• 한국분말재료학회지
• /
• 제21권1호
• /
• pp.55-61
• /
• 2014

Fe-Cr-Al powder porous metal was manufactured by using new electro-spray process. First, ultra-fine fecralloy powders were produced by using the submerged electric wire explosion process. Evenly distributed colloid (0.05~0.5% powders) was dispersed on Polyurethane foam through the electro-spray process. And then degreasing and sintering processes were conduced. In order to examine the effect of cell size ($200{\mu}m$, $450{\mu}m$, $500{\mu}m$) in process, pre-samples were sintered for two hours at temperature of $1450^{\circ}C$, in $H_2$ atmospheres. A 24-hour thermo gravimetric analysis test was conducted at $1000^{\circ}C$ in a 79% $N_2$ + 21% $O_2$ to investigate the high temperature oxidation behavior of powder porous metal. The results of the high temperature oxidation tests showed that oxidation resistance increased with increasing cell size. In the $200{\mu}m$ porous metal with a thinner strut and larger specific surface area, the depletion of the stabilizing elements such as Al and Cr occurred more quickly during the high-temperature oxidation compared with the 450, $500{\mu}m$ porous metals.

• 한국분말재료학회지
• /
• 제22권6호
• /
• pp.408-412
• /
• 2015

This study attempts to manufacture a Ni-Cr-Al-Y coating layer using a kinetic spray process and investigates the microstructure and physical properties of the manufactured layer. The Ni-22Cr-10Al-1Y (wt.%) composition powder is used, and it has a spherical shape with an average diameter of $23.7{\mu}m$. Cu plate is used as the substrate. Optical microscope, X-ray diffraction, scanning electron microscope and Vickers hardness test are carried out to characterize the macroscopic properties of the coating layer. Furthermore, the coating layer underwent vacuum heat treatment at temperatures of $400^{\circ}C$ and $600^{\circ}C$ for 1 hour to check the effect of heat treatment temperature on the properties. The manufactured coating layer is 1.5 mm thick, and featured identical phases to those found in the powder. The porosity of the coating layer is measured at 2.99%, and the hardness is obtained at $490.57H_v$. The layer shows reduced porosity as heat treatment temperature increased, and hardness is reduced at $400^{\circ}C$ but shows a slight increase at $600^{\circ}C$. Based on the findings described above, this study also discusses possible manufacturing methods for a Ni-Cr-Al-Y coating layer using the kinetic spray process.

• 한국분말재료학회지
• /
• 제1권1호
• /
• pp.42-51
• /
• 1994

6061Al-SiCP metal matrix composite materials(MMCs) were fabricated by injecting SiCP particles directly into the atomized spray. The main attraction of this technique is the rapid fabrication of semi-finished, composite products in a combined atomization, particulate injection(10 $\mu\textrm{m}$, 40 $\mu\textrm{m}$, SiCP) and deposition operation. Conclusions obtained are as follows; The microstructure of the unreinforced spray formed 6061Al alloy consisted of relatively fine(50 $\mu\textrm{m}$) equiaxed grains. By comparision, the microstructure of the I/M materials was segregated and consisted of relatively coarse(150 $\mu\textrm{m}$) grains. The probability of clustering of SiCP particles in co-sprayed metal matrix composites increased it ceramic particle size(SiCP) was reduced and the volume fraction was held constant. Analysis of overspray powders collected from the spray atomization and deposition experiments indicated that morphology of powders were nearly spherical and degree of powders sphercity was deviated due to composite with SiCp particles. Interfacial bonding between matrix and ceramics was improved by heat treatment and addition of alloying elements(Mg). Maximum hardness values [Hv: 165 kg/mm2 for Al-10 $\mu\textrm{m}$ SiCp Hv--159 kg/mm2 for Al-40 $\mu\textrm{m}$SiCp] were obtained through the solution heat treatment at $530^{\circ}C$ for 2 hrs and aging at $178^{\circ}C$, and there by the resistance were improved.

• Journal of Welding and Joining
• /
• 제22권5호
• /
• pp.46-52
• /
• 2004

AlSi-Al$_2$O$_3$ composite layer was prepared by plasma spray on steel substrate. The composite powder for plasma spray was prepared by simple mechanical blending. The wear resistance of the composite layers and matrix aluminum alloy were performed in terms of size distribution of ceramic particles. Friction coefficients of AlSi were decreased with incorporation of $Al_2$O$_3$. The tribological properties of coated layers were affected by the size of incorporated $Al_2$O$_3$ particle. The reinforcement of $Al_2$O$_3$ particle into aluminum alloy matrix decreased the friction coefficient as well as wear loss.

• 동력기계공학회지
• /
• 제10권2호
• /
• pp.93-98
• /
• 2006

Metal matrix composites(MMCs) reinforced with ceramic particulates are receiving increasing attention because their high specific strength, low coefficient of thermal expansion and excellent wear resistance. Especially, Al-based composites(AMCs) have been widely applied for the aerospace and automotive industries. Such composites are mainly fabricated by the cast, powder metallurgy and infiltration process. In this study, SiC particulate reinforced Al-based composites were fabricated by thermal spray process and their wear behavior were investigated. Composites with different spray parameter were fabricated by using flame spray apparatus. Microstructure and wear behavior of the composites were observed by scanning electron microscope(SEM) and electron probe micro-analysis(EPMA).

• 동력기계공학회지
• /
• 제15권5호
• /
• pp.72-76
• /
• 2011

In this work, the parameter optimization for thermal-sprayed Al/SiC composites have been designed by $L_9(3^4)$ orthogonal array and analysis of variance(ANOVA). Al/SiC composites were fabricated by flame spray process on steel substrate. The hardness of composites were measured using micro-vickers hardness tester, and these results were analyzed by ANOVA. The ANOVA results showed that the oxygen gas flow, powder feed rate and spray distance affect on the hardness of the Al/SiC composites. From the ANOVA results, the optimal combination of the flame spray parameters could be extracted. It was considered that experimental design using orthogonal array and ANOVA was efficient to determine optimal parameter of thermal-sprayed Al/SiC composites.

• 한국재료학회지
• /
• 제27권7호
• /
• pp.374-380
• /
• 2017

Properties of coatings produced by warm spray were investigated in order to utilize this technique as a repair method for Al tire molds. $Al-(0-10%)Al_2O_3$ composite powder was sprayed on Al substrate by warm spraying, and the microstructure and mechanical properties of the composite coating layer were investigated. For comparative study, the properties of the coating produced by plasma spray, which is a relatively high-temperature spraying process, were also investigated. The composite coating layers produced by the two spray techniques exhibited significantly different morphology, perhaps due to their different process temperatures and velocities of particles. Whereas the $Al_2O_3$ particles in the warm sprayed coating layer maintained their initial shape before the spray, flattened and irregular shape $Al_2O_3$ particles were distributed in the plasma sprayed coating layer. The coating layer produced by warm spray showed significantly higher adhesive strength compared to that produced by plasma spray. Hardness was also higher in the warm sprayed coating layer compared to the plasma sprayed one. Moreover, with increasing the fraction of $Al_2O_3$, hardness gradually increased in both spray coating processes. In conclusion, an $Al-Al_2O_3$ composite coating layer with good mechanical properties was successfully produced by warm spray.

• The Korean Journal of Ceramics
• /
• 제1권1호
• /
• pp.35-39
• /
• 1995

Yttrium aluminum garnet(YAG) powders were synthesized by spray-drying of the hydroxides coprecipitated from a mixture of aqueous solutions of $Al(NO_3)_3.9H_2O \;and\; Y(NO_3)_3.6H_2O$ Phase formation in the powders during heat treatments and their sintering charactristics were investigated. In the powder obtained by washing the hydroxides before spray-drying, a metastable yttrium aluminum hexagonal (YAH) phase was first crystallized and then transformed into YAG as temperature was increased. The formation of YAH was attributed to a deviation in compositions of the particles from the starting composition of YAG. However, the powder prepared without washing step contained a stable yttrium aluminum monoclinic(YAM) phase in addition to YAG due to a large deviation from the starting composition. A powder compact of a single phase YAG was pressureless-sintered for 4 hrs at $1700^{\circ}C$ and the density was 93% of the theoretical density.

• 한국분말재료학회지
• /
• 제17권3호
• /
• pp.209-215
• /
• 2010

Mesoporous alumina particles were prepared by spray pyrolysis using cetyltrimethyl-ammonium bromide (CTAB) as a structure directing agent and the effect of Al precursor types on the texture properties was studied using $N_2$ adsorption isotherms, small-angle X-ray scattering (SAXS), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The surface area and the microstructure of alumina particles were significantly influenced by the Al precursor type. The largest BET surface area was obtained when Al chloride was used, whereas alumina particles prepared from Al acetate had the largest pore volume. According to small-angle X-ray scattering (SAXS) analysis, the alumina powders prepared using nitrate and acetate precursors had a clear single SAXS peak around $2{\theta}=1.0{\sim}1.5^{\circ}$, indicating that regular mesopores with sponge-like structure were produced. On the basis of TEM, SAXS, and $N_2$ isotherm results, the chloride precursor was most profitable to obtain the largest surface area ($265\;m^2/g$), whereas, the nitrate precursor is useful for the preparation of non-hollow mesoporous alumina with regular pore size, maintaining high surface area (${\sim}233\;m^2/g$).

• 대한기계학회논문집A
• /
• 제35권9호
• /
• pp.1035-1040
• /
• 2011

본 논문은 세라믹과 금속파우더를 이용한 복합소재를 플라즈마 용사 방식으로 개발한 결과를 수록하였다. 사용된 세라믹 파우더는 $Al_2O_3+40TiO_2$ 이고 입자 크기는 $20{\mu}m$, $Al_2O_398+$파우더의 입자 크기는 $45{\mu}m$를 사용하였다. $20{\mu}m$, $30{\mu}m$ 및 $50{\mu}m$ 금속필터 입자는 SIKA-R 20IS, 30IS 및 50IS(소결금속필터)을 사용 했으며, $75{\mu}m$ 금속필터 입자는 5 겹 소결메쉬 필터를 사용��다. 용사 공정으로 가공된 복합 필터는 세라믹 파우더의 종류, 크기 및 코팅 두께에 따라 성능의 차이를 보였으나, 전반적으로 필터링 가능 능력은 향상되었다.