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Thermite compounds have received a renewed interest due to their ability to store large quantities of energy that is comparable to conventional energetic materials. Such reactive materials can be manipulated to create a nanolaminated structure. It has been shown that an increase in the fraction of nanolaminated particles can reduce the ignition temperature and increase reactivity. In the present study, methods to lower the ignition temperature of aluminium copper-oxide (Al-CuO) are assessed. Arrested reactive milling (ARM) was used on stoichiometric Al-CuO powders to increase the nanolamination and reduce the ignition temperature to 840 Kelvins (K). Milling alone not only reduced the ignition temperature slightly, but for milling times greater than 30 minutes, intermediate phases were produced, which had negative impacts on the reaction characteristics. Another method to reduce the ignition temperature of Al-CuO involved creating a hybrid mixture using a compound with a lower ignition temperature to further decrease the ignition temperature of Al-CuO. ARM was used to lower the ignition temperature of a nickel aluminium (Ni-Al) intermetallic compound down to 480 K. Hybrid mixtures were then created with varying concentrations of milled and unmilled Al-CuO-Ni. Powders were then tested in a tubular furnace to determine the ignition temperature dependence on heating rate and concentration of constituents. It has been shown that an unmilled hybrid mixture with 75% and 50% concentration of Al-CuO has an ignition temperature of 840 K. Higher concentrations of Ni-Al resulted in lowered ignition temperatures which varied between 600 K and 480 K. A milled hybrid mixture has lower ignition temperatures than an unmilled mixture. It was shown that a milled hybrid mixture with a 75% concentration of Al-CuO has an ignition temperature of 840 K, corresponding to pure Al-CuO. The ignition temperature of the milled hybrid mixture was reduced to approximately 520-620 K for concentrations of Ni-Al of 50%, and 473-573 K for concentrations of 75% Ni-Al.

Thesis (MEngineering)--University of South Australia, 2004.

The KTH Department of Materials Science and Engineering has lacked powder metallurgy research for many years, and as this field is constantly gaining in importance, such research needs to be reestablished. This requires the department to be able to accurately and efficiently characterize the properties of a powder, such as size distribution and composition, and in the short term, this needs to be done using non-specialized equipment. This project aimed to assess the availability and usefulness of both traditional and novel characterization methods by way of trial characterization experiments as well as a literature review.   The experiments resulted in some data about three sample powders, as well as the conclusions that size distribution could be effectively characterized by automatized image analysis, composition could be characterized using Energy Dispersive X-ray Spectroscopy and that sample preparation was key to good results. It was concluded that the department could conceivably evaluate the most important properties, but that sampling and sample preparation routines need to be established to ensure efficient characterization and representative data. / Materialinstitutionen på Kungliga Tekniska högskolan har i många år helt saknat pulvermetallurgiforskning och eftersom detta fält ständigt blir mer relevant behöver denna forskning återetableras. Detta kräver att institutionen med tillräcklig noggrannhet och effektivitet kan bestämma egenskaper hos ett pulver, såsom storleksfördelning och sammansättning, och på kort sikt behöver detta ske med ickespecialiserad utrustning. I detta projekt har tillgänglighet och användbarhet hos både traditionella och innovativa analysmetoder utvärderats med hjälp av experimentell karaktärisering av pulver samt en litteraturstudie. Experimenten gav data om de tre undersökta pulvren och resulterade även i slutsatsen att storleksfördelning kunde bestämmas med automatiserad bildanalys, att samansättning kunde bestämmas med Energi Dispersiv Röntgen Spektroskopi och att provpreparering äravgörande för bra resultat. Av detta följer att institutionen rimligtvis kan bestämma de viktigaste egenskaperna hos ett pulver, men att rutiner för provtagning och provpreparering behöver etableras för att säkerställa effektiv analys och representativ data.

Published Article / Metal injection moulding (MIM) offers advantages for mass production of components over conventional production methods for parts with complex shapes and large production runs. The MIM process includes mixing a fine metallic powder with a polymeric binder to produce a homogeneous feedstock. This enables the production of metallic components in a similar manner to plastic injection moulding. After undergoing a process of binder removal the components undergo a conventional sintering cycle. As significant shrinkage occurs (as much as 30%) this must be considered when designing the die cavity. This paper describes the design and manufacture of a die to produce tensile specimens. Extensive injection moulding trials to produce acceptable tensile components were undertaken. The complexities and possible implications of the design of a mould on the process are discussed. The outcomes of this research will be used by the CSIR for further development and application of the MIM technology for manufacture of high value components, such as dental implants.

All materials in dust form pose an increased risk of accidental deflagration, or explosion. For workplace safety, this risk of deflagration for a solid particulate sample is characterized through specialized dust explosibility testing systems. These systems disperse a cloud of powder inside a spherical chamber via a pressure gradient, where a timed ignition occurs. The accuracy of measurements taken during this process are predicated upon the assumption that the cloud of powder is uniformly distributed during the ignition period. Metal additive manufacturing (AM) is a rapidly expanding technology that, in some cases, involves heavy metal powders that do not disperse well in standard explosibility testing vessels. Consequently, there is a need to validate explosibility data for heavy metal powder blends to ensure that the dust sample is adequately dispersed in the chamber at the time of ignition. This thesis provides a method for employing optical dust probes to determine the concentration of a tungsten metal AM powder cloud inside an enclosed vessel. Optical dust probes are devices that measure light transmission through an attenuating medium, in this case a cloud of powder, and utilize Bouguer-Beer-Lambert (BBL) law to determine the concentration of particles. This thesis summarizes and synthesizes the assumptions and limitations of BBL law when used with optical dust probes, drawing from multiple published works with varying applications. The bounds of the average extinction efficiency are discussed, especially with respect to when the extinction paradox can be applied. Ultimately, it is determined that the BBL law can only be applied in this study to determine extinction coefficients, and that calculating a specific mass concentration value is theoretically misguided without specific modifications to the experimental setup. The extinction coefficients measured via an optical dust probe and a separate image analysis method are compared. Although no correlation could be established due to the limitations of this experimental setup, specific modifications are suggested that would enable this methodology to be used in future applications.

In metal powder compaction, density non-uniformity due to friction can be a source of flaws. Currently in industry, uniform density distribution is achieved by the optimization of punch motions through trial and error. This method is both costly and time consuming. Over the last decade, the finite element (FE) method has received significant attention as an alternative to the trial and error method; however, there is still lack of an accurate and robust material model for the simulation of metal powder compaction. In this study, Cam-clay and Drucker-Prager cap (DPC) material models were implemented into the commercial FE software ABAQUS/Explicit using the user-subroutine VUMAT. The Cam-clay model was shown to be appropriate for simple geometries. The DPC model is a pressure-dependent, non-smooth, multi-yield surface material model with a high curvature in the cap yield surface. This high curvature tends to result in instability issues; a sub-increment technique was implemented to address this instability problem. The DPC model also shows instability problems at the intersection of the yield surfaces; this problem was solved using the corner region in DPC material models for soils. The computational efficiency of the DPC material model was improved using a novel technique to solve the constitutive equations. In a case study it was shown that the numerical technique leads to a 30% decrease in computational cost, while degrading the accuracy of the analysis by only 0.4%. The forward Euler method was shown to be accurate in the integration of the constitutive equations using an error control scheme. Experimental tests were conducted where cylindrical-shaped parts were compacted from Distaloy AE iron based powder to a final density of 7.0 g/cm3. To measure local density, metallography and image processing was used. The FE results were compared to experimental results and it was shown that the FE analysis predicted local relative density within 2% of the actual experimental density. / Thesis (Ph.D, Mechanical and Materials Engineering) -- Queen's University, 2010-09-23 12:15:27.371

Thesis (M.S.)--University of Texas at El Paso, 2009. / Title from title screen. Vita. CD-ROM. Includes bibliographical references. Also available online.

This thesis focuses on the use of a design of experiment approach to examine the significance of process factors and interactions on the fabrication of micro- textured surfaces. The micro-textured surfaces examined contain pillar and hole features ranging from 80 – 2 micrometers in diameter. The processes examined are the deep reactive ion etching of silicon wafers for the production of silicon mould inserts and the micro-injection moulding of polypropylene, high density polyethylene and 316LS stainless steel replicate samples of the silicon mould insert. During the deep reactive ion etching of the silicon wafers the design of experiment approach was used to determine the significant of platen power, C4F8 gas flow and switching times to the presence of pillar undercut of 10 x 10, 5 x 5 and 2 x 2 micrometer pillars. Undercuts occur when the pillar base has a smaller cross-section than the apex of the pillar. Switching times was found to be the only statistically significant parameter for both 10 x 10 and 5 x 5 micrometer pillars. The design of experiment approach is used in the micro-injection moulding of polypropylene, high density polyethylene and 316LS stainless steel replicates to examine the significance of mould temperature, cooling time, holding pressure and injection speed on the part and buffer mass of the produce samples, the height and width of pillar on the replicate surfaces and the variation of the replicated pillars height and width from the original silicon mould insert. Examination of the high density polyethylene replicates found that mould temperature was the most significant factor regarding pillar dimensions (and variation from the silicon mould insert) across the range of pillar sizes. Upon examination of the polypropylene replicates it was found that the factor of most significance on pillar dimensions varied across the different pillar sizes. Holding pressure was identified as the most significant factor with regards to the 53 x 29 and 19 x 80 micrometer pillars. Injection speed was found to be most significant for the 25 x 25 and 19 x 29 micrometer pillars. Cooling time was found to be most significant with regards to the 30 x 10, 25 x 10, 20 x 10 and 15 x 10 micrometer pillars. While ii mould temperature was found to be most significant for the 20 x 20, 15 x 15 and 10 x 30 micrometer pillars. The interaction between mould temperature and injection speed was also found to be the most significant factor with regards to the 43 x 29 and 25 x 30 micrometer pillars. Examination of the 316LS replicates found that mould temperature was the most significant factor regarding pillar dimensions for 80 x 80 and 19 x 80 micrometer pillars. While holding pressure was found to be most significant to the 29 x 29 micrometer pillars and injection speed was identified as most significant to the 53 x 80 micrometer pillars. The samples produced during the design of experiment investigations were then used to examine the effect of surface texturing on droplet behaviour. Droplet contact angles were examined on polypropylene, high density polyethylene and silicon samples structured with 10 – 2 micrometer pillar. Initial droplet contact angles were found to be higher on the polypropylene samples than the high density polyethylene or silicon samples. With the lowest initial contact angles being found for the silicon inserts. Droplet ‘channelling’ and evaporation were examined on silicon, polypropylene, high density polyethylene and 316LS samples structured with micro-channel surface pillars and holes ranging from 80 – 2 micrometer in diameter. Contact pinning of the droplet to the surface via the three- phase contact-line was noted during observations of droplet ‘channelling’. This pinning effect was observed at all sample tilt angles (30 - 90 o ). With regards to droplet evaporation, the droplets were noted to evaporate evenly (with no or limited contact pinning) on all unstructured surfaces and the surfaces structured with hole features. On the surfaces structured with pillar features, the droplets appeared too evaporated along the surface gradient from the smallest pillars to the largest.

Neste trabalho foi desenvolvido o projeto e fabricação de quatro componentes de uma pinça de biópsia (concha, garfo, oito e haste), através da micromoldagem de pós metálicos por injeção. A matéria prima utilizada neste trabalho é conhecida comercialmente como CATAMOLD® 316L A. Corpos de prova foram obtidos através da injeção em uma injetora de baixa pressão para determinação da quantidade de pó de aço inoxidável 316L e sistema aglutinante contida na matéria prima. Ensaios de injetabilidade foram realizados para análise do comportamento da matéria prima no processo de injeção. Foram avaliados os parâmetros de injeção (temperatura de injeção, temperatura do molde e velocidade de injeção) e as variáveis de saída (pressão de injeção, massa, segregação entre pó e sistema aglutinante e densidade). A influência dos parâmetros de injeção sobre as variáveis de injeção foi analisada através do delineamento estatístico via Redes Neurais Artificiais (RNA), com a utilização do programa Statgraphics® Centurion XV. Os corpos de prova obtidos na injetora de baixa pressão apresentaram alta quantidade de pó de aço inoxidável (92,2% em massa). Devido a esta alta concentração de pó, os ensaios de injetabilidade realizados na injetora de alta pressão apresentaram valores elevados para as pressões de injeção, variando de 1641 a 2115 bars para que houvesse o preenchimento total das cavidades. O molde microusinado para os componentes da pinça se mostrou eficiente na fabricação dos componentes, porém apresentou dificuldades na extração das peças. Mesmo com a obtenção de todos os componentes a montagem da pinça não foi realizada, visto que as furações de montagem foram retiradas no projeto, consequentemente não foram usinados. Depois de microinjetados, os componentes da pinça foram sinterizados e apresentaram variação dimensional de 0,01 a 0,29 mm em relação às dimensões de projeto e variação na contração de 7,05 a 13,33%, diferentes dos 14,30% citados no catálogo do CATAMOLD® 316L A. / In this work the design and manufacture of four components of the biopsy forceps (ladle, fork, eight and rod), by metal powder injection molding was developed. The feedstock used in this work is known commercially as CATAMOLD® 316L A. Specimens were obtained by injection into a low-pressure injection molding machine for determining the amount of 316L stainless steel powder and binder system contained in the feedstock. Mouldability tests were performed to analyze the behavior of the feedstock in the injection process. The injection parameters (injection temperature, mold temperature and injection speed) and output variables (injection pressure, mass segregation between powder and binder system and density) were evaluated. The influence of injection parameters on the variables of injection was analyzed using the statistical design via Artificial Neural Networks (ANN), using the software Statgraphics® Centurion XV. The specimens obtained at low pressure injection showed high amount of stainless steel powder (92.2 wt%). Due to this high concentration of power, mouldability tests were performed in high-pressure injection showed high values for injection pressures ranging from 1641 to 2115 bars so that there was the complete filling of cavities. The micromachined mold for the components of the forceps proved efficient in the manufacture of components, but presented difficulties in the extraction of parts. Even with the obtaining of the all the components the biopsy forceps was not assembled, since the mounting holes were taken in the project, and therefore were not machined. After injected , the components of the forceps were sintered and showed dimensional variation from 0.01 to 0.29 mm in relation to project dimensions and variation in contraction from 7.05 to 13.33% , different from those 14.30% cited in the catalog of CATAMOLD® 316L A