The objective of this research was to design aluminum powder metallurgy (PM) alloys and processing strategies that yielded sintered products with thermal properties that rivaled those of the cast and wrought aluminum alloys traditionally employed in heat sink manufacture. Research has emphasized PM alloys within the Al-Mg-Sn system. In one sub-theme of research the general processing response of each PM alloy was investigated through a combination of sintering trials, sintered density measurements, and microstructural assessments. In a second, the thermal properties of sintered products were studied. Thermal conductivity was first determined using a calculated approach through discrete measurements of specific heat capacity, thermal diffusivity and density and subsequently verified using a transient plane source technique on larger specimens. Experimental PM alloys achieved >99% theoretical density and exhibited thermal conductivity that ranged from 179 Wm-1K-1 to 225 Wm-1K-1. Thermal performance was largely dominated by the amount of magnesium present within the aluminum grains and in turn, bulk alloy chemistry. Data confirmed that the novel PM alloys were highly competitive with even the most advanced heat sink materials such as wrought 6063 and 6061. Two methods of thermal analysis were employed in order to determine the thermal conductivity of each alloy. This first consisted of individual analysis of the specific heat capacity (Cp), thermal diffusivity (?) and density (?) as a function of temperature for each alloy. The thermal conductivity (K) was subsequently determined through the relationship: K=C_p ??. The second means of thermal analysis was a direct thermal conductivity measure using a transient plane source (TPS). The thermal diffusivity and density of samples were both found to decrease with temperature in a linear fashion. Conversely, the specific heat capacity was found to increase with temperature. The only measured thermal property that appeared to be influenced by the alloy chemistry was the thermal diffusivity (and subsequently the calculated thermal conductivity). Both means of thermal analysis showed high thermal conductivity in alloys with low concentrations of magnesium, demonstrating the significance of having alloying elements in solid solution with aluminum. Overall, several alloys were developed using a press and sinter approach that produced higher levels of thermal conductivity than conventional aluminum heat sink materials. The highest thermal conductivity was achieved by alloy Al-0.6Mg-1.5Sn with a calculated value of 225.4 Wm-1K-1. This novel aluminum PM alloy was found to exceed both wrought 6061 and 6063 (195 and 217 Wm-1K-1 respectively). Furthermore, PM alloy Al-0.6Mg-1.5Sn was found to have a significant advantage over die-cast A390 (142 Wm-1K-1).

Homogenization of alloying elements is desired during sintering of powder metallurgy components. The redistribution processes such as penetration of liquid phase into the interparticle/grain boundaries of solid particles and subsequent solid-state  diffusion of alloy element(s) in the base powder, are important for the effective homogenization of alloy element(s) during liquid phase sintering of the mixed powders. The aim of this study is to increase the understanding of alloy element redistribution processes and their effect on the dimensional properties of the compact by means of numerical and experimental techniques. The phase field model coupled with Navier-Stokes equations is used for the simulations of dynamic wetting of millimeter- and micrometer-sized metal drops and liquid phase penetration into interparticle boundaries. The simulations of solid particle rearrangement under the action of capillary forces exerted by the liquid phase are carried out by using the equilibrium equation for a linear elastic material. Thermodynamic and kinetic calculations are performed to predict the phase diagram and the diffusion distances respectively. The test materials used for the experimental studies are three different powder mixes; Fe-2%Cu, Fe-2%Cu-0.5%C, and Fe-2%(Cu-2%Ni-1.5%Si)-0.5%C. Light optical microscopy, energy dispersive X-ray spectroscopy and dilatometry are used to study the microstructure, kinetics of the liquid phase penetration, solid-state diffusion of the Cu, and the dimensional changes during sintering. The wetting simulations are verified by matching the spreading experiments of millimeter-sized metal drops and it is observed that wetting kinetics is much faster for a micrometer-sized drop compared to the millimeter-sized drop. The simulations predicted the liquid phase penetration kinetics and the motion of solid particles during the primary rearrangement stage of liquid phase sintering in agreement with the analytical model. Microscopy revealed that the C addition delayed the penetration of the Cu rich liquid phase into interparticle/grain boundaries of Fe particles, especially into the grain boundaries of large Fe particles, and consequently the Cu diffusion in Fe is also delayed. We propose that the relatively lower magnitude of the sudden volumetric expansion in the master alloy system could be due to the continuous melting of liquid forming master alloy particles. / <p>QC 20140515</p>

19 Dec 2004. / Published through the Information Bridge: DOE Scientific and Technical Information. "IS-T 2447" Amber Lynn Genau. 12/19/2004. Report is also available in paper and microfiche from NTIS.

Thesis (M. App. Sc.)--Carleton University, 2004. / Includes bibliographical references (p. 99-114). Also available in electronic format on the Internet.

Thesis (M. S.)--Materials Science and Engineering, Georgia Institute of Technology, 2009. / Committee Chair: Cochran, Joe; Committee Member: Berczik, Doug; Committee Member: Sanders, Tom; Committee Member: Sandhage, Ken; Committee Member: Thadhani, Naresh.

Thesis (M.App.Sc.) - Carleton University, 2007. / Includes bibliographical references (p. 66-71). Also available in electronic format on the Internet.

Made available in DSpace on 2014-06-11T19:27:11Z (GMT). No. of bitstreams: 0 Previous issue date: 2009-06-22Bitstream added on 2014-06-13T20:55:49Z : No. of bitstreams: 1 nogueira_rc_me_guara.pdf: 1525094 bytes, checksum: b0dcb8b9e8f6ae12a8d680a1344a5b04 (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / As ligas Ti-Nb são apropriadas para uso em implantes devido a sua alta resistência e biocompatibilidade. Um dos métodos de obter estas ligas é a metalurgia do pó, pois ele permite obter peças próximas ao seu formato final. Teorias indicam que a razão de densificação varia inversamente como uma função do tamanho da partícula. O aumento de interesse na fabricação de materiais nanoestruturados (partículas menores que 100 nm) é devido à possibilidade de obter um material sinterizado em um tempo menor e em temperaturas mais baixas, com uma melhor densificação do que pós convencionais, pois é mais reativo. Neste trabalho, após hidrogenação e moagem de alta energia por até 60 min, obteve-se pós de hidreto de titânio e hidreto de nióbio, com estrutura ultrafina/nanométrica, que auxilia o processo de difusão numa posterior etapa de sinterização. Meios de moagem de diferentes materiais (aço inoxidável e nitreto de silício - Si3N4) foram usados. Independentemente dos meios de moagem usados, o material obtido apresentou aproximadamente 5% das partículas com valores cumulativos de tamanhos de até 100 nm. Mas, o material obtido do recipiente de Si3N4 após 20 min de moagem apresentou uma maior porcentagem de partículas com diâmetros médios equivalentes entre 40 nm e 1000 nm, correspondente a 29%. / The Ti-Nb alloys are suitable for use in implants due to their high tensile strength and biocompatibility. One of the methods to obtain these alloys is the powder metallurgy, because it allowing to get pieces closer to near-net-shape. Theories showing that the densification rate range conversely like a function of the grain size. The great interest in the manufacturing of nanostructured materials – NsM (particles smaller than 100 nm) is due to possibility to obtain a sintered material in a smaller time and in more low temperatures than conventional powders, with the best densification, because it is more reactive. In this work, after hydrogenation and use of higher energy ball milling by until 60 min, were obtained powders of titanium hydride and niobium hydride, with ultra-fine/nanometric structure, what help in the diffusion process during a later stage of sintered. Milling medium of different materials (stainless steel and silicon nitride - Si3N4) were used. Independently of the grinding medium used, the material obtained exhibit approximating 5% of the particles with the cumulative values of size until 100 nm. But, is the possible to verify that the material obtained of the Si3N4 vessel, after milling by 20 min, exhibited a greater percentage of particles with average equivalent diameters between 40 nm and 1000 nm, than correspond to 29%.

Made available in DSpace on 2014-12-17T14:07:03Z (GMT). No. of bitstreams: 1 RobertoCM_DISSERT.pdf: 2213383 bytes, checksum: 38393df8ecbad522fe143dac8fca7042 (MD5) Previous issue date: 2012-03-30 / This research studies the sintering of ferritic steel chips from the machining process. Were sintered metal powder obtained from machining process chips for face milling of a ferritic steel. The chip was produced by machining and characterized by SEM and EDS, and underwent a process of high energy mill powder characterized also by SEM and EDS. Were constructed three types of matrixes for uniaxial compression (relation l / d greater than 2.5). The differences in the design of the matrixes were essentially in the direction of load application, which for cylindrical case axial direction, while for the rectangular arrays, the longer side. Two samples were compressed with different geometries, a cylindrical and rectangular with the same compaction pressure of 700 MPa. The samples were sintered in a vacuum resistive furnace, heating rate 20 ?C / min., isotherm 1300 ?C for 60 minutes, and cooling rate of 25 ?C / min to room temperature. The starting material of the rectangular sample was further annealed up to temperature of 800 ? C for 30 min. Sintered samples were characterized by scanning electron microscopy, optical microscopy and EDS. The sample compressed in the cylindrical matrix did not show a regular density reflecting in the sintered microstructure revealed by the irregular geometry of the pores, characterizing that the sintering was not complete, reaching only the second phase. As for the specimen compacted in the rectangular array, the analysis performed by scanning electron microscopy, optical microscopy and EDS indicate a good densification, and homogeneous microstructure in their full extent. Additionally, the EDS analyzes indicate no significant changes in chemical composition in the process steps. Therefore, it is concluded that recycling of chips, from the processed ferritic steel is feasible by the powder metallurgy. It makes possible rationalize raw material and energy by manufacture of known properties components from chips generated by the machining process, being benefits to the environment / Esta pesquisa aborda o desenvolvimento de novos materiais e processos atrav?s da sinteriza??o de cavaco de a?o ferritico oriundo do processo de usinagem. Foram sinterizados p?s met?licos a partir de cavacos obtidos do processo de usinagem por fresamento frontal de um a?o ferr?tico. O cavaco foi produzido atrav?s de usinagem e caracterizado por MEV (microscopia eletr?nica de varredura) e EDS (electron dispersive spectroscopy), e sofreu um processo de moagem em moinho convencional para transforma??o em p?, que foi caracterizado, tamb?m, atrav?s de MEV e EDS. Foram constru?dos tr?s tipos de matrizes para compacta??o uniaxial com rela??o l/d maior que 2,5. A diferen?a na concep??o de projeto das matrizes consiste basicamente na dire??o de aplica??o da carga, que no caso cil?ndrico foi na dire??o axial da pe?a, enquanto que nas matrizes retangulares a aplica??o da carga foi na face mais longa. Foram compactadas amostras com duas geometrias diferentes, uma cil?ndrica e outra retangular com a mesma press?o de compacta??o de 700 MPa. As amostras foram sinterizadas em forno resistivo a v?cuo, com taxa de aquecimento de 20 ?C/min., com isoterma de 1300 ?C, durante 60 minutos, e taxa de resfriamento de 25?C/min at? a temperatura ambiente. O material de partida do sinterizado retangular foi adicionalmente recozido a uma temperatura de 800 ?C durante 30 minutos. As amostras sinterizadas foram caracterizadas por MEV, MO (microscopia ?ptica) e EDS. O corpo de prova compactado na matriz cil?ndrica n?o apresentou uma densidade regular refletindo na microestrutura do sinterizado, revelado pela geometria irregular dos poros, caracterizando a sinteriza??o parcial, atingindo somente a segunda fase, consequ?ncia da dureza do p? resultante da usinagem e moagem. Quanto ao corpo de prova compactado na matriz retangular, as an?lises realizadas atrav?s do MEV, MO e EDS, indicam uma boa densifica??o, al?m de homogeneidade na sua microestrutura em toda extens?o. Adicionalmente, as an?lises de EDS indicam n?o haver modifica??es significativas nas composi??es qu?micas nas etapas do processo. Portanto, conclui-se que a reciclagem de cavacos, oriundos da usinagem do a?o ferr?tico ? vi?vel pelo processo de sinteriza??o, o que possibilita a racionaliza??o de mat?ria prima e de energia, com a fabrica??o de componentes com propriedades conhecidas a partir de cavacos gerados pelo processo de usinagem trazendo benef?cios para o meio ambiente

Made available in DSpace on 2014-10-09T12:48:21Z (GMT). No. of bitstreams: 0 / Made available in DSpace on 2014-10-09T13:57:22Z (GMT). No. of bitstreams: 1 08713.pdf: 6496941 bytes, checksum: 5803cb14028b4639afbb59fbc4cfa0d0 (MD5) / Tese (Doutoramento) / IPEN/T / Instituto de Pesquisas Energeticas e Nucleares - IPEN/CNEN-SP

abstract: Increasing demand for high strength powder metallurgy (PM) steels has resulted in the development of dual phase PM steels. In this work, the effects of thermal aging on the microstructure and mechanical behavior of dual phase precipitation hardened powder metallurgy (PM) stainless steels of varying ferrite-martensite content were examined. Quantitative analyses of the inherent porosity and phase fractions were conducted on the steels and no significant differences were noted with respect to aging temperature. Tensile strength, yield strength, and elongation to fracture all increased with increasing aging temperature reaching maxima at 538oC in most cases. Increased strength and decreased ductility were observed in steels of higher martensite content. Nanoindentation of the individual microconstituents was employed to obtain a fundamental understanding of the strengthening contributions. Both the ferrite and martensite hardness values increased with aging temperature and exhibited similar maxima to the bulk tensile properties. Due to the complex non-uniform stresses and strains associated with conventional nanoindentation, micropillar compression has become an attractive method to probe local mechanical behavior while limiting strain gradients and contributions from surrounding features. In this study, micropillars of ferrite and martensite were fabricated by focused ion beam (FIB) milling of dual phase precipitation hardened powder metallurgy (PM) stainless steels. Compression testing was conducted using a nanoindenter equipped with a flat punch indenter. The stress-strain curves of the individual microconstituents were calculated from the load-displacement curves less the extraneous displacements of the system. Using a rule of mixtures approach in conjunction with porosity corrections, the mechanical properties of ferrite and martensite were combined for comparison to tensile tests of the bulk material, and reasonable agreement was found for the ultimate tensile strength. Micropillar compression experiments of both as sintered and thermally aged material allowed for investigation of the effect of thermal aging. / Dissertation/Thesis / M.S. Materials Science and Engineering 2011