) lithium disilicate are limited. This comparative in vitro study evaluated the translucency degree of pre and fully sintered chairside CAD-CAM lithium disilicate crowns after optional, required, and additional firing processes.

MATERIALS AND METHODS

One hundred and five maxillary left central incisor crowns manufactured by three different CAD-CAM lithium disilicate brands shade A1 were assigned into seven groups as follows (n = 15): (1) Straumann n!ce without sintering; (2) Straumann n!ce with one additional sintering process; (3) Straumann n!ce with two additional sintering processes; (4) Amber Mill with one sintering process; (5) Amber Mill with two sintering processes; (6) IPS e.max CAD with one sintering process; and (7) IPS e.max CAD with two sintering processes. The translucency of all crowns was evaluated with a color imaging spectrophotometer. All statistical analyses were performed using statistical software. A standard level of significance was set at α < 0.05.

RESULTS

All the milled crowns presented different degrees of translucency, and additional sintering processes altered it. IPS e.max CAD with two (4.33 ± 0.26) and one (4.01 ± 0.15) sintering processes displayed the highest translucency, whereas Straumann n!ce with no sintering process provided the lowest value (2.82 ± 0.16).

CONCLUSIONS

The translucency of chairside lithium disilicate single-unit full-coverage restorations manufactured with subtractive technology was significantly influenced by the brand and the number of sintering processes. The traditional presintered IPS e.max CAD and the fully crystallized glass-ceramic Straumann n!ce considerably increased the translucency after one additional firing process, whereas Amber Mill decreased its translucency.

Nanostructure Tuning of Gold Nanoparticles Films via Click Sintering

Colloidal metal nanoparticles dispersions are commonly used to create functional printed electronic devices and they typically require time-, energy- and equipment-consuming post-treatments to improve their electrical and mechanical properties. Traditional methods, e.g. thermal, UV/IR, and microwave treatments, limit the substrate options and may require expensive equipment, not available in all the laboratories. Moreover, these processes also cause the collapse of the film (nano)pores and interstices, limiting or impeding its nanostructuration. Finding a simple approach to obtain complex nanostructured materials with minimal post-treatments remains a challenge. In this study, a new sintering method for gold nanoparticle inks that called as "click sintering" has been reported. The method uses a catalytic reaction to enhance and tune the nanostructuration of the film while sintering the metallic nanoparticles, without requiring any cumbersome post-treatment. This results in a conductive and electroactive nanoporous thin film, whose properties can be tuned by the conditions of the reaction, i.e., concentration of the reagent and time. Therefore, this study presents a novel and innovative one-step approach to simultaneously sinter gold nanoparticles films and create functional nanostructures, directly and easily, introducing a new concept of real-time treatment with possible applications in the fields of flexible electronics, biosensing, energy, and catalysis.

An Ultraviolet-Lithography-Assisted Sintering Method for Glass Microlens Array Fabrication

Glass microlens arrays (MLAs) have tremendous prospects in the fields of optical communication, sensing and high-sensitivity imaging for their excellent optical properties, high mechanical robustness and physicochemical stability. So far, glass MLAs are primarily fabricated using femtosecond laser modification assisted etching, in which the preparation procedure is time-consuming, with each concave-shaped microlens being processed using a femtosecond laser point by point. In this paper, a new method is proposed for implementing large-scale glass MLAs using glass particle sintering with the assistance of ultraviolet (UV) lithography. The glass particles are dispersed into the photoresist at first, and then immobilized as large-scaled micropillar arrays on quartz glass substrate using UV lithographing. Subsequently, the solidified photoresist is debinded and the glass particles are melted by means of sintering. By controlling the sintering conditions, the convex microlens will be self-assembled, attributed to the surface tension of the molten glass particles. Finally, MLAs with different focal lengths (0.12 to 0.2 mm) are successfully fabricated by utilizing different lithography masks. Meanwhile, we also present the optimization of the sintering parameter for eliminating the bubbles in the microlenses. The main factors that affect the focal length of the microlens and the image performance of the MLAs have been studied in detail.

Sintered Brake Pads Failure in High-Energy Dissipation Braking Tests: A Post-Mortem Mechanical and Microstructural Analysis

The industrial sintering process used to produce metallic matrix pads has been altered to diminish the amount of copper used. Unfortunately, replacing a large part of the copper with iron seems to have reached a limit. In the high-energy, emergency-type rail braking used in this study, the materials are put to the very limit of their usage capacity, allowing us to observe the evolution of the microstructure and mechanical properties of sintered, metallic matrix pads. After the braking test, their compressive behaviour was assessed using digital image correlation (DIC), and their microstructure with scanning electron microscopy (SEM). The worn material has three flat layers with different microstructures and compressive behaviours. The bottom layer seems unmodified. Macroscopic and microscopic cracks run through the intermediate layer (2-15 mm depth). The top layer has stiffened thanks to resolidification of copper. The temperature reaches 1000 °C during the braking test, which also explains the carbon diffusion into iron that result in the weakening of iron -graphite interfaces in the pad. Finally, submicronic particles are detected at many open interfaces of the worn and compressed pad. Associated with the predominant role of graphite particles, this explains the weak compressive behaviour of the pads.

Shock-Induced Microstructural Evolution, Phase Transformation, Sintering of Al-Ni Dissimilar Nanoparticles: A Molecular Dynamics Study

Molecular dynamic simulations have been performed to explore contact behavior, microstructure evolution and sintering mechanism of Al-Ni dissimilar nanoparticles under high-velocity impact. We confirmed that the simulated contact stress, contact radius, and contact force under low-velocity impact are in good agreement with the predicted results of the Hertz model. However, with increasing the impact velocity, the simulated results gradually deviate from the predicted results of the Hertz model due to the elastic-plastic transition and atomic discrete structure. The normalized contact radius versus strain exhibits a weak dependence on nanosphere diameter. Below a critical velocity, there are very few HCP atoms in the nanospheres after thermal equilibrium. There are two different sintering mechanisms: under low-velocity impact, the sintering process relies mainly on the dislocation slip of Al nanospheres, while the dislocation slip of Ni nanospheres and the atomic diffusion of Al nanospheres predominate under high-velocity impact.

Fabrication, microstructure and properties of advanced ceramic-reinforced composites for dental implants: a review

The growing field of dental implant research and development has emerged to rectify the problems associated with human dental health issues. Bio-ceramics are widely used in the medical field, particularly in dental implants, ortho implants, and medical and surgical tools. Various materials have been used in those applications to overcome the limitations and problems associated with their performance and its impact on dental implants. In this article we review and describe the fabrication methods employed for ceramic composites, the microstructure analyses used to identify significant effects on fracture behaviour, and various methods of enhancing mechanical properties. Further, the collective data show that the sintering technique improves the density, hardness, fracture toughness, and flexural strength of alumina- and zirconia-based composites compared with other methods. Future research aspects and suggestions are discussed systematically.

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.

Synthesis of Ti3SiC2 Phases and Consolidation of MAX/SiC Composites-Microstructure and Mechanical Properties

The article describes the Ti₃SiC₂ powder synthesis process. The influence of the molar ratio and two forms of carbon on the phase composition of the obtained powders was investigated. The synthesis was carried out using a spark plasma sintering (SPS) furnace. In addition, using the obtained powders, composites reinforced with SiC particles were produced. The obtained results showed no effect of the carbon form and a significant impact of annealing on the purity of the powders after synthesis. The composites were also consolidated using an SPS furnace at two temperatures of 1300 and 1400 °C. The tests showed low density and hardness for sinters from 1300 °C (maximum 3.97 g/cm³ and 447 HV5, respectively, for composite reinforced with 10% SiC). These parameters significantly increase for composites sintered at 1400 °C (maximum density 4.43 g/cm³ and hardness 1153 HV5, for Ti₃AlC₂-10% SiC). In addition, the crack propagation analysis showed mechanisms typical for granular materials and laminates.

Indirect Induction Sintering of Metal Parts Produced through Material Extrusion Additive Manufacturing

Avoiding loose powders and resins, material extrusion additive manufacturing is a powerful technique to produce near-net shape parts, being a cheap and safe alternative for developing complex industrial-grade products. Filaments embedded with a high packing density of metallic or ceramic granules are being increasingly used, resulting in almost fully dense parts, whereby geometries are shaped, debinded and sintered sequentially until the completion of the part. Traditionally, "brown" debinded geometries are transported to conventional furnaces to densify the powder compacts, requiring careful tailoring of the heating profiles and sintering environment. This approach is decoupled and often involves time-consuming post-processing, whereby after the completion of the shaping and debinding steps, the parts need to be transported to a sintering furnace. Here, it is shown that sintering via indirect induction heating of a highly filled commercially available filament embedded with stainless steel 316L powder can be an effective route to densify Fused Filament Fabricated (FFF) parts. The results show that densities of 99.8% can be reached with very short soaking times, representing a significant improvement compared to prior methods. A hybrid machine is proposed, whereby a custom-built machine is integrated with an induction heater to combine FFF with local indirect induction sintering. Sintering in situ, without the need for part transportation, simplifies the processing of metal parts produced through material extrusion additive manufacturing.

Influence of Sintering Atmosphere, Temperature and the Solution-Annealing Treatment on the Properties of Precipitation-Hardening Sintered 17-4 PH Stainless Steel

So far, unlike metal injection molding (MIM), conventional powder metallurgy technology (PM) has not been regarded as a method for producing structural elements from 17-4 PH powders, due to the problems of obtaining almost fully compacted shapes after sintering. Nevertheless, recent research demonstrates that it is possible to manufacture sintered parts with high strength by pressing and sintering. The purpose of the study was to determine the degree of densification of 17-4 PH sintered stainless steel during sintering at different temperatures and atmospheres. As a result of the study, it was pointed out that both the temperature and the sintering atmosphere play an essential role in the process of densification of the studied powders during sintering. The formation of delta ferrite and a more pronounced degree of spheroidization of the pores is activated by a higher sintering temperature. Furthermore, after solution-annealed and age-hardened treatment, sintered 17-4 PH stainless steel exhibits high strength with moderate ductility at a level that is difficult to achieve for other sintered stainless-steel grades, such as austenitic, ferritic and martensitic. In turn, the largest improvement in the pitting corrosion resistance in 0.5 M NaCl solution is reached by sintering at 1340 °C in hydrogen and after solid solution treatment.

Effect of Zirconium Diboride and Titanium Diboride on the Structure and Properties of 316L Steel-Based Composites

The effect of zirconium diboride (ZrB₂) and titanium diboride (TiB₂) on the microstructure as well as the physical, mechanical, and tribological properties of composites based on 316 L steel is presented. Each reinforcing phase was added to the base alloy in the amount of 5 wt% and 10 wt%. The composites were fabricated by the SPS process (Spark Plasma Sintering). The results show that the weight fraction of the reinforcing phase affects the physical, mechanical, and tribological properties of the sintered composites. The sintered materials were characterized by a very high level of density. The addition of TiB₂ has proved to be effective in increasing the hardness and compressive strength of the composites. The hardness of the composites with the addition of 10% TiB₂ increased by 100% compared to the hardness of sintered 316L steel. It was found that introducing ZrB₂ to the steel matrix significantly improved the wear resistance of the composites. The results showed that compared to 316L steel with the wear rate of 519 × 10^-6 mm³/Nm, the wear rate of the composites containing 10% ZrB₂ decreased more than twice, i.e., to 243 × 10^-6 mm³/Nm.

The influence of input material properties on hot melt granules prepared using a counter-rotating batch mixer

OBJECTIVE

The objective of this study was to develop a method that enabled granulation in a counter-rotating batch mixer to emulate large scale dry twin screw granulation trials.

METHODS

Four granulations were prepared using counter rotating batch mixing for formulations containing a mixture of different particle sizes of the API (70% w/w) and polymer (30% w/w). Milled theophylline (MTHF; fine API) was blended with coarse hydroxypropyl cellulose (HPC MF; coarse polymer), theophylline (THF; coarse API) with fine hydroxypropyl cellulose (HPC EXF, fine polymer), and the other two formulations consisted of both components in the blend being fine or coarse.

RESULTS

The formulations selected for granulation had the lowest friction coefficient, f, as a function of drug load determined by the iShear^® powder flow rheometer. Despite the non-uniform chaotic and random nature of thermal granulation, each formulation granulated reproducibly, though the evolution for each was different.

CONCLUSION

This work highlighted that, firstly it is possible to measure plastic and frictional energy dissipation as product temperature. Secondly, granule growth and density were found to be proportional to the onset of polymer molecular mobility activated by the heat liberated from interparticle velocity differences via mechanical work (torque) required to move agglomerates through the mixer for the duration of each run.

Intensive carbon combustion in sintering packed bed via steam spraying: An experimental study on carbon monoxide emission reduction

Improving the combustion efficiency of solid fuels is important for reducing carbon monoxide emissions in the iron ore sintering process. In this paper, the surface steam spraying technology is introduced in the sintering process based on the auxiliary combustion effect of steam on coke, and its potential to reduce carbon monoxide emissions is demonstrated. Thermogravimetric analysis experiments of coke breeze in air and air-steam mixed atmosphere are carried out, and the results show that the introduction of steam can reduce the concentration of carbon monoxide in the exhaust gas from 183×10^-6 to 78×10^-6. At the same time, the mechanisms of carbon monoxide emission reduction by surface steam spraying technology are analyzed from the thermodynamic and kinetic perspectives. Then, a series of laboratory-scale sintering pot tests are carried out under no spraying operation, interval spraying operation, and continuous spraying operation. The results indicate that both interval and continuous spraying operations can reduce carbon monoxide emissions. The optimal mode of steam spraying under the present experimental conditions is continuously spraying for 13 min at a volume rate of 0.053 m³/min. Compared with no spraying, the average carbon monoxide concentration in the exhaust gas is reduced from 7565×10^-6 to 6231×10^-6, and total carbon monoxide emissions for per ton sinter are reduced from 13.46 m³/t to 9.51 m³/t.