Metallic powder injection molding using low pressure

The demand by high performance materials that have to support severe service conditions at a reasonable cost has been forcing the powder metallurgy to improve constantly. The most recent and more important innovation in the area is the process of powder injection.Powder injection molding (PIM) is a technology capable of producing a new range of components from powders. This advanced technology overcomes the existent limitations in the forming of products with complex geometry. The process presents countless variations which are used in the industry today. Invariably, it consists of mixing the powders and a thermo-plastic binder, injecting the mass in the mold in the wanted form, debinding, sintering and making optional secondary operations, as for example, machinery.The purpose of this work is to review the metal injection molding techniques and apply the low pressure injection molding process to family of parts using metallic powder with 10 mum particle size. This work also comments the design and construction of a low pressure injection machine and injection molds. (C) 2001 Elsevier B.V. B.V. All rights reserved.

Mechanochemical synthesis of ceramic powders with perovskite structure

The mechanical activation is one of the most effective method for obtaining highly disperse system due to mechanical action stress fields form in solids during milling procedure. This effect results in changes of free energy, leading to release of heat, formation of a new surface, formation of different crystal lattice defects and initiation of solid-state chemical reaction. The accumulated deformation energy determines irreversible changes of crystal structure and consequently microstructure resulting in the change of their properties. Mechanochemical processing route has been developed recently for the production of intermetallic and alloy compounds. The intrinsic advantage of this process is that the solid-state reaction is activated due to mechanical energy instead of the temperature. It was shown that the chemical reactivity of starting materials could be improved significantly after mechanochemical activation and, subsequently, the calcination temperature was reduced. Besides, it was apparent that the mechanochemical treatment could enhance the reactivity of constituent oxides; however, the sintering process could not be avoided to develop the desired ceramics. A novel mechanochemical technique for synthesis of fine-grained perovskite structured powders has shown that it is possible to form perovskite at room temperature. The effect of milling on the formation of perovskite structure of barium titanate (BT), lead titanate (PT), PZT, PZN, magnesium niobate (PMN) and LM ceramic materials was analyzed. The dielectric properties of sintered ceramics are comparable with those prepared by other methods in the literature. (C) 2003 Elsevier B.V. B.V. All rights reserved.

Numerical simulation of magnetic-field-enhanced plasma immersion ion implantation in cylindrical geometry

Recent studies have demonstrated that the sheath dynamics in plasma immersion ion implantation (PIII) is significantly affected by an external magnetic field. In this paper, a two-dimensional computer simulation of a magnetic-field-enhanced PHI system is described. Negative bias voltage is applied to a cylindrical target located on the axis of a grounded vacuum chamber filled with uniform molecular nitrogen plasma. A static magnetic field is created by a small coil installed inside the target holder. The vacuum chamber is filled with background nitrogen gas to form a plasma in which collisions of electrons and neutrals are simulated by the Monte Carlo algorithm. It is found that a high-density plasma is formed around the target due to the intense background gas ionization by the magnetized electrons drifting in the crossed E x B fields. The effect of the magnetic field intensity, the target bias, and the gas pressure on the sheath dynamics and implantation current of the PHI system is investigated.

Foundry sand recycling in the troughs of blast furnaces: a technical note

The foundry sand agglomerated with alkaline phenolic resin, used for the manufacture of molds, was found to be a residue which is able to be recycled, minimizing the costs of disposal and the environmental impact. This paper analyzes the thermomechanical regeneration and leaching processes and also assesses the influence of additives on the improvement of the mechanical properties of the sands. Besides, the industrial experiments carried out at CSN aiming at the foundry sand recycling in the covering of the blast furnace troughs are presented. (C) 2003 Elsevier B.V. All rights reserved.

Influence of the yielding criterion on total forming force in metallic junctions using elastomers

The production of metallic junctions employing elastomers is an unconventional technique that has been in development in the last 20 years. The forming process gets successfull just if a simultaneous compression between the elastomers and the tube takes place. Exact solutions for problems involving forming with elastomers are quite difficult to determine. However, the upper-bound theory can be used in order to predict the necessary load for junctions forming. Thus, it is necessary to develop a model capable to provide an estimate of the total forming force, which is useful to set-up tools and equipments required for the process. In this work, Von Mises, Hill's 1948 and Hill's 1979 associated yielding theories, and the Hosford's theory (1979) as well, were used in order to study the anisotropic behaviour on total forming force of junctions using elastomers, insuring the functionality of the proposed model. (c) 2006 Elsevier B.V. All rights reserved.

Size effect on structure and dielectric properties of Nb-doped barium titanate

It is known that the dielectric properties of BaTiO3 (BT) are strongly dependent on its grain size. Coarse-grained ceramics of pure BT showed lower dielectric constant at room temperature then fine grained. Many authors considered that when the grain size is lower than 700 nm, the lattice of BT changes from tetragonal to pseudocubic, and the dielectric constant value is very low. In the doped BT this effect is more complex, because it is necessary to consider also the influence of dopants. The grain size effect on the structure and dielectric properties of niobium-doped barium titanate was investigated. Niobium-doped barium titanate was prepared from powders obtained by doping of commercial barium titanate and from organometallic complex using citrates as precursors (Pechini procedure). The crystal and microstructure of sintered niobium-doped barium titanate were determined. Dielectric constant and dissipation factor were measured. The observation confirmed that the structure and properties are strongly dependent on grain size. (C) 2003 Elsevier B.V. B.V. All rights reserved.

Pyrosol preparation and structural characterization of SnO2 thin films

Polycrystalline tin oxide thin films were prepared from ethanol solution of SnCl2.H2O (concentrations: 0.05, 0.1, 0.2 and 0.4 mol/dm(3)) at different substrate temperatures ranging from 300 to 450 degreesC. The kinetic deposition processes were studied in terms of various process parameters. The crystal phases, crystalline structure, grain size and surface morphology are revealed in accordance to X-ray diffractometry and scanning electron microscopy (SEM). Texture coefficients (TCs) for (110), (2 0 0), (2 11) and (3 0 1) reflections of the tetragonal SnO2 were calculated. Structural characteristics of deposited films with respect to varying precursor chemistry and substrate temperature are presented and discussed. (C) 2003 Published by Elsevier B.V.

Experimental and theoretical study of workpiece temperature when end milling hardened steels using (TiAl)N-coated and PcBN-tipped tools

The present work shows an experimental and theoretical study on heat flow when end milling, at high-speed, hardened steels applied to moulds and dies. AISI H13 and AISI D2 steels were machined with two types of ball nose end mills: coated with (TiAl)N and tipped with PcBN. The workpiece geometry was designed to simulate tool-workpiece interaction in real situations found in mould industries, in which complex surfaces and thin walls are commonly machined. The compressed and cold air cooling systems were compared to dry machining Results indicated a relatively small temperature variation, with higher range when machining AISI D2 with PcBN-tipped end mill. All cooling systems used demonstrated good capacity to remove heat from the machined surface, especially the cold air. Compressed air was the most indicated to keep workpiece at relatively stable temperature. A theoretical model was also proposed to estimate the energy transferred to the workpiece (Q) and the average convection coefficient ((h) over bar) for the cooling systems used. The model used a FEM simulation and a steepest decent method to find the best values for both variables. (c) 2007 Elsevier B.V. All rights reserved.

Expert system for hot forging design

Planning hot forging processes is a time-consuming activity with high costs involved because of the trial-and-error iterative methods used to design dies and to choose equipment and process conditions. Some processes demand many months to produce forged parts with controlled shapes, dimensions and microstructure. This paper shows how expert systems can help engineers to reduce the time needed to design precision forged parts and dies from machined parts. The software ADHFD interfacing MS Visual Basic v.5.0 and SolidEdge v.3.0 was used to design flashless hot forged gears, chosen from families of gears. © 1998 Elsevier Science S.A. All rights reserved.

Compositional influence on spectroscopic properties of Yb3+ doped tellurite glasses

Spectroscopic properties of ytterbium-doped tellurile glasses with different compositions are reported. Results of linear refractive index, absorption and emission spectra, and fluorescence lifetimes are presented. The studied samples present high refractive index (∼2.0) and large transmission window (380-6000nm). Absorption and emission cross-sections are calculated as well as the minimum pump laser intensity. The results are compared with the values of other laser materials, in order to investigate applications as laser media in the infrared region.

Influence of the coloring agent concentration on bleaching gel and pulp chamber temperatures during dental bleaching

This study evaluated the Influence of the coloring agent concentration on the temperature of the gel layer and pulp chamber during dental bleaching with an LED/laser light source. Ten human incisors and a digital thermometer with K-type thermocouples were used. Using a high-speed spherical diamond bur, endodontic access was gained through openings on the lingual faces until pulp chamber was exposed. One end of the thermocouple was placed on the labial surface (immersed in bleaching gel) and the other end in the pulp chamber. The same 10 specimens were used in the 12 groups, according to the type and concentration of bleaching gel. Each bleaching gel was used in four different concentrations: manipulated without coloring, with normal quantity recommended by the manufacturer, with double the recommended amount of coloring, and with triple the recommended amount of coloring. The temperature rise was measured every 30 seconds for three minutes with a K-type thermocouple. The data were analyzed by ANOVA to examine the concentration and type of bleaching gel. This test was followed by Tukey's test, which was performed Independently for the gel at the labial surface and the pulp chamber (a = 5%). For both surfaces, values of p = 0.00 were obtained for all factors and for the Interaction between them. The varying concentrations of coloring agent produced statistically significant differences in terms of temperature increase for both the gel layer and the pulp chamber during activation.

Effect of bleaching agent on dental ceramics roughness.

The aim of this study was to assess the effect of bleaching agents (10% and 16% carbamide peroxide) on the roughness of two dental ceramics in vitro, and to analyze the surface by scanning electronic microscopy (SEM). Two bleaching agents (10% and 16%/Whiteness, FGM Gel) and two microparticle feldspathic ceramics (Vita VM7 and Vita VM13) were used. Forty disks of Vita VM7 and Vita VM13 ceramic were manufactured, measuring 4 mm in diameter and 4 mm high, in accordance with the manufacturers' recommendations, and were divided into 4 groups (n = 10): (1) VM7 + Whiteness 10%; (2) VM7 + Whiteness 16%; (3) VM13 + Whiteness 10%; (4) VM13 + Whiteness 16%. The bleaching agent was applied for 8 hours a day for 15 days and during the intervals the test specimens were stored in distilled water at 37 degrees C. The roughness (Ra) of the test specimens was evaluated before and after exposure to the bleaching agents using a laser roughness meter and the topographic description was analyzed by SEM. The statistical analysis of roughness data showed significant differences in the VM7 groups, using paired t-test, p = 0.05 (VM7 + Whiteness 10%: p = 0.002; VM7 + Whiteness 16%: p = 0.001) and two-sample t-test (VM7 p = 0.047), and no significant difference was found among VM13 groups. The qualitative SEM analysis showed different degrees of surface changes. The results suggest that the roughness of the tested ceramic surfaces increased after exposure to the bleaching agents.

alpha-SiAlON-SiC composites obtained by gas-pressure sintering and hot-pressing

The objective of this work was the obtaining in situ of alpha-SiAlON-SiC composite, using an alternative rare-earth oxide mixture, RE2O3, as sintering additive, by two different sintering processes. As sintering additive, 20 vol.% of AlN-RE2O3 in a molar ratio of 90: 10 was mixed to the alpha-Si3N4 powder. In the Si3N4-AlN-RE2O3 powder mixture, 0, 10, 15 and 20wt.% of SiC were added. The powder batches were milled, dried and compacted by cold isostatic pressing. Two different sintering processes were used: gas-pressure sintering at 1950 degrees C for 1 h under 1.5 MPa of N-2 atmosphere, or uniaxial hot-pressing at 1750 degrees C, for 30 min under pressure of 20 MPa. The sintered samples were characterized by X-ray diffraction, scanning electron microscopy and mechanical properties. XRD patterns indicate only alpha-SiAlON (alpha') and beta-SiC as crystalline phases. It was observed that the SiC addition did not influence the alpha-SiAlON formation, although the growth of elongated alpha'-grains is substantially decreased. The hot-pressed composites presented better mechanical properties, exhibiting fracture toughness of 5 MPa m(1/2) and hardness around 21.5 GPa. (c) 2007 Elsevier B.V. All rights reserved.

Emission features of microstructures fabricated by two-photon polymerization containing three organic dyes

Fabrication of microstructures containing active compounds, such as fluorescent dyes and nanoparticles have been exploited in the last few years, aiming at applications from photonics to biology. Here we fabricate, using two-photon polymerization, microstructures containing the fluorescent dyes Stilbene 420, Disodium Fluorescein and Rhodamine B. The produced microstructures, containing dyes at specific sites, present good structural integrity and a broad fluorescence spectrum, from about 350 nm until 700 nm. Such spectrum can be tuned by using different excitation wavelengths and selecting the excitation position in the microstructure. These results are interesting for designing multi-doped structures, presenting tunable and broad fluorescence spectrum. (C)2012 Optical Society of America

Photoinduced electronic transitions and leakage correlation to defects/dislocations in GaN heterostructures

III-nitride materials are very promising for high speed electronics/optical applications but still suffer in performance due to problems during high quality epitaxial growth, evolution of dislocation and defects, less understanding of fundamental physics of materials/processing of devices etc. This thesis mainly focus on GaN based heterostructures to understand the metal-semiconductor interface properties, 2DE(H)G influence on electrical and optical properties, and deep level states in GaN and InAlN, InGaN materials. The detailed electrical characterizations have been employed on Schottky diodes at GaN and InAl(Ga)N/GaN heterostructures in order to understand the metal-semiconductor interface related properties in these materials. I have observed the occurrence of Schottky barrier inhomogenity, role of dislocations in terms of leakage and creating electrically active defect states within energy gap of materials. Deep level transient spectroscopy method is employed on GaN, InAlN and InGaN materials and several defect levels have been observed related to majority and minority carriers. In fact, some defects have been found common in characteristics in ternary layers and GaN layer which indicates that those defect levels are from similar origin, most probably due to Ga/N vacancy in GaN/heterostructures. The role of structural defects, roughness has been extensively understood in terms of enhancing the reverse leakage current, suppressing the mobility in InAlN/AlN/GaN based high electron mobility transistor (HEMT) structures which are identified as key issues for GaN technology. Optical spectroscopy methods have been employed to understand materials quality, sub band and defect related transitions and compared with electrical characterizations. The observation of 2DEG sub band related absorption/emission in optical spectra have been identified and proposed for first time in nitride based polar heterostructures, which is well supported with simulation results. In addition, metal-semiconductor-metal (MSM)-InAl(Ga)N/GaN based photodetector structures have been fabricated and proposed for achieving high efficient optoelectronics devices in future.