O NbAl3 e algumas ligas intermetálicas do sistema Nb-Ni-AI foram sintetizadas por combustão a partir dos pós de seus elementos constituintes. O efeito de variáveis de processo, como o tamanho de partícula dos pós, a composição química, a pressão de compactação, o tratamento de desgaseificação e a taxa de aquecimento, foram investigados na síntese do NbAl3 na forma de pastilhas cilíndricas. A síntese de ligas do sistema Nb-Ni-AI foi realizada a partir de misturas com as composições Nb10Ni70AI, Nb20Ni65AI e Nb30Ni60AI. A microestrutura das amostras reagidas foi caracterizada por microscopia óptica, microscopia eletrônica de varredura, EDS e difração de raios-X (método de Rietveld). Foram obtidas pastilhas de NbAl3 com 98,5 % da densidade teórica, superior ao valor encontrado na literatura (95%), mediante o controle de variáveis de processo. Nas pastilhas contendo níquel, a combustão ocorreu nas pastilhas de todas as composições. Fases metaestáveis, presentes na microestrutura das pastilhas baitas de reação, foram transformadas após tratamento térmico, originando ligas trifásicas com diferentes concentrações de fases (NbAl3, NiAI e NbNiAI), conforme a composição inicial do compactado. Algumas propriedades mecânicas de amostras brutas de reação e tratadas termicamente foram determinadas pela técnica da impressão (microdureza e tenacidade). Os resultados obtidos são comparáveis aos da literatura, salvo algumas discrepâncias atribuídas a processos de fabricação distintos. As etapas de reação da síntese do NbAl3 e de ligas Nb-Ni-AI foram posteriormente investigadas mediante interrupção da reação durante sua propagação ao longo de barras paralelepipédicas compactadas. Verificou-se que a síntese do NbAl3 ocorre pela dissolução de nióbio no alumínio fundido, seguida da precipitação do NbAl3. Nas amostras contendo níquel, a síntese ocorre em dois estágios: no primeiro estágio formam-se o Ni2Al3 ou o NiAl3, em quantidades relativas dependentes da composição geral. As reações deste primeiro estágio podem disparar as reações do segundo estágio, referentes à síntese do NbAl3. / NbAl3 and Nb-Ni-AI intermetallic alloys have been obtained by pressureless combustion synthesis from elemental powders. The effects of process variables as powder particle size, composition, compaction pressure (green density), degassing treatment and heating rate on the combustion (thermal explosion mode) of NbAl3 cylindrical pellets were studied. Combustion synthesis of Nb-Ni-AI alloys was performed on powder mixtures with nominal compositions Nb10Ni70AI, Nb20Ni65AI and Nb30NI60AI. The microstructure of reacted samples was characterized by optical microscopy, scanning electron microscopy, EDS and X-ray diffraction (Rietveld method). It was shown that careful control of the processing conditions allowed near full (98,5%) dense pellets of NbAl3. In the nickel containing pellets, reaction occurred for all the compositions investigated. Metastable phases were seen to be present in the as reacted pellets, which were transformed after a heat treatment, producing a three phase alloy (NbAl3, NiAI and NbNiAI) with different phase concentrations, depending on the initial compact composition. Some mechanical properties, like microhardness and tenacity were measured by microidentation technique on the as reacted and heat-treated samples. The results are comparable with the literature, excepted for some discrepancies caused by different fabrication processes. The reaction sequence for both cases (NbAl3 and Nb-Ni-AI alloys) was further investigated by DSC analysis and also by interrupting the reaction during its propagation along compacted parallelopipedal bars. It was found that the NbAl3 synthesis occurs through niobium dissolution in molten aluminum and precipitation of NbAl3. In the nickel containing samples, synthesis occurs as two-stage reaction: Ni2Al3 or NiAl3 are formed in the first stage, with relative amounts depending on the general composition. This first stage reaction can trigger the second one, related to the formation of NbAl3.

Les cermets, nommés M(p)-CMC(s), « Ceramic Matrix Composite dispersed with Metallic Particles », sont prometteurs dans les applications à haute température. Un cermet modèle (304L-YSZ) constitué de 40 % vol. de particules d'acier inoxydable 304L dispersées dans une matrice de zircone partiellement stabilisée à l’yttrium a été préparé par métallurgie des poudres. Les cermets sont homogènes et possèdent une densité voisine de 97 % par rapport à la densité théorique. Une étude cinétique basée sur l’hypothèse de l’étape limitante, a été réalisée afin de proposer un mécanisme et un modèle d’oxydation du cermet. Dans un premier temps, l’oxydation de la poudre d’acier inoxydable a été étudiée sous oxygène à 800 °C. Les expériences d'oxydation sous He (80 %)-O2 (20 %) ont été conduites par thermogravimétrie. Conformément à la littérature, la cinétique d’oxydation de la poudre suit un régime de diffusion. Une couche d’oxyde à base de chrome à croissance externe est observée.En revanche, la cinétique d’oxydation du cermet modèle est différente de celle de la poudre de 304L. Un fort gain de masse est observé dès l’introduction de l’oxygène au début du palier isotherme. Pendant le palier isobare, la prise de masse est lente et n’est pas régie par la diffusion. La caractérisation des cermets oxydés montre que des nodules riches en chrome apparaissent tout d’abord à l’intérieur du métal. Puis une couche d’oxyde à base de chrome et de fer se forme par croissance externe. La matrice de zircone ne limite pas la diffusion de l’oxygène vers le métal. Elle se fissure sous l’action des contraintes mécaniques induites par le changement de volume des particules de 304L pendant l’oxydation. / Ceramic matrix composite dispersed with metallic particles, called M(p)-CMC(s), are being developed for optimizing several functions of industrial components in severe atmospheres at high temperature.The corrosion of a model M(p)-CMC(s), based on 304L stainless steel and yttrium doped zirconia (304L(p)-ZrO2(s); 40%/60% in volume) is studied and compared with the oxidation behaviour of the stainless steel powders. The oxidation behaviour of the model 304L(p)-ZrO2(s) composite produced by powder metallurgy, studied by means of the thermogravimetry under 20 % O2 in helium at 800 °C, is presented. Oxidation curves show a fast increase in mass gain followed by slow one for the composite material. SEM observations and Auger spectroscopy measurements of the oxidized composite indicate an outward complex Cr and Fe rich oxide layer whereas Cr2O3 nodules are observed to nucleate and develop inward. For 304L stainless steel powder, the shape of the mass gain curve is parabolic, in agreement with a diffusion controlled oxidation. SEM observations of oxidised powder and in situ XRD measurements at 800 °C under oxygen show an external growth of Cr2O3 oxide layer.The low resistance to oxidation of the composite (compared to the powder) in the initial period seems to be due to the properties of the zirconia/metallic particles interface obtained after the sintering process. Under reducing conditions, the initial Cr2O3 layer reacts with zirconia matrix. TEM observation of the “as sintered” interface between the metallic particles and the ceramic shows no chromia layer. Sudden changes in oxygen partial pressure during experiments reveal an accelerating effect of the oxygen pressure.

L’allègement des structures des véhicules est l’une des problématiques actuelles majeures car il permet d’atteindre de meilleures performances, une autonomie plus importante et une consommation plus faible. Ceci est d’autant plus vrai dans le domaine de la défense où la nécessité de se protéger face aux menaces balistiques implique un ajout de masse conséquent. Les alliages d’aluminium sont pour l’instant l’un des meilleurs compromis, mais augmenter leurs performances permettrait un nouveau gain de masse. Dans ce contexte, la métallurgie des poudres (MdP) se présente comme une alternative de choix aux procédés de mise en forme traditionnels car elle permet de combiner différents modes de renforcement des propriétés mécaniques, à savoir la nanostructuration, l’écrouissage, les solutions solides et les renforts particulaires. Dans un premier temps, l’étude s’est focalisée sur la possibilité de combiner haute densité et durcissement structural d’un alliage Al-Zn-Mg. La précipitation confère au matériau brut fritté des propriétés mécaniques un peu plus faibles que celles d’un alliage AA7020 de coulée traité à l’état T651. L’approche a ensuite été appliquée à la poudre broyée, le but étant alors d’associer densité et précipitation tout en préservant les grains ultrafins obtenus par broyage. Enfin, la problématique de la consolidation de composites à matrice métallique à grains ultrafins et à renforts B4C a été abordée / Lightweight materials are very attractive in the global industry, and more specifically in the field of automotive and aeronautics fields. For army vehicles the reduction of the weight has increased the need for lightweight metal and ceramic armor systems ; the combination of these materials being a key element in modern packages. Nowadays, aluminum alloys are widely introduced in such systems. Increasing the mechanical properties of these alloys will automatically imply a decrease of the mass of ballistic protections. In this context, the powder metallurgy route appears promising as it allows simultaneously to nanostructure the matrix by strain hardening and to scatter properly particles reinforcements. First, the choice has been made to focus on the combination of high density and hardening precipitation of an Al-Zn-Mg alloy. Strengthening precipitates give the consolidated raw powder mechanical properties close to the ones of a commercial wrought aluminum alloy AA7020 in a T651 temper. Then the same process was optimized on a milled powder in order to preserve the fine grains obtained by high energy ball milling. Finally, B4C particles were introduced as reinforcements in the aluminum matrix to develop an ultrafine-grained metal matrix composite

Les alliages métalliques amorphes, appelés aussi verres métalliques connaissent un intérêt grandissant, de par leurs propriétés remarquables comparées à celles des alliages métalliques cristallins, comme par exemple, une haute limite élastique due à l’absence de dislocations, une résistance élevée à la corrosion provoquée par l’absence de microstructure, ou encore un faible module de Young. Ce dernier point est intéressant pour une application en tant que biomatériaux, dans le but d’éviter les phénomènes d’ostéolyses. Cependant, ce type de matériaux possède deux inconvénients majeurs : (i) un manque de déformation plastique, ainsi (ii) qu’une taille critique faible, provoquée par la nécessité d’avoir une vitesse de refroidissement très élevée. Pour pallier ce problème, l’ajout d’éléments avec un petit rayon atomique, comme le béryllium ou l’aluminium, est fréquemment employé. Cependant, ces éléments peuvent même être dangereux pour le corps humain, sous forme d’ions relargués. L’objectif de cette thèse est donc, tout d’abord, de développer de nouvelles nuances de verres métalliques complètement biocompatibles, puis de définir des axes d’amélioration pour augmenter la taille critique, ainsi que la ductilité de ces matériaux. Dans une première partie, deux nouvelles compositions biocompatibles ont été développées, la première a été réalisée dans l’objectif d’obtenir un biomatériau résorbable, base Mg. La seconde a permis d’étudier un biomatériau de renfort, base Zr. Mais les éléments tels que le Be ou Al sont difficiles à éviter car ils jouent un rôle sur le diamètre critique et les propriétés mécaniques. Ainsi, dans un second temps, l’objectif a été de trouver des voies d’amélioration, tant au niveau procédé de fabrication, qu’au niveau de la composition du matériau. Premièrement, en utilisant un système déjà connu, Cu-Zr-Ti, l’addition de terre-rares, comme l’yttrium, a été étudiée. En ajoutant 1% atomique d’yttrium au système, la déformation plastique a été augmentée de 2 points, ainsi que la résistance à la corrosion et la biocompatibilité. La formation de précipités d’Y2O3, créant des zones cristallisées, semblent être responsables d’une augmentation de la ductilité. Une autre technique de mise en forme, par la métallurgie des poudres, a pu être abordée. La vitesse de refroidissement par atomisation, très élevée, permet d’obtenir une poudre complètement amorphe, même pour des systèmes présentant une faible aptitude à former des verres. Aussi, l’élaboration de composites alliant poudres amorphe et cristalline est possible est possible par frittage. Enfin, le rôle du pré-cyclage mécanique et de la vitesse de déformation sur les mécanismes de déformation ont été étudiés en associant simulation par dynamique moléculaire et essais de compression quasi-statiques. Une homogénéisation de la déformation, dûe au pré-cyclage, semble être responsable de l’augmentation de ductilité. / Metallic glasses exhibit improved properties compared to pure crystalline metals, as for example, a high strength and a high corrosion resistance, due to the absence of microstructure and also a low Young modulus. This last feature is interesting for use as biomaterials to prevent bone osteolysis. However, these materials exhibit two main drawbacks: a lack of ductility and a small critical size. To improve these points, most parts of the glasses for biomedical applications still contain toxic elements, such as Be or Al. This work aims to find new fully biocompatible compositions of metallic glasses and suggest three solutions to remedy some issues, based on micro-alloying, powder metallurgy and deformation mechanisms understanding. In the first part of the work, two new compositions for metallic glasses were elaborated: a Mg-Ca-Au-Yb system for use as bioresorbable materials and a Zr-based glassy system for use as reinforcement materials. A complete study on the processing and the characterization of the samples has been conducted: thermal stability, also corrosion properties, cytotoxicity and mechanical properties are also crucial to characterize for a use as biomaterials. However, trying to use only biocompatible elements considerably reduces the possibility to obtain fully amorphous large diameter samples. In that respect, the other part of the work consists to study the possible ways of increasing the samples size, using an Al-free, Ni-free well-known system: Cu-Zr-Ti. First, yttrium additions in the Cu-Zr-Ti system has been investigated. The optimum amount of yttrium to add and the characterization of this material was conducted. 1 at. % of Y in the Cu-Zr-Ti leads to an increase of 2% of plastic strain, of the corrosion resistance, and biocompatibility. The microstructure was precisely studied using Transmission Electron Microscopy (TEM) observations and some explanation about this improvement can be discussed. To the author knowledge, for the first time, yttrium nano-precipitates with a core-shell structure were observed. This leads to an improvement of the ductility of the material, due to the nano-crystallized areas induced by the precipitates. Moreover, a new process, the powders metallurgy with Spark Plasma Sintering (SPS) allows the creation of larger sintered samples. Indeed, the high cooling rate of the atomization allows to obtain fully amorphous powder, even for low GFA systems. Processing of ex-situ composites samples, adding some ductile particles in the amorphous matrix. At last, the role of the mechanical pre-cycling and of the strain rate on the elementary deformation mechanisms were investigated using both atomistic simulation and compressive mechanical tests. A homogenization of the deformation, caused by the pre-cycling, seems to improve the ductility.

<p>In powder metallurgy research field, Direct Metal Laser Sintering (DMLS) and Metal Powder Starch Consolidation (MPSC) are relatively new rapid forming techniques to fabricate complex and near net-shaped components. The working principles of DMLS are to melt and fuse metal powder layer by layer in computer controlled systems to pile up components like three dimensional printing. It has been for instance extensively used for mould inserts, die parts, and functional metal prototypes. Another, less explored method, starch consolidation is a pressureless direct casting method which consists principally of mixing powder slurry, casting into moulds, consolidation, drying, and sintering. With a strong focus on both methods, the study here combines several strong material technology sectors; powder, rapid forming, mechanical property testing and surface technology. It covers the processing chain from green body preparation, optimization of</p><p>sintering, nitriding, post sinter heat treatment, to modeling and assessment of material behaviour for end-user applications. An iron based powder and a high vanadium high speed steel powder with low and high carbon contents were used in the DMLS and MPSC processes, respectively. The overall aim of the study is to synthesize near net-shaped powder-based components, to characterize pores and microstructure, and to establish a fundamental understanding of failure mechanisms of powder based materials in bending fatigue, thermal fatigue and wear.</p><p>The study showed the DMLS and MPSC technologies could produce shaped components with a multi-phased structure, controllable nitriding depth and high relative densities in a range of 97 - 99.7 %. Materials' heterogeneity and porosity have detrimental influence on mechanical properties, especially on crack initiation and subsequent propagation.</p>

In the present study, the powder metallurgy was evaluated as a technique to produce high performance Al &amp / #8211 / 8Fe &amp / #8211 / 1.7V &amp / #8211 / 7.9Si (wt%) alloys for elevated temperature applications and the role of powder particle size range and extrusion ratio in the microstructural and mechanical properties of the extruded alloys was investigated. For this purpose, an air atomization method was employed to produce powders of the high temperature alloy and after that the produced powders were sieved and cold compacted. The compacted billets were subsequently hot extruded at 450 &amp / #8211 / 480 &deg / C. Five selected ranges of powders which were different in particle size (&amp / #8722 / 2000+212 &amp / #956 / m, &amp / #8722 / 212+150 &amp / #956 / m, &amp / #8722 / 150+106 &amp / #956 / m, &amp / #8722 / 106+90 &amp / #956 / m, and &amp / #8722 / 90 &amp / #956 / m) and three different extrusion ratios (144:1, 81:1, and 26:1) were used in this study. In the first part of the thesis, microstructure and thermal stability of as &amp / #8211 / air atomized powders were described. &amp / #945 / &amp / #8211 / Al matrix and &amp / #945 / &amp / #8211 / Al13(Fe, V)3Si phases were characterized in all rapidly solidified powders by XRD. The fraction of the intermetallic phases was reduced as the powder particle size increased. DTA analysis revealed an exothermic reaction at 581 &deg / C in all alloy powders of different size fractions. In the second part of the study, the effect of powder particle size and extrusion ratio on microstructural and mechanical properties (at different temperatures) of the extruded alloys was investigated. The results showed that decrease in powder particle size and increase in extrusion ratio refined the microstructure and improved the mechanical properties. It was revealed that the effect of powder size was more evident than that of extrusion ratio. Remarkable increases in mechanical properties (e.g. 60.7% increase in ultimate tensile strength at 250 &deg / C) were observed as a result of rapid solidification process (atomization) and hot extrusion.

In this thesis I present studies of some transport and spectroscopic properties for two di erent materials exhibiting large magnetoresistance. Both of these materials are oxides of transition metals, showing exotic magnetic and transport properties. Despite these similarities, they are very different in many other aspects. One of them is an oxide of Manganese, along with a rare-earth metal, and exhibits large magnetoresistance under certain conditions, when doped by an alkaline earth metal. They are known as doped rare-earth manganites. The other material, Sr2FeMoO6, exhibits large magnetoresistance in the parent compound, without any doping, but only in the polycrystalline state. The manganites, on the other hand, show magnetoresistance under appropriate conditions in both single crystal and in polycrystalline state. Moreover, manganites exhibit several Metal-Insulator Transitions (MIT) as a function of doping, temperature and magnetic field. Sr2FeMoO6, on the other hand, is usually always metallic. In the first chapter, a brief introduction is provided regarding different types of magnetoresistance (MR) phenomena observed in different materials, namely Anisotropic MR (AMR), Giant MR (GMR), Collosal MR (CMR), Tunneling MR (TMR), Powder MR (PMR) etc. Out of these, CMR and PMR are found in doped manganites, while Sr2FeMoO6 exhibits PMR only. Next, a brief overview of the structure, properties and theories for both of these materials is provided. For the case of doped manganites, a short introduction is given for a novel two-fluid hamiltonian (called l - b model) which was proposed recently by Ramakrishnan et. al.. This model reproduces several exotic transport and magnetic properties of manganites which were inexplicible by earlier theories. The model was solved within the Dynamical Mean Field Theory (DMFT) framework by Hassan et. al.. A brief description of this DMFT solution is given. Many of the DMFT results for this model have been used in the subsequent chapters. In the second chapter, the hysteresis behaviour of the magnetoresistance and the magnetization (M ) of powdered Sr2FeMoO6 is considered in detail. In a recent experi- ment by Sarma et. al., it was found that this material, when powdered exhibits an exotic variety of PMR. In ordinary PMR, the hysteresis behaviour of the MR is supposed to follow that of M, in the sense that the coercive fields should be identical in both cases. Also, the MR is supposed to be roughly proportional to the square of the magnetization. However, in the experiments by Sarma et. al. on cold-pressed Sr2FeMoO6 powder, it was observed that the M R did not appear to be determined purely by the magnetization. Rather, the coercive fields for the hysteresis of the MR was almost 6 times that of M . Moreover, the quantity M R/M2, instead of remaining constant with changing magnetic field, itself has a hysteresis loop. Apart from establishing the exotic nature of the PMR, the experiment also tries to determine whether the MR originates from intra-grain or inter-grain tunneling. In the second chapter we present a simple toy model to reproduce the experimental results, and provide theoretical explanations. A combination of Monte Carlo and transfer matrix methods are used to simulate the hysteresis behaviour of the M R as well as of M . We show that the observed data can be understood if it is as- sumed firstly that the MR arises predominantly from inter-grain rather than intra-grain tunneling, and that the inter-grain boundaries are themselves magnetic with a coercive field higher than that of the grains. In order to motivate the use of Monte Carlo method for studying hysteresis, a brief survey of main results obtained for some simple models using this technique is also provided. In the third chapter, we study the doping and temperature dependence of core-level photoemission spectra in doped rare-earth manganites. In some recent experiments on Strontium doped (LSMO) and Barium doped (LBMO) samples, it has been observed that the M n2p3/2 core-level spectra shows an intriguing spectral weight transfer over a range of several eV , as a function of doping (x) and temperature (T ), in the ferromagnetic metallic phase. Specifically, there appears a shoulder adjacent to the main peak on the side of lower binding energy, which increases in weight and intensity as the doping increases or the temperature decreases. In LSMO samples, another shoulder was noticed on the higher binding energy side also. Moreover, in data obtained from LBMO samples, the spectra at different temperatures was subtracted from the spectra at/above Tc, and then this difference spectrum was integrated. The integrated weight, when normalized by the weight at the lowest temperature, appears to follow the square of the measured magnetization almost exactly. In order to understand the experimental data, we extended the aforementioned l - b model to include a core-level, and the attractive interaction due to a core-hole on the local valence levels. The impurity problem arising in DMFT, consisting of a single impurity site coupled to a bath, was tailored for the photoemission problem, by including this extra core-level at the impurity site. The hybridization parameters for the bath were determined self-consistently from the DMFT, and then the single particle spectral function for the core-hole was determined. This spectral function is proportional to the photo emission intensity. We found that our calculations reproduced the observed spectral weight transfer as a function of x and T both in trends and in magnitude. The integrated difference spectra weight was found to follow the square of the DMFT magnetization, just as in the experiment. Linear discretization of the conduction bath was used for all the above-mentioned cases. In one particular case, a logarithmic discretization was also undertaken for comparison, and also to obtain the exponents of the edge singularities in the theoretical spectra. In the fourth chapter, the possibility of Anderson Localization in manganites is in- vestigated, using the l - b model. According to this model, a large fraction of the valence electrons are polaronically self-trapped even in the ferromagnetic metallic phase. Due to strong on-site Coulomb interaction, these polarons provide a strongly scattering background, which can localize the mobile-electron band states close to the band edges. Since the fraction of valence electrons which are truly mobile is small, hence the Fermi energy lies close to the lower band edge. Hence, there is a possibility of an Anderson Insulator phase where all charge carriers are localized. To investigate this, we studied the behaviour of the mobility edges as a function of doping. DMFT alone does not include the physics of localization. Hence, in order to obtain the mobility edges, we combined the DMFT results with the Self-consistent Theory of Localization (STL), using a simplified prescription called Potential Well Analogy (PWA) due to Economou et. al.. We found that there is indeed an Anderson Insulator phase in a certain region of doping, which would otherwise have been supposed to be metallic based on purely DMFT results. Finally, we have compared this result, obtained using effective field theories, with an actual real space simulation of the l - b model at T=0. In this case, the mobility edge trajectories were obtained by studying the Inverse Participation Ratio (IPR), as a function of band energy and doping. In the concluding chapter, the principal results presented in this thesis are summa- rized. The limitations of the approach or approximations used are discussed, and future possibilities for overcoming these limitations outlined.

Amorphous and nanostructured Al-based alloys have attracted significant interest owing to their promising properties, including high strength combined with low density. Unfortunately, the production of these advanced materials is limited to powders or ribbons with thickness of less than 100 micrometers due to the reduced glass forming ability of the Al-based alloys. Powder metallurgy through pressure-assisted sintering is a good solution to overcome the size limitation of these materials. In this thesis, Al84Gd6Ni7Co3 glassy powders were consolidated into high-strength bulk materials by hot pressing. The sintering behavior and the microstructural evolution during hot pressing were analyzed as a function of temperature. The results reveal that, through the careful control of the sintering temperature, the combined devitrification and consolidation of the amorphous Al84Gd6Ni7Co3 powders can be achieved, leading to bulk samples with the desired hybrid microstructure and with excellent room temperature mechanical properties. Beside the sintering temperature, the microstructural state of the starting material is critical in order to obtain bulk samples with the desired microstructure and related properties. Consequently, the variation of the initial structural state of the powders as well as of their thermal stability and phase evolution during heating may be used for further tuning the mechanical performance of the hot pressed Al84Gd6Ni7Co3 samples. In order to analyze this aspect, ball milling was used to vary the crystallization behavior of the gas-atomized Al84Gd6Ni7Co3 glassy powder. The influence of milling on microstructure and thermal stability was investigated as a function of the milling time. The results show that the traces of crystalline phases present in the as-atomized powder decrease gradually with increasing the milling time. The thermal stability of the fcc-Al primary phase increases while the thermal stability of the intermetallic phases decreases with increasing milling. Moreover, significant improvement in hardness occurs after milling, which is attributed to the amorphization of the residual crystalline phases present in the as-atomized powder. These finding demonstrate that milling is an effective way to change the initial structural state of the powders and to control the thermal stability of the material. The effect of the microstructural state of the starting material on the mechanical properties of the consolidated samples was investigated in detail. For this, the milled Al84Gd6Ni7Co3 glassy powders were consolidated into bulk specimens by hot pressing. These materials exhibit superior mechanical properties than the samples produced from the as-atomized powder: record high yield strength of 1.7 GPa and fracture strength exceeding 1.8 GPa. This is combined with a plastic strain of about 4 %, Young’s modulus of 120 GPa and density of 3.75 g/cm3. A bimodal microstructure consisting of coarse grained and fine grained regions was achieved in the hot pressed samples by properly controlling the milling process. The exceptionally high strength is attributed to the increased volume fraction of the fine regions, whereas the plastic deformation is favored by the coarse regions, which are able to hinder crack propagation during loading. In addition, the fracture toughness is also improved by the existence of the coarse regions. The tribological properties of the Al84Gd6Ni7Co3 bulk samples were also evaluated. The wear resistance of the bulk samples produced from the milled powder is enhanced with respect to the specimens fabricated from the as-atomized powder, and both alloys exhibit improved wear properties compared to pure aluminum and Al88Si12. Abrasive wear is the main mechanism for these alloys. Finally, the corrosion resistance of these alloys was studied. The results indicate that the Al84Gd6Ni7Co3 bulk material produced from the as-atomized powder has better corrosion resistance than the samples obtained from the milled powder. The main corrosion behavior for these alloys is pit corrosion, intermetallic particle etchout and the corrosion of the Al-rich inter-particle areas. These results clearly demonstrate that, by the proper selection of the sintering temperature and through the appropriate choice of the initial structural state of the powders, the combined devitrification and consolidation of amorphous precursors can be successfully used to produce bulk amorphous/nanostructured Al-based materials with tunable physical and mechanical properties. This expands the known boundaries of Al alloys and offers a new route for the development of novel and innovative high-performance Al-based materials capable to meet specific requirements.

In powder metallurgy research field, Direct Metal Laser Sintering (DMLS) and Metal Powder Starch Consolidation (MPSC) are relatively new rapid forming techniques to fabricate complex and near net-shaped components. The working principles of DMLS are to melt and fuse metal powder layer by layer in computer controlled systems to pile up components like three dimensional printing. It has been for instance extensively used for mould inserts, die parts, and functional metal prototypes. Another, less explored method, starch consolidation is a pressureless direct casting method which consists principally of mixing powder slurry, casting into moulds, consolidation, drying, and sintering. With a strong focus on both methods, the study here combines several strong material technology sectors; powder, rapid forming, mechanical property testing and surface technology. It covers the processing chain from green body preparation, optimization of sintering, nitriding, post sinter heat treatment, to modeling and assessment of material behaviour for end-user applications. An iron based powder and a high vanadium high speed steel powder with low and high carbon contents were used in the DMLS and MPSC processes, respectively. The overall aim of the study is to synthesize near net-shaped powder-based components, to characterize pores and microstructure, and to establish a fundamental understanding of failure mechanisms of powder based materials in bending fatigue, thermal fatigue and wear. The study showed the DMLS and MPSC technologies could produce shaped components with a multi-phased structure, controllable nitriding depth and high relative densities in a range of 97 - 99.7 %. Materials' heterogeneity and porosity have detrimental influence on mechanical properties, especially on crack initiation and subsequent propagation.

Metal matrix composites can produce mechanical and physical properties better than those of the monolithic metal. Titanium alloys are widely used matrix materials as they can offer outstanding specific strength, corrosion resistance and other advantages over its competitors, such as aluminium, magnesium and stainless steel. In past decades, titanium matrix composites served in broad areas, including aerospace, military, automobile and biomedical industries. In this project, a revised powder metallurgy method, which contains cold isostatic pressing and hot isostatic pressing, was adopted to refine the microstructure of monolithic titanium. It was also used to manufacture titanium matrix composites. TiH2 powder was selected as the starting material to form Ti matrix and the reinforcements were sub-micron and nano-metric TiB particles. Mechanical properties and microstructure of commercial titanium composites exhaust valves from Toyota Motor Corporation have been studied as the reference of properties of titanium composites manufactured in this project. It has been shown that tensile strength and hardness of exhaust valves increase about 30% than those of similar matrix titanium alloys. Examination on powder starting materials of this project was also carried out, especially the dehydrogenation process shown in the DSC result. Mechanical properties and microstructures of titanium matrix composites samples in this project, as related to the process parameter, have also been investigated. The density of these samples reached 96% of theoretical one but cracks were found through out the samples after sintering. Fast heating rates during the processing was suspected to have caused the crack formation, since the hydrogen release was too fast during dehydrogenation. Hardness testing of sintered samples was carried out and the value was comparable and even better than that of commercial exhaust valves and titanium composites in literature. Microstructure study shows that the size of reinforcements increased and the size of grains decreased as the increasing amount of TiB reinforcements. And this condition also resulted in the increasing amount of the acicular alpha structure.