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This work details an investigation into the production of porous shape memory alloys (SMAs) via hot isostatic press (HIP) from prealloyed powders. HIPing is one of three main methods for producing porous SMAs, the other two are conventional sintering and selfpropagating hightemperature synthesis (SHS). Conventional sintering is characterized by its long processing time at near atmospheric pressure and samples made this way are limited in porosity range. The SHS method consists of preloading a chamber with elemental powders and then initiating an explosion at one end, which then propagates through the material in a very short time. HIPing provides a compromise between the two methods, requiring approximately 5 hours per cycle while operating in a very controlled environment. The HIPing method gives fine control of both temperature and pressure during the run which allows for the production of samples with varying porosity as well as for finetuning of the process for other characteristics. By starting with prealloyed powder, this study seeks to avoid the drawbacks while retaining the benefits of HIPing with elemental powders. In an extension of previous work with elemental powders, this study will apply the HIP method to a compact of prealloyed powders. It is hoped that the use of these powders will limit the formation of alternate phases as well as reducing oxidation formed during preparation. In addition, the nearspherical shape of the powders will encourage an even pore distribution. Processing techniques will be presented as well as a detailed investigation of the thermal and mechanical properties of the resulting material.

There are four big medium density fibreboard (MDF) plants in New Zealand with a total production capacity of close to one million cubic meters per year. A significant quantity of boards (nearly 3% or about 30,000 cubic meters per year) is rejected due to defects such as weak core, low modulus of rupture and elasticity, low internal bonding and delamination. The main cause of these defects, is lack of complete understanding of the inter relationship during the hot-pressing stage between the initial inputs such as temperature, moisture content, platen pressure and its impact on the properties of boards. The best solution is to develop a mathematical model to assist in understanding these relationships and to solve the equations in the model by using advanced software. This will reduce the number of expensive experiments and will enable us to see some of the parameters, which are otherwise difficult to visualise. Several earlier researchers have tried to model hot pressing of wood composites, mostly either for particle board or oriented strand board (OSB), and only a few are for MDF. The type of numerical methods used to solve the model equations and various assumptions, changes from one investigator to the other. The non-availability of source code to convert the mathematical equations into programme, is one of the reasons for this model development. To improve the productivity of MDF plants in New Zealand, there was a need to develop a computer programme which can include all the latest findings and can remove the defects which are present in earlier models. This model attempts a more complete integration than in the previous models of all the components such as heat transfer, moisture movement and vertical density profile formation in a one-dimensional model of hot pressing of MDF. One of the important features added in the heat and mass transfer part of the model is that the equilibrium moisture content (EMC) equation given for solid wood was modified to be applicable for the MDF fibres. In addition, this EMC equation can cover the complete range of hot pressing temperature from 160ºC to 200ºC. The changes in fibre moisture content due to bound water diffusion, which was were earlier neglected, was considered. The resin curing reactions for phenol formaldehyde and urea formaldehyde resins are also incorporated into the model, with the energy and water released during the curing reaction being included in the energy and mass balances. The validation of the heat and mass transfer model was done by comparing the values of core temperature and core pressure from the model and the experiments. The experimental value of core pressure and core temperature is obtained by putting a thermocouple and pressure transducer in the middle of the mat. The experimental core temperature results show qualitative agreement with the predicted results. In the beginning, the core temperatures from both experiment and model overlap each other. In the middle of the press cycle, the experimental core temperature is higher by 10ºC and by the end the difference decreases to 5ºC. The vertical density profile (VDP) is a critical determining factor for the strength and quality of MDF panels. The earlier concept of ratio of modulus of elasticity of the layer to the sum of modulus of elasticity of all the layers in the previous time step, given by Suo and Bowyer (1994), is refined with the latest published findings. The equation given by Carvalho et al. (2001) is used to calculate the MOE of different layers of the mat. The differential equation of a Maxwell element given by Zombori (2001) is used to measure stress, nonlinear strain function and relaxation of fibres. The model gives good agreement of peak and core density at lower platen temperature at 160ºC but with the increase of platen temperature to 198ºC, the rise in peak density is comparatively higher. There is a distinct increase in predicted peak density by 150 kg/m³ in comparison to the experimental result, where the increase is only by 10 kg/m³. There is a large decline (50 kg/m³) in core density in the experimental results in comparison to only a slight decline (13 kg/m³) in the predicted results. The use of Matlab provides a very convenient platform for producing graphical results. The time of computation at present is nearly 20 hrs in a personal computer with Pentium four processor and one GB RAM. The model can predict properties of a pressed board for the standard manufacturing conditions and also the new hot pressing technologies such as the use of steam injection or a cooling zone in the continuous press. A comparative study has been done to show the advantages of using new hot pressing technology. The present model will become an important tool in the hands of wood technologist, process engineers and MDF manufacturing personnel, to better understand the internal processes and to improve production and quality of MDF boards. This theoretical model helped in developing better understanding of internal processes. By using it, we can analyse the impact of platen temperature, moisture content on the core temperature, core pressure and density profile. It gives better insight into the relationship between core pressure and delamination of the board. The model is also able to predict the internal changes in the new hot pressing technologies such as the steam injection pressing and the use of a cooling zone in a continuous press. Using the simulation results, the exact time needed for the complete curing of resin can be calculated and then these results can be applied in the commercial plants. If the pressing time is reduced, then the over all production of both batch press and continuous press will increase. The second part of the project is the development of an empirical model to correlate the physical properties from the MDF board to the mean density. The empirical model is simple and straightforward, and thus can be applied in commercial operation for control and optimization. The empirical model can predict peak density, core density, and modulus of rupture, elasticity and internal bonding within the limits in which those relationships are derived. The model gives good results for thickness ranging from 10 to 13.5 mm and density ranging from 485 kg/m³ to 718 kg/m³.

The aim of this thesis was to improve the properties of pressed and sintered aluminium powder alloys. This improvement was to be achieved using two methods. The first method involved the selection of an alloy system using binary aluminium phase diagrams and a knowledge of the phase diagram characteristics of ideal sintering systems. The second approach involved the judicious use of selected trace element additions to modify the sintering characteristics of aluminium and its alloys. A trace amount of magnesium was found to be critical to the sintering of aluminium powder due to its disrupting effect on the tenacious oxide layer covering the powder particles. The critical amount of Mg required to optimise both density and mechanical properties is dependent on the specific volume of oxide and the therefore particle size. The optimum concentration is 0.1-1.0wt% Mg. The Al-Sn phase diagram exhibits many of the characteristics of an ideal sintering system. Unsurprisingly, Sn was found to be an extremely efficient sintering aid, but only in the presence of Mg. Near full density parts were produced using an Al-8Sn-0.15Mg alloy in short sintering times (30 minutes). Additionally, as-sintered ductilities exceeding 20% were achieved using an Al-2Sn-0.15Mg alloy. Alloys based on the Al-Sn-Mg system lend themselves to sintering without compaction and therefore freeformed Al-Sn-Mg alloys have been produced and sintered to near full density from a starting density of ~50%. Trace amounts of Sn (Pb, In, Bi, or Sb) enhance the sintering response of an Al-4Cu-0.15Mg alloy via a vacancy binding mechanism. A similar mechanism suppresses natural ageing and stimulates artificial ageing when trace amounts of Sn are added to this alloy. A Sn-modified 2XXX series alloy has also been produced with mechanical properties nearly 20% above current commercial alloys. Along with the addition of 0.1wt%Sn, this improvement required an alteration to the solution treatment cycle which allowed the use of a higher sintering temperature without the formation of large amounts of boundary phase.

Thesis (Ph. D.)--Ohio State University, 2006. / Title from first page of PDF file. Includes bibliographical references (p. 346-353).

Thesis (M.Sc.)--City University of Hong Kong, 2005. / At head of title: City University of Hong Kong, Department of Physics and Materials Science, Master of Science in materials engineering & nanotechnology dissertation. Title from title screen (viewed on Aug. 31, 2006) Includes bibliographical references.

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Made available in DSpace on 2014-06-11T19:28:20Z (GMT). No. of bitstreams: 0 Previous issue date: 2011-01-18Bitstream added on 2014-06-13T18:57:24Z : No. of bitstreams: 1 bukvic_g_me_bauru.pdf: 10769904 bytes, checksum: 62e0300f452d06ec5fe503cb8b56d8d5 (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / A usinagem de cerâmicas avançadas geralmente é feita com o objetivo de corrigir as deformações após a etapa de sinterização, conferir precisão dimensional e qualidade superficial. Para cumprir esta tarefa é utilizada, principalmente, a retificação com rebolo de diamante sob baixas taxas de remoção de material. O torneamento com ferramenta de diamante pode ser aplicado para a maioria das cerâmicas, mas esbarram em condições limites de remoção de material, como profundidade de corte nanamétricas, que se ultrapassadas mudam o regime de remoção de dúctil para frágil. Uma alternativa é a usinagem da peça no estado verde, a qual apresenta fácil usinagem com a diminuição da introdução de defeitos prejudiciais à resistência mecânica. Após a sinterização invariavelmente ocorrem distorções devido à distribuição heterogênea de gradientes de densidade que se localizam nas porções mais externas do compactado. Na tentativa de remover estes gradientes, o presente trabalho analisou a influência da remoção de sobrematerial no estado verde na distorção da peça após a sinterização. Corpos-de-prova de alumina, com 99,8% de pureza, foram torneados com sobremateriais de 1,0, 2,0 3,0, 4,0 e 5,0 mm por uma ferramenta de metal duro sob condições constantes de usinagem. Além da distorção, outras variáveis de saída foram analisadas, com desgaste de ferramenta, força de corte (Fc) e rugosidade média aritmética (Ra) do compactado em verde e sinterizado. Os resultados apontam uma redução da distorção da peça sinterizada de até 81,4% com o maior valor de remoção de sobrematerial em verde e a influência do desgaste da ferramenta na rugosidade da peça em verde e na correspondente peça sinterizada / Advanced ceramics machining is generally done with the objective of correcting distortions in pieces after sintering. In order to comply with this task grinding with a diamond grinding wheel is mainly used with low material removal rates. Turning can be done diamong tool to most of the ceramics, but is runs into very narrow material removal limit conditions, as nanometric cutting depths, which if exceeded change the removal system from ductile to brittle. An alternative is machining the piece on the green state, which presents easy machining without the introduction of harmful defects to mechanical resitance. However, after sintering there are invariably distortions caused by the heterogeneous distribution of density gradients that are located in the most outlying portions of the compacted. In an attempt to remove these gradients, this study examined the influence of different allowance values removed and the corresponding distortion after sintering. Alumina speciments are used for this procedure, with 99,8% purity, from which allowances of 1.0,2.0,3.0,4.0, 5.0 mm are removed by turning with a cermented carbine tool under constant machining conditions. Besides distortion, other output variables were analyzed, such as tool wear, cutting force and surface roughness of the green ceramics and the sintered. The results presents a reduction of the distortion of the sintered piece of 81,4% with the greater allowance removal values and the influence of tool wear on the green machining surface roughness and on the corresponding sintered piece

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