Study of fracture behaviour of bond coats on nickel superalloy by three-point bending of microbeams

A microbeam testing geometry is designed to study the variation in fracture toughness across a compositionally graded NiAl coating on a superalloy substrate. A bi-material analytical model of fracture is used to evaluate toughness by deconvoluting load-displacement data generated in a three-point bending test. It is shown that the surface layers of a diffusion bond coat can be much more brittle than the interior despite the fact that elastic modulus and hardness do not display significant variations. Such a gradient in toughness allows stable crack propagation in a test that would normally lead to unstable fracture in a homogeneous, brittle material. As the crack approaches the interface, plasticity due to the presence of Ni3Al leads to gross bending and crack bifurcation.

Deformation and failure of a film/substrate system subjected to spherical indentation: Part 1. Experimental validation of stresses and strains derived using Hankel transform technique in an elastic film/substrate system

Our concern here is to rationalize experimental observations of failure modes brought about by indentation of hard thin ceramic films deposited on metallic substrates. By undertaking this exercise, we would like to evolve an analytical framework that can be used for designs of coatings. In Part I of the paper we develop an algorithm and test it for a model system. Using this analytical framework we address the issue of failure of columnar TiN films in Part II [J. Mater. Res. 21, 783 (2006)] of the paper. In this part, we used a previously derived Hankel transform procedure to derive stress and strain in a birefringent polymer film glued to a strong substrate and subjected to spherical indentation. We measure surface radial strains using strain gauges and bulk film stresses using photo elastic technique (stress freezing). For a boundary condition based on Hertzian traction with no film interface constraint and assuming the substrate constraint to be a function of the imposed strain, the theory describes the stress distributions well. The variation in peak stresses also demonstrates the usefulness of depositing even a soft film to protect an underlying substrate.

Microwave irradiation-assisted method for the deposition of adherent oxide films on semiconducting and dielectric substrates

We report a method for the deposition of thin films and thick coatings of metal oxides through the liquid medium, involving the micro waveirradiation of a solution of a metal-organic complex in a suitable dielectric solvent. The process is a combination of sol-gel and dip-coating methods, wherein coatings can be obtained on nonconducting and semiconducting substrates, within a few minutes. Thin films of nanostructured ZnO (wurtzite) have been obtained on Si(100), glass and polymer substrates, the nanostructure determined by process parameters The coatings are strongly adherent and uniform over 15 mm x 15 mm, the growth rate similar to 0.25 mu m/min Coatings of nanocrystalline Fe2O3 and Ga2O3 have also been obtained The method is scalable to larger substrates, and is promising as a low temperature technique for coating dielectric substrates, including flexible polymers. (C) 2010 Elsevier B.V. All rights reserved.

Laser Surface Alloying of a Creep Resistant Magnesium Alloy MRI 230D with Al and Al2O3

A creep resistant permanent mould cast Mg alloy MRI 230D was laser surface alloyed with Al and a mixture of Al and Al2O3 using pulsed Nd:YAG laser irradiation at four different scan speeds in order to improve the corrosion and wear resistance. The microstructure, corrosion and wear behavior of the laser surface alloyed material is reported in this manuscript. The coating comprised of a featureless microstructure with cellular-dendritic microstructure near the interface and exhibited good interfacial bonding. A few solidification cracks reaching down to substrate were also observed. The two step coating with Al followed by a mixture of Al and Al2O3 exhibited a slightly better corrosion resistance than the single step coating with Al. In the long run, however, corrosion resistance of both the coatings became comparable to the as-cast alloy. The corroded surface of the laser surface alloyed specimens revealed a highly localized corrosion. The laser surface alloyed specimens exhibited an improvement in wear resistance. The laser scan speed did not exhibit a monotonic trend either in corrosion or wear resistance.

Effect of substrate roughness on growth of diamond by hot filament CVD

Polycrystalline diamond coatings are grown on Si (100) substrate by hot filament CVD technique. We investigate here the effect of substrate roughening on the substrate temperature and methane concentration required to maintain high quality, high growth rate and faceted morphology of the diamond coatings. It has been shown that as we increase the substrate roughness from 0.05 mu m to 0.91 mu m (centre line average or CLA) there is enhancement in deposited film quality (Raman peak intensity ratio of sp (3) to non-sp (3) content increases from 1.65 to 7.13) and the substrate temperature can be brought down to 640A degrees C without any additional substrate heating. The coatings grown at adverse conditions for sp (3) deposition has cauliflower morphology with nanocrystalline grains and coatings grown under favourable sp (3) condition gives clear faceted grains.

Microwave Assisted Synthesis of Nanostructured Titanium Dioxide with High Photocatalytic Activity

TiO2 (anatase) was synthesized using a microwave-irradiation-assisted chemical method. The reaction conditions were varied to obtain unique nanostructures of TiO2 comprising nanometric spheres giving the materials a very porous morphology. The oxide was characterized by X-ray diffraction (XRD), Raman spectroscopy, transmission electron microscopy (TEM), scanning electron microscopy (SEM), X-ray photoelectron spectroscopy (XPS), Fourier transform infrared (FTIR) spectroscopy, and thermogravimetric analysis (TGA). The specific surface area and porosity were quantified by the BET method, and the degradation of dyes was carried out using these materials. The photocatalytic activity of the nanometric TiO2 was significantly higher than that of commercially available TiO2 (Degussa P25) for the degradation of the dyes.

Analysis of reflection characteristics of a normal incidence plane wave on resonant sound absorbers: A finite element approach

Resonant sound absorbers are used widely as anechoic coatings in underwater applications. In this paper a finite element scheme based on the Galerkin technique is used to analyze the reflection characteristics of the resonant absorber when insonified by a normal incidence plane wave. A waveguide theory coupled with an impedance matching condition in the fluid is used to model the problem. It is shown in this paper that the fluid medium encompassing the absorber can be modeled as an elastic medium with equivalent Lamé constants. Quarter symmetry conditions within the periodic unit cell are exploited. The finite element results are compared with analytical results, and with results published elsewhere in the literature. It is shown in the process that meshing of the fluid domain can be obviated if the transmission coefficients or reflection coefficients only are desired as is often the case. Finally, some design curves for thin resonant absorbers with water closure are presented in this paper.

Modified-Pore-Filled-PVDF-Membrane Electrolytes for Direct Methanol Fuel Cells

The polyvinylidene fluoride (PVDF) membrane is modified by the chemical etchant-route employing a sodium naphthalene charge-transfer complex followed by impregnation with Nafion ionomer or polyvinyl alcohol (PVA)-polystyrene sulfonic acid (PSSA) polymeric blend solutions by a dip-coating technique to form pore-filled-membrane electrolytes for application in direct methanol fuel cells (DMFCs). The number of coatings on the surface-modified PVDF membrane is varied between 5 and 15 and is found to be optimum at 10 layers both for Nafion and PVA-PSSA impregnations for effective DMFC performance. Hydrophilicity of the modified-membrane electrolytes is studied by determining average contact angle and surface-wetting energy. Morphology of the membranes is analyzed by a cross-sectional scanning electron microscope. The modified PVDF membrane electrolytes are characterized for their water-methanol sorption in conjunction with their mechanical properties, proton conductivity, and DMFC performance. Air permeability for the modified membranes is studied by a capillary-flow porometer. Methanol crossover flux across modified-PVDF-membrane electrolytes is studied by measuring the mass balance of methanol using a density meter. DMFCs employing membrane electrode assemblies with the modified PVDF membranes exhibit a peak power-density of 83 mW/cm(2) with Nafion impregnation and 59 mW/cm(2) for PVA-PSSA impregnation, respectively. Among the membranes studied here, stabilities of modified-pore-filled PVDF-Nafion and PVDF-PVA-PSSA membranes with 10-layers coat are promising for application in DMFCs. (C) 2010 The Electrochemical Society. DOI: 10.1149/1.3518774] All rights reserved.

Structure evolution and phase change in Ag-5.1 at.% Bi alloy during mechanical alloying

In this paper we explore the enhancement of solubility in a mechanically driven immiscible system experimentally using a mixture of Ag and Bi powders corresponding to a composition of Ag-5.1 at.% Bi. Increase in solubility can be correlated with the combination of sizes of both Ag and Bi at the nanometric scale. It is shown that complete solid solution of Ag-5.1 at.% Bi forms when the respective sizes of :Bi and Ag exceed 13 and 8 nm respectively. We have carried out a thermodynamic analysis of the size- and strain-dependent free energy landscape and compared the results to the initial mixture of microsized particles to rationalize the evolution of Ag solid solution. The agreement indicates that the emerging driving force for the formation of solid solution is primarily due to size reduction rather than the enhanced kinetics of mass transport due to mechanical driving. (c) 2011 Published by Elsevier Ltd. on behalf of Acta Materialia Inc.

Ultrasonic spray pyrolysis of CZTS solar cell absorber layers and characterization studies

CZTS (Copper Zinc Tin Sulphide) is a wide band gap quartnery chalcopyrite which has a band gap of about 1.45 eV and an absorption coefficient of 10(4) cm(-1); thus making it an ideal material to be used as an absorber layer in solar cells. Ultrasonic Spray Pyrolysis is a deposition technique, where the solution is atomized ultrasonically, thereby giving a fine mist having a narrow size distribution which can be used for uniform coatings on substrates. An Ultrasonic Spray Pyrolysis equipment was developed and CZTS absorber layers were successfully grown with this technique on soda lime glass substrates using aqueous solutions. Substrate temperatures ranging from 523 K to 723 K were used to deposit the CZTS layers and these films were characterized using SEM, EDAX and XRD. It was observed that the film crystallized in the kesterite structure and the best crystallites were obtained at 613 K. It was observed that the grain size progressively increased with temperature. The optical band gap of the material was obtained as 1.54 eV.

A simple method for the preparation of plasma-sprayable powders based on ZrO2

Plasma-sprayable powders of calcia, magnesia and yttria-stabilized zirconia have been prepared by using polyvinyl alcohol binders. The powders have been characterized for sprayability by spray coating on steer plates previously coated with an NiAl bond coat. The suitability of these coatings for thermal barrier applications have been examined. Thermal barrier and related properties, along with phase stability and mechanical properties, have been found to be good. Failure of the thermal barrier coating has been observed to occur at the interface between the bond coat and the substrate, due to the formation of a pile-up layer consisting of Fe-Zr-Al-O compound.

Nanocomposites by rapid solidification route

Nanometric aggregates of solids can be classified into two types, nanograined or nanophased materials and nanocomposites. In the present paper after a brief review including the relation between size and boundary fraction, the basic principles that can be utilized to synthesize these materials from liquid route has been discussed. We shall present examples to show that with proper choice of systems and conditions it is possible to obtain nanocomposites in systems showing clustering tendencies in liquid as well as the systems exhibiting ordering tendencies leading to compound formation

Heterogeneous nucleation of nanometre-sized Bi particles embedded in a Zn matrix

It is argued that the nanometric dispersion of Bi in a Zn matrix is an ideal model system for heterogeneous nucleation experiments. The classical theory of heterogeneous nucleation with a hemispherical cap model is applied to analyse the nucleation data. It is shown that, unlike the results of earlier experiments, the derived site density for catalytic nucleation and contact angle are realistic and strongly suggest the validity of the classical theory. The surface energy between the 0001 plane of Zn and the <10(1)over bar 2> plane of Bi, which constitute the epitaxial nucleation interface, is estimated to be 39 mJ m(-2).

Nanocomposite microstructure in a melt spun Al-Cu-Zr alloy

Rapid solidification of a ternary Al-Cu-Zr alloy results in a nanocomposite microstructure. In this study, melt spinning a Al82Cu15Zr3 alloy has resulted in the combined occurrence of, (a) 0.5 mu m sized grains of Al solid solution and (b) fine grains (10-20 nm) of intermetallic Al2Cu (theta) and alpha-Al, along side each other. The larger alpha-Al grains contain nanometric GP zones, with the Zr addition resulting in a grain refinement. In the other type of microstructure Zr promotes simultaneous nucleation of nanosized grains of the two equilibrium phases, Al2Cu and alpha-Al. Both these lead to a very high hardness of similar to 540 VHN for this alloy and can be used as a candidate for a high strength alloy with good ductility at a low strain rate.

Synthesis and properties of nanodispersed granular materials

Nanometric granular materials represent a new class of materials with significant promise. We shall discuss in this paper two phase granular materials where one of the phases having nanometric dimension is embedded in a matrix of larger dimension. These materials show many interesting properties which include structural, magnetic and transport properties, The phase transformation of the embedded particles shows distinctive behavior and yields new insight. We shall first highlight the strategy of synthesis of these materials through rapid solidification. This will be followed by three examples where the nanoscale dimension of the embedded particles play a unique role. These are melting and solidification of the nanodispersed embedded particles and the superconducting transition. (C) 1997 Elsevier Science S.A.