Abstract Theoretical investigations on the ZrxTa1-xO1+xN1-x system predict that some of its phases are likely to possess relatively high hardness values.(1) Such materials may be suitable for industrial application as cutting tools. The motive of the project was to investigate the best synthesis route and a method for obtaining well sintered, dense oxynitride phases with a nominal composition TaON (x=0), Ta0.8Zr0.2O1.2N0.8 (x=0.2) and Ta0.3Zr0.7O1.7N0.3 (x=0.7). This was achieved through three main steps, i.e. synthesis of the oxynitride powders, high pressure sintering and evaluation of mechanical properties. A sol gel method was used to obtain the precursor oxide powders. TaCl5 and 70wt% zirconium propoxide were used as the starting materials. Oxide gels were formed by dissolving precursor materials in absolute ethanol for 15minutes with continuous stirring, followed by subsequent hydrolysis to form gels which were aged for 24hrs at 800C. The gels were dried in air at 1000C for 12hrs in a drying oven followed by calcinations in a muffle furnace at 6000C for 6hrs to remove the alkyls and chloride ions. High surface area amorphous powders were obtained (~6.60 ± 0.02 m2/g in the case of Ta2O5) after milling with 4mm steel balls for 4hrs in a planetary mill. The respective oxynitrides were obtained by thermal nitridation using an ammonia (99.99%) flow method. A temperature of 9000C maintained for 4hrs in the presence of water vapour at an ammonia flow rate of 50cm3/min were found to be the optimum nitridation conditions. The water vapour pressure was realised by bubbling the ammonia through a water bath at room temperature prior to supply to the furnace. The water vapour pressure of such a set up was approximated to be ~3.1*103Pa. This nitridation process was carried out in a tube furnace using a silica tube of length 1200mm and external diameter of 40mm and an alumina boat as the holding vessel. Approximately 2g of oxide powder were used for each run. The dependency of nitridation on temperature and ammonia flow rate iii was investigated for the formation of TaON. Pure TaON formation was found to be more favoured by temperatures of 9000C with a heating rate of 200C/min and by an ammonia flow rate range of 40-50cm3/min. These conditions were also used for the mixed Ta-Zr oxynitrides. Ta0.3Zr0.7O1.7N0.3 formation was found to be dependent on the heating rate with ZrO2 forming beside the oxynitride solid solution above a heating rate of 100C/min. In the present work the phenomenon has been found to be dependent on the kinetics of the crystallisation reactions. At higher heating rates crystallisation of the separate phases is favoured leading to the formation of separate phases. On the other hand with an optimum heating rate the solid solution is maintained to the final nitridation temperature. The powders were found to be thermally stable in air above 6000C with TaON being the most stable with a weight change occurring at a temperature of ~6900C. The powders were stable in pure nitrogen well above 10000C. Sintering in a hot press in the temperature range of 900-14000C at a heating rate of 500C/min and a pressure range of 50-85MPa using previously heat treated h-BN crucibles in argon resulted in porous, partially densified materials. A maximum % theoretical density of 81.6% was obtained for TaON at 10000C and 85MPa pressure applied for 1hr. TaON oxidised to Ta2O5 above 10000C with an oxide phase transition being observed above 13000C. High pressure sintering was carried out in the temperature and pressure regime of 920- 12000C and 3-5.5GPa respectively in the case of TaON. The mixed Ta-Zr oxynitrides were sintered at 3GPa at a temperature of 11000C. No phase transitions were observed in all cases. An average hardness value of ~16.8GPa and fracture toughness of ~3.4MPam1/2 were obtained for the TaON phase. Ta0.3Zr0.7O1.7N0.3 and Ta0.8Zr0.2O1.2N0.8 were found to possess hardness values of 13.4GPa and 13.02GPa respectively under the same sintering conditions. It was observed that the hardness values obtained for TaON are higher than those for ZrO2 or HfO2 ceramics, due to the stronger covalent bonding in nitrogen present in TaON. On the other hand the fracture toughness values are as low as those of fully stabilised ZrO2 materials due to lack of phase transformation toughening.

Digitized by Kansas Correctional Industries

The processing of boron carbide powder including sintering optimization, green body optimization and sintering behavior of nano-sized boron carbide was investigated for the development of complex shaped body armor. Pressureless sintered B4C relative densities as high as 96.7% were obtained by optimizing the soak temperature, and holding at that temperature for the minimum time required to reach terminal density. Although the relative densities of pressureless sintered specimens were lower than that of commercially produced hot-pressed B4C, their (Vickers) hardness values were comparable. For 4.45cm diameter and 1.35cm height disk shaped specimens, pressureless sintered to at least 93.0% relative density, post-hot isostatic pressing resulted in vast increases in relative densities (e.g. 100.0%) and hardness values significantly greater than that of commercially produced hot-pressed B4C. The densification behavior of 20-40nm graphite-coated B4C nano-particles was studied using dilatometry, x-ray diffraction and electron microscopy. The higher than expected sintering onset from a nano-scale powder (15008C) was caused by remnant B2O3 not removed by methanol washing, keeping particles separated until volatilization and the carbon coatings, which imposed particle to particle contact of a substance more refractory than B4C. Solid state sintering (1500-18508C) was followed by an arrest in contraction attributed to formation of eutectic liquid droplets of size more than 10X the original nano-particles. These droplets, induced to form well below known B4C-graphite eutectic temperatures by the high surface energy of nano-particles, are interpreted to have quickly solidified to form a vast number of voids in particle packing, which in turn, impeded continued solid state sintering. Starting at 22008C, a permanent liquid phase formed which facilitated a rapid measured contraction by liquid phase sintering and/or compact slumping.

Thesis (Ph. D.)--Lehigh University, 2000. / Includes vita. Includes bibliographical references (leaves 158-168).

Thesis (M.S.)--Tennessee Technological University, 2009. / Title from title page screen (viewed on Mar. 18, 2010). Bibliography: leaves 55-58.

Thesis (Ph. D.)--University of Texas at Austin, 2002. / Vita. Includes bibliographical references. Available also from UMI Company.

A lower limb prosthesis provides assistance to its user in both ambulation and stationary support. The lower limb prosthesis consists of a socket, which interfaces with the residual limb, a pylon, attachment hardware to secure the pylon to the socket, and a prosthetic foot. For the prosthesis to be effective, the socket must be comfortable, functional and aesthetically appealing, usually in that order. Lack of comfort and fit can cause movement problems and health issues. The residual limb of the amputee changes its volume throughout the day and in order to maintain comfort a socket must be able to adapt to these volume changes. Previous research has resulted in the development of concepts for inflatable prosthetic sockets capable of addressing this need. The concepts rely on laser sintering (LS) to manufacture the parts. This research focuses on the development of a finite element analysis (FEA) method to assist in the design of adaptive sockets. The FEA can be used to predict the pressure-deflection curve of a given socket design. The FEA method was verified by experiments using LS manufactured test specimens. Results from FEA simulations indicate that the LS-manufactured sockets will achieve the desired deflection (~0.1 in) for relatively low pressures (< 10 psi), providing evidence for the feasibility of this approach. / text

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published_or_final_version / Mechanical Engineering / Master / Master of Philosophy