Intermetallic composites of molybdenum disilicide reinforced with various amounts of silicon carbide particulate were produced by combustion synthesis from their elemental powders. Elemental powders were mixed stoichiometrically then ball-milled. The coldpressed mixture was then chemically ignited at one end under vacuum at approximately 700°C. The combustion temperature of the process was approximately 1600°C which was lower than the melting point of molybdenum disilicide. This processing technique allowed the fabrication of the composites at 700°C within a few seconds, instead of sintering at temperatures greater than 1200°C for many hours. The end product was a porous composite, which was densified to >97% ofthe theoretical density by hot pressing. The grains ofthe matrix were 8-14 μm in size surrounded by SiC reinforcement of 1-5 μm. The morphology and structure of the products were studied by x-ray diffraction and scanning electron microscopy (SEM). Samples were prepared for hardness, fracture strength, and toughness testing at room temperature. There were improvements in the mechanical properties of the composites with increasing SiC reinforcement. The hardness of the materials increased from 10.1 ± 0.1 GPa (959 ± 13 kg/mm2) to 11.7 ± 0.6 GPa (1102 ± 52 kg/mm2) to 12.7 ± 0.4 GPa (1199 ± 36 kg/mm2) with the 10 vol% and 20 vol% SiC reinforcement, respectively. The strength increased from 195±39 MPa to 237±39 MPa with 10 vol% and to 299 ± 43.2 MPa with a 20 vol% SiC reinforcement. The fracture toughness increased from 2.79 ± 0.36 MPa.m1/2 to 3.31± 0.41 MPa.m1/2 with 10 vol% SiC and to 4.08± 0.30 MPa.m1/2 with 20 vol% SiC. The increase in hardness and flexural strength is due to the effective load transfer across the strong interface in the composites. The main toughening mechanism is crack deflection by the residual stress in the materials, induced by the differences in the thermal expansion coefficients and the elastic moduli ofthe matrix and reinforcement. / Thesis / Master of Engineering (ME)

This thesis describes experimental investigation of thermal and combustion phenomena as well as structure for self- propagating combustion synthesis of porous Ni - Ti intermetallic aimed for structural biomedical application. The control parameters for the porosity distribution have been investigated experimentally through varying the preheat temperature, initial porosity, initial elemental particle size, and applied pressure during the fabrication process. Ni and Ti elemental powders are mixed using a 1:1 ratio. The mixture is compressed using several different compression forces to produce cylindrical samples of 1.1 cm diameter and 2-3cm length, with initial porosity ranging from 30% to 40%. The samples are preheated to various initial temperatures and ignited from the top surface such that the flame propagates axially downwards. The combustion reaction is recorded with a motion camera. An infrared sensor is used to record the temperature profile during the combustion process. The samples are then cut using a diamond saw in both longitudinal and transverse directions. Image analysis software is then used to analyze the porosity distribution in each sample.

Intermetallic composites of molybdenum disilicide reinforced with various amounts of silicon carbide particulate were produced by combustion synthesis from their elemental powders. Elemental powders were mixed stoichiometrically then ball-milled. The cold- pressed mixture was then chemically ignited at one end under vacuum at approximately 700°C. The combustion temperature of the process was approximately 1600°C which was lower than the melting point of molybdenum disilicide. This processing technique allowed the fabrication of the composites at 700°C within a few seconds, instead of sintering at temperatures greater than 1200°C for many hours. The end product was a porous composite, which was densified to >97% of the theoretical density by hot pressing. The grains of the matrix were 8-14 μm in size surrounded by SiC reinforcement of 1-5 μm. The morphology and structure of the products were studied by x-ray diffraction and scanning electron microscopy (SEM). Samples were prepared for hardness, fracture strength, and toughness testing at room temperature. There were improvements in the mechanical properties of the composites with increasing SiC reinforcement. The hardness of the materials increased from 10.1 ± 0.1 GPa (959 ± 13 kg/mm2) to 11.7 ± 0.6 GPa (1102 ± 52 kg/mm2) to 12.7 ± 0.4 GPa (1199 ± 36 kg/mm2) with the 10 vol% and 20 vol% SiC reinforcement, respectively. The strength increased from 195±39 MPa to 237±39 MPa with 10 vol% and to 299 ± 43.2 MPa with a 20 vol% SiC reinforcement. The fracture toughness increased from 2.79 ± 0.36 MPa.m1/2 to 3.31± 0.41 MPa.m1/2 with 10 vol% SiC and to 4.08± 0.30 MPa.m1/2 with 20 vol% SiC. The increase in hardness and flexural strength is due to the effective load transfer across the strong interface in the composites. The main toughening mechanism is crack deflection by the residual stress in the materials, induced by the differences in the thermal expansion coefficients and the elastic moduli of the matrix and reinforcement. / Thesis / Master of Engineering (ME)

Neste trabalho, a moagem com alta energia foi utilizada para a ativação mecânica de misturas de pós de alumínio e nióbio, na proporção de 75% atômico de alumínio, para a síntese por reação de combustão do NbAl3. O objetivo foi investigar os mecanismos de ativação atuantes e a eventual preponderância de um deles. A moagem foi realizada tanto nos pós de alumínio e de nióbio separadamente (pré-ativação), como nas misturas. O processo de síntese por reação foi realizado no modo combustão simultânea, em pastilhas compactadas a partir de misturas com e sem ativação mecânica. O comportamento térmico das pastilhas foi registrado durante todo o ciclo térmico de aquecimento e, as principais características térmicas da reação de combustão, foram determinadas. O parâmetro de rede, o tamanho de cristalito e a microdeformação elástica do alumínio e do nióbio foram determinados por difratometria de raios X, mediante análise pelo método de Rietveld. A microscopia eletrônica de varredura foi utilizada para caracterização microestrutural dos pós moídos e da pastilha reagida. Constatou-se que o mecanismo preponderante de ativação mecânica é o aumento da área de interface, que ocorre durante a formação de agregados de partículas de alumínio e nióbio. A eficiência na formação de interfaces diminuiu com a utilização de nióbio pré-ativado (encruado) e com o aumento da quantidade de ácido esteárico (utilizado como agente controlador de processo durante a moagem). O efeito principal da ativação mecânica na síntese por reação de combustão foi a redução da temperatura de ignição com o aumento do tempo de moagem. A alta densidade de defeitos cristalinos, gerada durante a pré-ativação dos pós de alumínio e nióbio e na ativação mecânica das misturas, não produziu efeitos mensuráveis sobre o comportamento térmico das pastilhas. / In this work, mechanical activation of mixtures of niobium and aluminum powders (75 at.% of Al) was carried out by high energy ball milling, in order to produce NbAl3 by combustion synthesis. The purpose was to investigate activation mechanisms present and the eventual preponderancy of one of them. Beside mixtures, aluminum and niobium powders were separately activated by milling (pre-activation). Reaction synthesis, by simultaneous combustion mode, was conducted on compacted pellets made of activated and non-activated powder mixtures. The thermal behavior of the compacted pellets upon heating was recorded and main thermal characteristics of the combustion reaction were evaluated. Lattice parameter, crystallite size and microstrain for niobium and aluminum were measured by X-ray diffraction analysis, using the Rietveld method. Scanning electron microscopy was used for microstructural characterization of milled powders and reacted pellets. The growth of interface area in the aggregates of aluminum and niobium, formed during milling, was shown to be the main activation mechanism. Both pre-activated niobium and increased quantities of stearic acid (milling process control agent) hinder the interface formation. The main effect of mechanical activation in the reaction synthesis was to reduce the ignition temperature with the increase of the milling time. High density of crystal defects attained during milling (pre-activation of single powders or activation of the mixtures) produced no measurable effects to the thermal behavior of pellets.

Neste trabalho, a moagem com alta energia foi utilizada para a ativação mecânica de misturas de pós de alumínio e nióbio, na proporção de 75% atômico de alumínio, para a síntese por reação de combustão do NbAl3. O objetivo foi investigar os mecanismos de ativação atuantes e a eventual preponderância de um deles. A moagem foi realizada tanto nos pós de alumínio e de nióbio separadamente (pré-ativação), como nas misturas. O processo de síntese por reação foi realizado no modo combustão simultânea, em pastilhas compactadas a partir de misturas com e sem ativação mecânica. O comportamento térmico das pastilhas foi registrado durante todo o ciclo térmico de aquecimento e, as principais características térmicas da reação de combustão, foram determinadas. O parâmetro de rede, o tamanho de cristalito e a microdeformação elástica do alumínio e do nióbio foram determinados por difratometria de raios X, mediante análise pelo método de Rietveld. A microscopia eletrônica de varredura foi utilizada para caracterização microestrutural dos pós moídos e da pastilha reagida. Constatou-se que o mecanismo preponderante de ativação mecânica é o aumento da área de interface, que ocorre durante a formação de agregados de partículas de alumínio e nióbio. A eficiência na formação de interfaces diminuiu com a utilização de nióbio pré-ativado (encruado) e com o aumento da quantidade de ácido esteárico (utilizado como agente controlador de processo durante a moagem). O efeito principal da ativação mecânica na síntese por reação de combustão foi a redução da temperatura de ignição com o aumento do tempo de moagem. A alta densidade de defeitos cristalinos, gerada durante a pré-ativação dos pós de alumínio e nióbio e na ativação mecânica das misturas, não produziu efeitos mensuráveis sobre o comportamento térmico das pastilhas. / In this work, mechanical activation of mixtures of niobium and aluminum powders (75 at.% of Al) was carried out by high energy ball milling, in order to produce NbAl3 by combustion synthesis. The purpose was to investigate activation mechanisms present and the eventual preponderancy of one of them. Beside mixtures, aluminum and niobium powders were separately activated by milling (pre-activation). Reaction synthesis, by simultaneous combustion mode, was conducted on compacted pellets made of activated and non-activated powder mixtures. The thermal behavior of the compacted pellets upon heating was recorded and main thermal characteristics of the combustion reaction were evaluated. Lattice parameter, crystallite size and microstrain for niobium and aluminum were measured by X-ray diffraction analysis, using the Rietveld method. Scanning electron microscopy was used for microstructural characterization of milled powders and reacted pellets. The growth of interface area in the aggregates of aluminum and niobium, formed during milling, was shown to be the main activation mechanism. Both pre-activated niobium and increased quantities of stearic acid (milling process control agent) hinder the interface formation. The main effect of mechanical activation in the reaction synthesis was to reduce the ignition temperature with the increase of the milling time. High density of crystal defects attained during milling (pre-activation of single powders or activation of the mixtures) produced no measurable effects to the thermal behavior of pellets.

A primary purpose of the present work was to develop an experimental technique using Differential Scanning Calorimetry (DSC) capable of elucidating phase formation during sintering of a 50 atomic percent Ni and 50 atomic percent Ti powder compact in order to increase the understanding of the sintering mechanisms that take place during solid state and reactive sintering. Using a variety of Nickel and Titanium powder sizes, effects due to powder size, peak temperature and hold time were studied in situ using DSC, which allowed for a number of qualitative and quantitative relationships to be developed. In studying the eutectoid decomposition of β-Ti using DSC, a simple model was developed (Eq. 4-7) to relate the measured enthalpy of this reaction to the area fraction observed microstructurally. This allowed for the determination of the standard enthalpy for the β-Ti eutectoid decomposition, which was found to be ΔHf = 64.8 J/g. This value, coupled with the measured eutectoid enthalpy, allowed for the determination of the weight fraction of β-Ti present as a function of hold time at 900°C. It was found that the β-Ti removal followed a two-stage parabolic decay. The rate constant for stage I was found to be kI = -0.0347 fβ/(mins)^1/2 and that for stage II, kII = - 0.0123 fβ/(mins)^1/2. A relationship between the enthalpy observed for the combustion reaction versus the fraction of β-Ti present at the time of combustion was also developed (Eq. 4-15). This represents the first published evidence that combustion actually depends on the β-Ti content, which in turn precipitates a melting event significant enough to initiate combustion.

A primary purpose of the present work was to develop an experimental technique using Differential Scanning Calorimetry (DSC) capable of elucidating phase formation during sintering of a 50 atomic percent Ni and 50 atomic percent Ti powder compact in order to increase the understanding of the sintering mechanisms that take place during solid state and reactive sintering. Using a variety of Nickel and Titanium powder sizes, effects due to powder size, peak temperature and hold time were studied in situ using DSC, which allowed for a number of qualitative and quantitative relationships to be developed. In studying the eutectoid decomposition of β-Ti using DSC, a simple model was developed (Eq. 4-7) to relate the measured enthalpy of this reaction to the area fraction observed microstructurally. This allowed for the determination of the standard enthalpy for the β-Ti eutectoid decomposition, which was found to be ΔHf = 64.8 J/g. This value, coupled with the measured eutectoid enthalpy, allowed for the determination of the weight fraction of β-Ti present as a function of hold time at 900°C. It was found that the β-Ti removal followed a two-stage parabolic decay. The rate constant for stage I was found to be kI = -0.0347 fβ/(mins)^1/2 and that for stage II, kII = - 0.0123 fβ/(mins)^1/2. A relationship between the enthalpy observed for the combustion reaction versus the fraction of β-Ti present at the time of combustion was also developed (Eq. 4-15). This represents the first published evidence that combustion actually depends on the β-Ti content, which in turn precipitates a melting event significant enough to initiate combustion.

Titanium diboride was produced both by volume combustion synthesis (VCS) and by mechanochemical synthesis through the reaction of TiO2, B2O3 and metallic Mg. Reaction products were expected to be composed of TiB2 and MgO. However, side products such as Mg2TiO4, Mg3B2O6, MgB2 and TiN were also present in the products obtained by volume combustion synthesis. Formation of TiN could be prevented by conducting the volume combustion synthesis under argon atmosphere. Mg2TiO4 did not form when 40% excess Mg was used. Wet ball milling of the products before leaching was found to be effective in removal of Mg3B2O6 during leaching in 1M HCl. When stoichiometric starting mixtures were used, all of the side products could be removed after wet ball milling in ethanol and leaching in 5 M HCl. Thus, pure TiB2 was obtained with a molar yield of 30%. Pure TiB2 could also be obtained at a molar yield of 45.6% by hot leaching of VCS products at 75oC in 5 M HCl, omitting the wet ball milling step. By mechanochemical processing, products containing only TiB2 and MgO were obtained after 15 hours of ball milling. Leaching in 0.5 M HCl for 3 minutes was found to be sufficient for elimination of MgO. Molar yield of TiB2 was 89.6%, much higher than that of TiB2 produced by volume combustion synthesis. According to scanning electron microscope analyses, produced TiB2 had average particle size of 0.27&plusmn / 0.08 &amp / #956 / m.

Materiais nanoestruturados são caracterizados por terem tamanho de cristalito inferior a 100 nm e apresentarem propriedades diferenciadas em relação aos materiais convencionais. A intensificação da nanotecnologia como uma área de pesquisa vem gerando grandes expectativas na ciência de materiais, tendo em vista a vasta gama de novas propriedades físicas e químicas e as potencialidades tecnológicas decorrentes dos materiais nanoestruturados. O óxido de zinco (ZnO) encontra importantes aplicações tecnológicas em borrachas e tintas industriais. As propriedades químicas e microestruturais desse óxido, por sua vez, dependem do método de síntese empregado. Este trabalho teve como objetivo principal a síntese de óxido de zinco nanoestruturado através do método de combustão em solução e sua caracterização quanto às suas características microestruturais e atividade fotocatalítica. Como combustível utilizou-se o ácido cítrico. Para tanto, foram definidas as razões combustível/oxidante a partir de cálculo termodinâmico.Os produtos da reação de síntese foram caracterizados por difração de raios X (fases cristalinas presentes e tamanho de cristalito por single line), por microscopia eletrônica de varredura (análise morfológica), pelo método Branauer, Emmet e Teller - BET (área superficial), por análises térmicas (perda de massa e endo- ou exotermia sob aquecimento), por análise granulométrica (diâmetro médio do grão);Os resultados obtidos indicam que é possível obter ZnO nanoestruturado via síntese por combustão em solução utilizando ácido cítrico como combustível nas razões combustível/oxidante investigadas. Os produtos da síntese apresentaram características microestruturais e atividade fotocatalítica diferentes em função da quantidade de combustível utilizado no processo de combustão. Verificou-se a discordância do efeito da razão combustível/oxidante observado com o que é relatado na literatura para determinadas características dos produtos de reação.O tratamento térmico dos produtos da síntese influenciou diretamente na atividade catalítica de algumas amostras, conferindo-lhe aumento da cristalinidade. / Nanostructured materials are characterized by a crystallite size below 100 nm and display different properties compared to conventional materials. The intensification of nanotechnology as a research area has generated great expectations in materials science, taking into account the wide range of new physical and chemical properties and technological potential of the resulting nanostructured materials. Zinc oxide has important technological applications in rubber and industrial paints. The chemical properties and microstructure of ZnO powder depends on the synthesis method employed. This work aimed to the synthesis of nanostructured zinc oxide by combustion method and their mircrosctrucutural characterization and photocatalytic activity. As fuel was used the citric acid. To do so, the reasons were defined fuel / oxidizer from thermodynamic calculation.The products of the reaction of synthesis were characterized by diffraction of rays-X (present crystalline phases and size of cristallite by single line), by electronic microscopy of scan (morphological analysis), by the approach Branauer, Emmet and Teller - BET (superficial area), by thermal analyses (weight loss and endo- or exotermia under heating), by granulometric analysis (medium diameter of the grain). The results obtained indicate that is possible obtain ZnO nanostructured by synthesis Combustion in solution utilizing citric acid as fuel in the reasons fuel/oxidized investigated.The products of the synthesis presented characteristics microstructured and activity photocatalytic different in function of the quantity of fuel utilized in the porcedure of combustion. There was the disagreement of the effect of the reason fuel/oxidant observed with what is related in the literature for determined characteristics of the products of reaction.The thermal treatment of the synthesis directly influenced in the catalytic activity of some samples, giving it increased crystallinity.

Este trabalho teve por objetivo investigar a obtenção de espinélio MgAl2O4 nanoestruturado através da síntese contínua por combustão em solução e sua caracterização por diferentes técnicas. Incluso neste estudo a influência do tipo de combustível e a razão combustível-oxidante no tamanho do cristalito. As partículas de espinélio MgAl2O4 foram sintetizadas utilizando-se os precursores químicos nitrato de alumínio e nitrato de magnésio como fonte dos cátions metálicos. Uréia, glicina e sacarose foram empregadas como agentes redutores, com diferentes valores da razão combustível-oxidante para a sacarose. Estes parâmetros foram relacionados com sua influência no tamanho de cristalito, tamanho de partícula e área superficial. Na caracterização do pó obtido, foram utilizadas técnicas como análise termodiferencial (ATD) e termogravimétrica (ATG), granulometria por difração de laser (GDL), análise de área superficial (BET), análise cristalográfica por difração de raios X (DRX), morfologia por microscopia eletrônica de varredura (MEV). As reações químicas da síntese contínua por combustão em solução resultaram na formação in situ de fases cristalinas para reações estequiométricas de uréia, glicina e sacarose e as deficientes de sacarose. Preponderância de fase amorfa ocorreu nas reações com excesso de sacarose para o pó como-sintetizado. A totalidade de fase cristalina foi obtida após um tratamento térmico a 900°C do pó como-sintetizado. Os pós de espinélio MgAl2O4 obtidos apresentaram-se como constituídos de cristalitos nanométricos, dispostos na forma de agregados de tamanho micrométrico. O tamanho de cristalito médio, calculado pelo método Single Line, a partir de dados de análises por DRX, foi de 13 nm. A área superficial média dos pós calcinados medida pelo método BET foi de 54 g/m2 Por análise granulométrica constatou-se um Tamanho de partícula médio de 17 μm para o pó como-sintetizado e 17,1 μm para o calcinado a 900ºC. As análises por MEV confirmaram a agregação das partículas do pó sintetizado, a partir de partículas preponderantemente esféricas e algumas com morfologia irregular. / This study has investigated a continuous solution combustion synthesis technique to obtain the nanostructured MgAl2O4 spinel powder and their characterize them by different tecniques. This study has also included the investigation of the influence of different kinds of fuel and fuel-to-oxidant ratio on crystallite size. The MgAl2O4 spinel powder was performed using aluminum nitrate and magnesium nitrate to obtain the metallic ions. Urea, glycine and sucrose were used like fuel, with several fuel-to-oxidant ratio. These parameters were correlating with powders characteristics, like crystallite size, particle size and superficial area. The techniques used for powder characterization included differential thermal analyzer (DTA), thermogravimetric analyzer (TGA), particles size analyzer (PSA), surface area by BET analysis, X-ray diffraction (XRD) and scanning electron microscopy (SEM). The chemical reactions of solution combustion resulted on crystalline phase to the reactions with urea, glycine and sucrose (to desabilites on fuel and stoichiometric) and amorphous phase formation of MgAl2O4 in situ for as-synthesized powder. The crystalline phase formation of spinel MgAl2O4 was only succeeded obtained after a thermal treatment of as-synthesized powder under 900°C.The spinel MgAl2O4 powders obtained were composed of nano-size crystallites, but in micrometer-sized aggregates. The mean particle size calculated, via Single Line method, using XRD was 13 nm. PSA indicated that the synthesized powders contain a mean aggregates size with a tri mode distribution of around 17.1 μm. SEM analyses confirmed that the as-synthesized powders are composed of particles aggregation. They have an irregular morphology and nano-size crystallites.