TIMIS2012 141B t Annual Meeting & Exhibition

S u p p l e m e n t a l P roceed ings Volume 1:

Materials Processing and Interfaces

TIMIS2012 141 s t Annual Meeting & Exhibition

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Energy Technology 2012: C02 Management and Other Technologies

EPD Congress 2012

International Smelting Technology Symposium (Incorporating the 6th Advances in Sulfide Smelting Symposium)

Light Metals 2012

Magnesium Technology 2012

Supplemental Proceedings: Volume 1: Materials Processing and Interfaces

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TIMS2012 141 s t Annual Meeting & Exhibition

Supplemental Proceedings Volume 1:

Materials Processing and Interfaces

About this volume

The TMS 2012 Annual Meeting Supplemental Pmceeclings, Volume I: Materials Pir>cessinx and Interfaces, is a collection of papers from the 2012 TMS Annual Meeting and Exhibition, held Marchl l-March 15, in Orlando. California, U.S.A.

The papers in this volume were selected based on technical topic compatibility and represent ten symposia from the meeting. This volume, along with the other proceedings volumes published for the mecting,.and archival journals, such as Metallurgical anil Materials Transactions and lite Journal of Electronic Materials, represents the available written record of the 65 symposia held at the 2012 TMS Annual Meeting.

The individual papers presented within this proceedings volume have nut necessarily been edited or reviewed by the conference program organizers and are presented ''as is." The opinions and statements expressed within the papers are those of the individual authors only and are not necessarily those of anyone else associated with the proceedings volume, the source conference, or TMS. No confirmations or endorsements are intended or implied.

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Copyright © 2012 by The Minerals, Metals, & Materials Society. All rights reserved.

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TABLE OF CONTENTS Supplemental Proceedings: Volume I: Materials Processing and Interfaces

Advances in Surface Engineering: Alloyed and Composite Coatings

Session II

Structural Coatings in Aluminum Alloy Microtruss Materials 3 B. Yu, andG. Hibbard

Laser Cladding of High-Performance CPM Tool Steels on Hardened HI 3 Hot-Work Tool Steel for Automotive Tooling Applications 11

J. Chen, andL. Xue

Electron Beam Deposited Multilayer Optical Interference Coatings Using Oxide Composites 19

A. Nayak, N. Sahoo, R. Tokas, A. Biswas, andN. Kamble

Session III

Microstructure and Wear Properties of Laser In-situ Formation of TiBx and TiC Titanium Composite Coatings 27

J. Liang, C. Liu, S. Chen, and C. Ren

Creep Behavior of Plasma Sprayed Y-PSZ Coated 6063-T6 Aluminum Alloy 35

E. Erzi, C. Kahruman, andS. Yilmaz

Contribution of Ti Addition to the Electronic Structure and Adhesion at the Fe2Al5/Fe Interface in 55%A1-Zn Coating 41

G. Wu, Y. Ren, J. Zhang, andK. Chou

v

Session IV

The Roles of Diffusion Factors in Electrochemical Corrosion of TiN and CrN (CrSiCN) Coated Mild Steel and Stainless Steel 49

F. Cai, Q. Yang, andX. Huang

Effect of Electroplating Parameters on "HER" Current Density in Ni-MoS2 Composite Plating 57

E. Saraloglu Guler, I. Karakaya, andE. Konca

Production of Ceramic Layers on Aluminum Alloys by Plasma Electrolytic Oxidation in Alkaline Silicate Electrolytes 65

A. Lugovskoy, A. Kossenko, B. Kazanski, andM. Zinigrad

Abrasive Wear Properties of Plasma Sprayed Y-PSZ Coated 6063-T6 Aluminum Alloy 73

E. Erzi, S. Yildirim, andS. Yilmaz

The Electrochemical Behavior of Surgical Grade 316L S S with and without HA Coatings in Simulated Body Fluid 79

T. Singh, H. Singh, H. Singh, andH. Saheet

Modification Research on the Influence on Corrosion Film Properties of Pb-Ca-Sn Alloys of with Addition of Bi, Ag and Zn 87

L. Xu, L. Liu, and P. Zhu

Session V

Evaluation of Residual Stress in Fe2B Coating on Ductile Cast Iron 95 M. Donu Ruiz, N. Lopez Perrusquia, V. Cortez Suarez, and D. Sanchez Huitron

General Poster Session

Session I

Influence of Heat Treatment on the Corrosion of Steels in CCS Environment 103

A. Pfennig, S. Schulz, A. Kranzmann, T. Werlitz, S. Wetzlich, E. Billow, J. Tietböhl, and C. Frieslich

vi

Microstructure and Property Modifications in Mould Steels Treated by Pulsed Electron Beam I l l

K. Zhang

Potential Fiberboard Material from Cow Manure and Disposable Water Bottle 119

B. Ng, M. Murray, C. Bradfield, andR Pritish

Influence of Process and Thermo-physical Parameters on. the Heat Transfer at Electron Beam Melting of Cu and Ta 125

K. Vutova, V. Donchev, V. Vassileva, and G. Mladenov

Industrial Use of a New Ultrasound Spray for Cooling and Wet Gas Treatment in the Pyrometallurgical Processes 133

M. Cirkovic, V. Trujic, and Z. Kamberovic

Development of 3D Porous Nickel Electrodes for Hydrogen Production 141 V. Pérez-Herranz, I. Herrâiz-Cardona, E. Ortega, andJ. Garcia-Anton

Electrochemical Recovery of Zinc Present in the Spent Pickling Baths Coming from Hot Dip Galvanizing Processes 149

V. Pérez-Herranz, J. Carrillo-Abad, M. Garcia-Gabaldôn, andE. Ortega

Laboratory Testing Results of Kinetics and Processing Technology of the Polymetallic Sulphide Concentrate Blagojev Kamen - Serbia 157

M. Cirkovic, Z. Kamberovic, and V. Trujic

Hidrotalcite with Gentamicine, of the Type Mg0.68Alo.32(OH)2

(N03)o.32*0.1H20, Formed by Chemical Coprecipitation in Controlled Atmosphere 165

H. Rodriguez-Santoyo, and O. Martinez-Alvarez

Effect of Thiodiglycolamide Addition to Di-n-hexyl Sulfide on the Pd(II) Extraction Rate 173

H. Narita, M. Tanaka, andS. Ueno

Synthesis and Characterization of Metallic Oxides 179 E. Brocchi, R. Souza, M. Doneda, J. Campos, A. Wimmer, andR. Navarro

Fabrication of Lotus-Type Porous Copper by Centrifugal Casting Technique 187

Y. Lee, H. Kim, M. Kim, andS. Hyun

vii

Effects of Pulsed Magnetic Annealing on the Grain Boundary of Primary Recrystallized Microstructure in the Grain-Oriented Silicon Steel 191

J. Huang, L. Liu, X. Xia, X. Jiang, L. Li, and Q. Zhai

Relationship between Heat Input and Microstructure and Mechanical Properties of Laser Beam Welded Superalloy Inconel 718 199

A. Odabasi, N. Ünlti, G. Göller, M. Eruslu, andE. Kayali

Experimental Study on the Behavior of Slag Entrapment and Inclusion Removal in 441 Ladle with Argon Blowing 207

S. Zheng, M. Zhu, andZ. Cheng

The Effect of High Superheat on the Solidification Structure and Carbon Segregation of Ferrite-Based Alloy 215

H. Zhong, Y. Tan, H. Li, X. Mao, and Q. Zhai

Refinement of Ligaments of Nanoporous Ag Ribbons by Controlling the Surface Diffusion of Ag 223

T. Song, Y. Gao, Z. Zhang, and Q. Zhai

Thermal Analysis of the Composition of Poly(Acrylic AcidyCarboxymethylstarch Used as a Polymeric Binder 231

B. Grabowska, M. Holtzer, S. Eichholz, K. Hodor, andE. Olejnik

Mechanical Behavior Related to Interface Physics

Grain Boundaries; Experiment and Modeling

Interfacial Strength of Al/Zr/DU-10%wtMo Subject to Different Loading Modes 241

M Lovato, C. Liu, and W. Blumenthal

Interface Evolution under Mechanical Loading: Experiment, Characterization, and Theoretical

Modeling

Uniaxial Tension of Friction-Welded 304-Stainless Steel and 6061 Aluminum 249

C. Liu, M. Lovato, and W. Blumenthal

via

Interface Structures; Characterization, Theory, and Modeling

Ultra Fast Grain Boundary Segregation In Hot Deformed Nickel 257 M Allart, F. Christien, and R. Le Gall

Quantitative NanoSIMS Analysis of Grain Boundary Segregation in Bulk Samples 265

F. Christien, K. Moore, C. Downing, andC. Grovenor

The Periodic Unit of Doubly-diffracted Reflections from Periodic Grain Boundaries in Cubic Crystals and Its Relationship with Coincident Site Lattice 273

M. Shamsuzzoha

Poster Session

The In-situ Intrinsic Stress Measurements of Cu and Al Thin Films 281 J. Yu, and Y. Kim

Delamination Characterization of Bonded Interface Using Surface Based Cohesive Model 289

M. Ramamurthi, and Y. Kim

Nanocomposites

Mechanical Behavior and Modelling of Nanocomposites

Compressive Strength of Epoxy- Graphite Nanoplatelets Composites 299 H. Colorado, A. Wong, andJ. Yang

Micromechanical Analysis of Influences of Agglomerated Nanotube Interphase on Effective Material Properties of a Three Phase Piezoelectric Nanocomposite 307

T. Tang, and P. Wang

Effect of Nano-Paper Coating on Flexural Properties of a Fire-Treated Glass Fiber-Reinforced Polyester Composite 313

J. Skovron, J. Zhuge, A. Gordon, J. Kapat, andJ. Gou

IX

Finite Element Modeling of the Nanoscratching of Polymer Surfaces 321 W. Chirdon, andJ. Rozas

Processing of Nanocomposites I

Manufacturing and Characterization of an Auxetic Composite 329 F. Chiang

Microtruss Cellular Nanocomposites 337 K. Abu Samk, G. Huang, M. Skocic, H. Zur ob, D. Embury, O. Bouaziz, and G. Hibbard

Nanocomposites for Magnetic and Dielectric Applications

Synthesis of Tailored Core-Shell Magnetic Microparticles for Intravascular Embolization 345

G. Ferreira, A. Umpierre, andF. Machado

Dramatic Expansion of Luminescence Region in GaP/Polymer Nanocomposites 353

S. Pyshkin, andJ. Ballato

Nanocomposite Interfaces and Characterization

Positron Lifetime Analysis of Polyurea-Nanoclay Composites 361 N. Seetala, D. Hubbard, G. Burks, A. Trochez, and V. Khabashesku

Processing of Nanocomposites II

Rheological Properties of Suspensions of Nanopowders Yttrium Oxide (Y203) and Magnesium-Aluminum Spinel (MgAl204) 367

G. Zyla, M. Cholewa, A. Witek, J. Plog, V. Lehmann, T. Oerther, andD. Gross

Thermal Properties of Hemp-High Density Polyethylene Composites: Effect of Two Different Chemical Treatments 375

N. Lu, and S. Oza

x

Discarded Ultrafine Particulate Carbonaceous Materials Used as Reinforcers of Rubber Vulcanized Products 383

G. Martin-Cortés, F. Esper, L. Galvào Dantas, W. Hennies, andF. Valenzuela-Diaz

Properties of Additional Reinforcers Materials Used to Complement NAOB -A Rubber / Organoclay Nanocomposite Material 389

F. Esper, G. Martin-Cortés, L. Dantas, A. Cutrim, W. Hennies, andF. Valenzuela-Diaz

Poster Session

Thermal Properties of Carbon Nano Tubes Reinforced Mg-Matrix Nanocomposites 395

S. Iqbal, A. Mustafa, S. Talapatra, and P. Filip

New Advances in Synthesis, Characterization, and Application of Layered Double Hydroxides

Session I

Designing Layered Double Hydroxides for Targeted Applications 405 J. Hossenlopp, S. Majoni, and C. Machingauta

Electrochemical Synthesis of Layer Double Hydroxides, Its Characterization, and Performance Study for Removal of Nitrate and Arsenic 413

M. Haider, J. Gomes, K. Urbanczyk, D. Cocke, H. McWhinney, G. Irwin, and P. Bernazzani

Removal of Direct Red and Orange II Azo Dye from Synthetic Textile Water Using Electrochemically Produced Fe-LDH 421

S. Jame, J. Gomes, and D. Cocke

Removal of Arsenic Using Green Rust and Other Electrochemically Generated Floe 429

M. Rahman, J. Gomes, K. Urbanczyk, andD. Cocke

Formation of Layered Double Hydroxides in Self-Purification of Polynary Metal Electroplating Wastewaters for Effective Removal of Anionic Dye 437

J. Zhou, G. Qian, C. Liu, Y. Wu, X. Ruan, Y. Xu, andJ. Liu

XI

Characterization and Chemical Modification of Electrochemically Produced Layered Double Hydroxides as Nanomaterials 445

M. Islam, J. Gomes, and P. Bernazzani

Randall M. German Honorary Symposium on Sintering and Powder-Based Materials

Sintering Theory and Practice

A Review on Alloying in Tungsten Heavy Alloys 455 A. Bose, R. Sadangi, and R. German

Current Activated and Conventional Sintering

Low-Thermal Load Consolidation of Sm-Fe-N Flake Powder by Combination of Cyclic Compression and Current Sintering 467

K. Takagi, H. Nakayama, andK. Ozaki

Fabrication of TiN / Fe-Al Cermet from Mixture of TiN, Fe and Al Powders 475

H. Nakayama, K. Ozaki, andK. Kobayashi

Transparent Polycrystalline Alumina Obtained by SPS: Single and Double Doping Effect 481

B. Apak, H. Kanbur, E. Ozkan Zayim, G. Goller, O. Yucel, andF. Cinar Sahin

Sintering of Nanocrystalline Tungsten Powder 489 W. de Rosset

Powder Technology

Effect of Powder Synthesis and Processing on Luminescence Properties 497 J. McKittrick, J. Han, J. Choi, andJ. Talbot

Effect of Rapid Solidification and Heat Treatment on D2 Tool Steel 505 P. Delshad Khatibi, H. Henein, andD. Ivey

XI1

Powder Processing and Consolidation I

Development of Solid Freeform Fabrication for Metallic Parts Using Selective Inhibition of Sintering 513

M. Yoozbashizadeh, andB. Khoshnevis

Numerical Simulation of Cold Pressing of Armstrong CP-Ti Powders 521 A. Sabau, S. Gorti, W. Peter, W. Chen, and Y. Yamamoto

The Effect of Coke Particle Size on the Thermal Profile of the Sintering Process Product 529

N. Tahanpesarandezfuly, and A. Heidary Moghadam

Powder Processing and Consolidation II

Powder Material Principles Applied to Additive Manufacturing 537 D. Bourell, andJ. Beaman

Processing Challenges of Dual-Matrix Carbon Nanotube Aluminum Composites 545

A. Esawi, K. Morsi, I. Salama, and H. Saleeb

Influence of High Pressure Torsion on the Consolidation Behavior and Mechanical Properties of AA6061-SiCp Composite Powders 553

H. Salem, W. El-Garaihy, andE. Rassoul

Powder Processing and Consolidation III

LASER Powder Deposition of AlMgBi4-TiB2 Ultra-Hard Coatings on Titanium and Steel Substrates 561

J. Fuerst, M. Carter, andJ. Sears

Mechanical Properties of Spark Plasma Sintered ZrC-SiC Composites 569 S. Sagdic, I. Akin, F. Sahin, O. Yucel, and G. Goller

Intense Pulsed Light Sintering Technique for Nanomaterials 577 H. Colorado, S. Dhage, J. Yang, andH. Hahn

xni

Recent Developments in Biological, Electronic, Functional and Structural Thin Films and Coatings

Process-Properties-Performance Correlations I

Dependence of Tribology of Carbide Derived Carbon Films on Humidity 587 M. Tlustochowicz

Structural and Optical Properties of Silicon Carbonitride Thin Films Deposited by Reactive DC Magnetron Sputtering 595

O. Agirseven, T. Tavsanoglu, E. Ozkan Zayim, and O. Yucel

Influence of TIG Re-Melting and RE (La203) Addition on Microstructure, Hardness and Wear of Ni-WC Composite Coating 603

B. Dhakar, D. Dwivedi, andS. Sharma

Evaluation of Mechanical Properties of Ni-Ti Bi-Layer Thin Film 609 M. Mohri, and M. Nili-Ahmadabadi

Anodic Ti02 Nanotubular Arrays with Pre-Synthesized Hydroxyapatite - A Promising Approach to Enhance the Biocompatibility of Titanium 617

L. Wang

Preparation and Properties of Cu2ZnSnS4 Thin Films by Electrodeposition and Sulfurization 625

C. An, H. Lu, andX. Chen

Process-Properties-Performance Correlations II

Formation of Crystalline and Amorphous Phases During Deposition of NixTi].x

Thin Film on Si Substrate - Interpretation of Experimental Results Using Molecular Dynamics Simulations 633

S. A ich, G. Priyadarshini, M. Gupta, S. Ghosh, and M. Chakraborty

Applications to Bio, Energy and Electronic Systems

Doping and Co-Doping of Bandgap-Engineered ZnO Films for Solar Driven Hydrogen Production 641

S. Shet, N. Ravindra, Y. Y an, and M. Al-Jassim

Magnetic Field Assisted Heterogeneous Device Assembly 651 V. Kasisomayajula, M. Booty, A. Fiory, andN. Ravindra

xiv

Organic Thermal Mode Photoresists for Applications in Nano-Lithography ...663 H. Wu, M. Li, C. Yang, C Cheng, S. Chen, andD. Huang

Process-Properties-Performance Correlations III

Nitrogen Doped ZnO (ZnO:N) Thin Films Deposited by Reactive RF Magnetron Sputtering for PEC Application 669

S. Shet, K. Ahn, N Ravindra, Y. Y an, and M. Al-Jassim

Spin-Coated Erbium-Doped Silica Sol-Gel Films on Silicon 677 S. Abedrabbo, B. Lahlouh, S. Shet, A. Fiory, andN. Ravindra

Influence of Annealing on the Martensitic Transformation and Magnetocaloric Effect in Ni49Mn39Sni2 Ribbons 685

D. Wu, S. Xue, H. Zheng, andQ. Zhai

Metal Diaphragm Based Magnetic Field Sensor 693 A. Banobre, I. Padron, A. Fiory, andN. Ravindra

Optical and Electronic Properties of AlN, GaN and InN: An Analysis 701 C. Lamsal, D. Chen, andN. Ravindra

Science and Engineering of Light Metal Matrix Nanocomposites and Composites

Metal Matrix Nanocomposites

Interfacial Analysis of CNT Reinforced AZ61 Mg Alloy Composites 717 K. Kondoh, H. Fukuda, J. Umeda, and B. Fugetsu

Biodegradability and Mechanical Performance of Hydroxyapatite Reinforced Magnesium Matrix Nanocomposite 725

C. Ma, L. Chen, J. Xu, A. Fehrenbacher, Y. Li, F. Pfefferkorn, N. Duffie, J. Zheng, andX. Li

Mechanical Properties of A356-CNTCast Nano Composite Produced by a Special Compocasting Route 733

B. Abbasipour, B. Niroumand, andS. Monirvaghefi

Production of Cast AZ91-CNT Nano-Composite by Addition of Ni-P-CNT Coated Magnesium Powder to the Melt 741

M. Firoozbakht, B. Niroumand, andS. Monirvaghefi

xv

Wear Behavior of Magnesium Matrix Nanocomposites at Room and Elevated Temperature 749

W. Li, andS. Liu

Nanocomposites and Composites

Uniform Dispersion of Nanoparticles in Metal Matrix Nanocomposites 757 L. Chen, H. Choi, A. Fehrenbacher, J. Xu, C. Ma, andX. Li

Effect of Core-shelled Nanoparticles of Carbon-Coated Nickel on Magnesium 765

Y. Sun, H. Choi, H. Konishi, V. Pikhovich, R. Hathaway, andX. Li

In Situ Composite of (Mg2Si)/Al Fabricated by Squeeze Casting 775 H. Lus, G. Ozer, andK. Guler

Optimization of Tensile Strength of Friction Stir Welded Al-(10 tol4 wt.%) TiB2 Metal Matrix Composites 783

S. Joseph Vijay, N. Murugan, andS. Parameswaran

Metal Matrix Composites

Slow-Shot High Pressure Die-Casting (SS-HPDC) Process for AE44 Magnesium Single-Cylinder Engine Block with Short-Fiber Reinforcement in the Bore 791

B. Hu, P. Wang, B. Powell, andX. Zeng

Compressive Properties of A1-B4C Composites over the Temperature Range of 25-500°C 799

S. Gangolu, A. Rao, N. Prabhu, V. Deshmukh, andB. Kashyap

Aluminum Metal Matrix Composite via Direct Metal Laser Deposition: Processing and Characterization 807

B. Wälder a, and S. Kalita

Damage Evolution Model for Hybrid Metal Matrix Composites 815 J. Dibelka, andS. Case

Numerical Simulation of Pressure Infiltration Process for Making Metal Matrix Composites: Effect of Process Parameters 823

B. Wang, andK. Pillai

xvi

Titanium: Advances in Processing, Characterization and Properties

Processing and Process Modeling I

Microstructural Evolution and Mechanical Properties of ß-Titanium Ti-lOV-2Fe-3Al during Incremental Forming 833

S. Winter, S. Fhtsch, andM. Wagner

Study on Hot Deformation Behavior of TC4 Titanium Alloy 841 Y. Lu, S. Jiao, X. Zhou, and A. Dong

Evolution of Microstructures and Properties of Ti-44Al-6V-3Nb-0.3Y Alloy after Forging and Rolling 849

Y. Chen, H. Niu, S. Xiao, P. Sun, and C. Zhang

Effect of Forging on Microstrutural Characteristic and Tensile Properties of In-Situ (TiB+TiC)/Ti Composite 857

Y. Chen, C. Zhang, S. Xiao, D. Wu, and H. Niu

Processing and Process Modeling II

Microstructure and Mechanical Properties of Ti-6A1-4V Fabricated by Selective Laser Melting 863

M. Simonelli, Y. Tse, and C. Tuck

Computational Modeling of the Dissolution of Alloying Elements 871 J. Ou, A. Chatterjee, D. Maijer, S. Cockcroft, and C. Reilly

Cost Effective and Eco-Friendly Process for Preparation of Wrought Pure Ti Material via Direct Consolidation of TiH2 Powders 879

T. Mimoto, N. Nakanishi, T. Threrujirapapong, J. Umeda, andK. Kondoh

Effect of Dual-Laser Beam Welding on Microstructure Properties of Thin-Walled y-TiAl Based Alloy Ti-45Al-5Nb-0.2C-0.2B (TNB) 887

J. Liu, V. Ventzke, P. Staron, H. Brokmeier, M. Oehring, N. Kashaev, andN. Huber

xvii

Microstructure Evolution and Characterization I

Recrystallization Behavior in Ti-13Cr-lFe-3Al Alloy after Severe Plastic Deformation 895

M. Ueda, H. Matsuhira, Y. Takasaki, M. Ikeda, and Y. Todaka

Mechanical Properties

Crack Initiation and Microstructurally Short Crack Growth of Ti-6A1-4V 903 H. Christ, H. Knobbe, P. Koester, C. Fritzen, and M. Riedler

Three-dimensional Investigation of the Microtexture near Tensile Crack Tip in Ti-6A1-4V 911

X. Xu, Y. Tse, G. West, and A. Huang

Machinability of ß-Titanium Alloy Ti-10V-2Fe-3Al with Different Microstructures 919

H. Abrahams, C. Mâchai, and D. Biermann

Residual Stress Relaxation Effects on the Cracking and Wear Processes of Shot Peened Ti-6A1-4V Titanium Alloy under Fretting-Fatigue Loading 927

R. Ferre, S. Fouvry, B. Berthel, R. Amargier, and A. Ferre

General Abstracts

Efficient Oxidation Protection of Ti- and TiAl-alloys by F-treatments 935 A. Donchev, M. Schütze, R. Yankov, and A. Kolitsch

Characteristics and Wear Performance of Nitrided Ti6A17Nb 941 F. Siyahjani, M. ïpekci, and H. Cimenoglu

Composition Analysis of Diffusion Bonded y-TiAl Intermetallic: TiAlV Alloy Interface by Using STEM 947

P. Sivagnanapalani, Gouthama, andM. Sujata

Effect of Erbium Addition on Microstructre of As-Cast Ti-22Al-25Nb Alloy 955

J. Dai, H. Lu, andZ. Cai

Fracture Behaviors of TiN and TiN/Ti Multilayer Coatings on Ti Substrate during Nanoindentation 963

Y. Sun, C. Lu, A. Tieu, Y. Zhao, H. Zhu, K. Cheng, and C. Kong

xvm

Deformation Mechanism in Nanoindentation of Ti63.375Fe34.i25Sn2 5 Alloy 971 K. Cheng, C. Lu, K. Tieu, L. Zhang, and Y. Sun

Wettability and Interfacial Phenomena between Metals and Ceramic/Refractory Materials

Session I

Chemical Wear of Basic Brick Linings in the Non-Ferrous Industry 981 D. Gregurek, A. Spanring, M Kirschen, andC. Majcenovic

Study on Wettability of Cu and 85Cu-15Ni Alloy on 18NiO-NiFe204

Composite Ceramics 989 J. Du, Y. Liu, G. Yao, Z. Zhang, and G. Zu

Interfacial Reactions in the Liquid/Solid and Liquid/Vapor Interfaces of Al-Si-Mg Alloys and B l 2 (Bc2) Substrates 997

O. Herr era-Romero, M. Pech-Canul, Z. Chaudhury, and G. Newaz

TMS2011 General Abstracts: Structural Materials Division

Microstructure

Microstructure of a' Martensites in Ti-V-Al Alloys Studied by High-Resolution Transmission Electron Microscopy 1007

K. Sato, H. Matsumoto, A. Chiba, and T. Konno

Author Index 1013

Subject Index 1019

xix

TIMIS2012 141 s t Annual Meeting & Exhibition

Advances in Surface Engineering: Alloyed and

Composite Coatings

The proceedings contained in this section have not been edited or reviewed by the conference program organizers. The opinions and statements expressed in the proceedings are those of the authors only and are not necessarily those of the editors or TMS staff. No confirmations or endorsements are intended or implied.

Supplemental Proceedings: Volume 1: Materials Processing and Interfaces TMS (The Minerals, Metals & Materials Society), 2012

STRUCTURAL COATINGS IN ALUMINUM ALLOY MICROTRUSS MATERIALS

Bosco Yu, Glenn D. Hibbard

Department of Materials Science and Engineering, University of Toronto, 184 College Street, Toronto, Ont., M5S 3E4, Canada

Keywords: Surface Engineering, Aluminum, Microtrusses, Energy Absorption

Abstract

Incorporating an internal cellular architecture of open space is one strategy to increase the potential functionality of aluminum alloys. Stretch-dominated microtruss cellular architectures, which are designed such that externally applied loads are resolved axially along the internal struts, provide enhanced strength and stiffness at low densities when compared to conventional metal foams. In this study we introduce the idea of using a structural coating to reinforce AA3003 aluminum alloy microtrusses. Because the internal surface area is large and the strut cross-sectional dimensions can be as small as hundreds of microns, only a 40 urn thick hard anodized alumina coating was needed to induce a four-fold increase in compressive strength and a six-fold increase in energy absorption at virtually no additional weight penalty. Backscatter electron microscopy was used to examine the failure mechanisms of the structural coatings and the cores in order to explain such a large change in behaviour.

Introduction

Microtrusses cellular materials have attracted considerable interest because of their structural efficiency and their potential to exhibit multifunctional characteristics [1-10]. In term of load bearing capacity, microtrusses are designed with a high degree of internal strut connectivity. Externally applied loads are resolved by axial (stretching) rather than bending deformation, making them up to ten times stiffer and three times stronger than conventional metal foams at low relativity densities [11], Since the internal surface areas are large and the strut cross-sections are small, surface modification can also be used to further enhance their mechanical behaviour. Recently, electrodeposition of a ~50um thick coating of ultrahigh strength nanocrystalline nickel was found to double and triple the compressive strength of low carbon steel and aluminum microtrusses, respectively [5, 6, 12].

Inelastic buckling was the overall failure mechanism seen for both conventional and structurally coated microtrusses [6]. Under this failure mechanism, the load carrying capacity of the microtruss progressively decreases making these materials less desirable for energy absorption applications. A recently study, however, indicated the possibility of enhancing the energy absorption behaviour of aluminum microtrusses by applying anodic oxide coating in order to change their overall collapse mechanism from inelastic buckling to hinge rotation and fracture [13]. The present study examines this hinge rotation and fracture failure mechanism in order to understand the mechanism of enhanced energy absorption in anodized microtruss materials.

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Experimental

AA3003 aluminum perforated sheets (sheet thickness of 0.74 ± 0.01 mm) were purchased from McNichols Perforated Products (Altanta, GA). The perforation pattern had square holes of 5.10x5.10 mm punched on a square lattice of 6.36x6.36 mm creating an open area fraction of <P = 0.64; Fig. la shows a schematic diagram of the starting sheet materials. The aluminum sheets were annealed at 600 °C for 30 minutes and then water cooled before forming into pyramidal microtrusses, after Bouwhuis et al. [5, 14]. Three forming/annealing cycles (with intermediate annealing treatments of 600 °C for 30 minutes) were used to achieve an internal truss angle of 0 = 42.6° ± 0.1° and a relative density of p = 4.8% (in Fig. lb). The microtrusses were subsequently given a post-fabrication annealing treatment of 600 °C for 30 minutes to remove any fabrication-induced work hardening, which was confirmed by taking microhardness measurements on axial cross-sections of the microtruss struts (an average of 36 ± 2 HV over all sample types using 0.98 N applied load and 10 s dwell time).

Fig. 1. Schematic diagram of a starting perforated aluminum sheet (a) and the final architecture after forming (b).

The AA3003 pyramidal microtrusses were then subjected to three surface cleaning processes (degreasing, etching, and de-smutting) followed by hard anodizing to form a 40 urn thick anodic aluminum oxide coating on the surface of the microtruss cores. Samples were rinsed with de-ionized water between each step and after hard anodizing. Table I summarizes the process conditions for each step. The microhardness of the anodized coating was 537 ± 38 HV (using 0.98 N applied load and 10 s dwell time). Coated and uncoated (only subjected to surface cleaning) samples were then tested in uniaxial compression at a cross-head displacement rate of 1 mm/min using confinement plates that restricted the nodal displacement in the microtrusses. In addition, four coated samples were partially compressed to different strain level (starting from e = 0 to e = 0.53). The axial cross-sections of their internal struts were characterized by scanning electron microscopy (SEM).

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Process Name Degreasing

Etching

De-smutting

Hard anodizing

Table I. Surface Cleaning and Hard Anodizing Specificatior Solution

5g/l Na2C03

5g/lNa3P04

5wt% NaOH

20vol% HNOj

12wt% H2SO4 lwt% (COOH)2

Time 10 min

2 min

1 min

45 min

Temperature 87 ± 5°C

57 ± 2°C

33 ± 2°C

10±1°C

Current density

4 A/dm2

Results and Discussion

Figure 2 presents typical compressive stress-strain curves of the coated and uncoated samples. Both samples exhibit an initial elastic region (of slope E) before reaching a peak stress (o>ra*) that is followed by post-peak softening until a valley stress (o\,a//«y), and eventually final densification is reached.

Fig. 2. Typical compressive stress-strain curves of the coated and uncoated microtrusses.

Figure 3 plots the slope of the stress-strain curve as a function of strain for both sample types. At a low strain level, both the coated and uncoated microtrusses elastically deform with nearly constant compressive modulus. After a strain of about e = 0.05, the samples begin to deform plastically and the moduli values decrease, eventually dropping below zero. In the case of the uncoated samples, the modulus drops gradually to zero; the first ̂ -intercept is the strain when the peak strength is recorded (e^*) while the second ^-intercept is the strain when the valley strength is recorded (£«,//*,,). In the case of the coated samples, the local modulus passes through large oscillations as it progressively decreases; the firsts-intercept is lower than the value of the Epeak while the last ^-intercept is higher than the value of the emuey- These modulus fluctuations indicate that the coated microtrusses are subjected to series of fracture events as they collapse, which is not commonly seen in the inelastic buckling of conventional microtrusses.

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Fig. 3. Modulus (do/de) curves of the coated and uncoated microtrusses.

The energy absorption properties of the microtrusses can also be examined by measuring the area under their stress-strain curves (starting from half the peak stress to twice the peak stress, after [15]):

çc(Zaveak)

Jdensification = 1 n ■. ( '

The compressive properties of the coated and uncoated microtrusses are summarized in Table II. It seems at first surprising that with only a 40 um thick anodized coating, the coated microtrusses were twice as stiff, four-times as strong, and had six-times the energy absorption capability of the uncoated microtrusses. Note that the post-peak softening region (defined as the difference between epeak and evaney) of the coated samples is 57% higher than that of the uncoated samples. Prolonging the post-peak behaviour while maintaining a high stress level is the key reason why the coated microtrusses have superior energy absorption characteristic.

Table II. Compressive Properties of the Coated and Uncoated Microtrusses. Sample

Coated

Uncoated

E [MPal

33

15

Gpeak

[MPal 4.20

1.03

Speak

[mm/mm] 0.26

0.1

Gvalley

[MPal 3.19

0.58

^valley

[mm/mm] 0.62

0.33

Jdensification

[MPal 2.96

0.50

Macroscopic Failure Mechanism

While the uncoated AA3003 microtrusses follow a conventional inelastic buckling collapse mechanism, the coated microtrusses fail in a very different manner. Backscatter scanning electron microscopy (figure 4) shows the evolution of the coated axial cross-sections of the coated microtrusses (^-direction in figure lb) after different levels of compressive strain: e = 0 (a), e = 0.24 (b), e = 0.33 (c), e = 0.44 (d), and e = 0.53 (e). The left-hand side of the as-coated sample (figure 4a) shows that the top part of the node is flattened due to the fabrication pin-indentation while the bottom part has a convex curvature, creating a region with a smaller cross-sectional thickness between the node and the strut. At e = 0.24 (figure 4b), the microtruss is compressed closed to its peak strength. The bottom part of the node is now flattened due to compression and the top part is bulged outward. On the right-hand side closer to the node, a series of oxide pulverizations is seen, which explains the modulus fluctuation of the coated sample (figure 3). At strain-levels beyond the peak strain (e = 0.33, 0.44 and 0.53), pulverization continues from the edge of the node, expanding along the strut length. Figure 5 shows the axial cross-sectional thickness of the core for each of these strain-levels along the length of the strut. For strain values greater than the initial peak strain of e = 0.26, the samples show that the axial cross-section thickness first decreases to a minimum at the edge of the node, then increases within the pulverized region before decreasing again to the thickness level seen in the undamaged region of the strut. It is interesting to note that the strut remained at an angle of-40° (near the starting angle of 8 = 42)6 throughout the collapse sequence. The fact that the undamaged segments of the struts retain nearly the same angle throughout collapse is one of the contributing factors to the prolonged post-peak behaviour of the coated microtrusses.

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Fig. 4. Backscatter scanning electron micrographs of the coated microtrusses at compressive strains of e = 0 (a), e = 0.24 (b), e = 0.33 (c), e = 0.44 (d), and e = 0.53 (e).

Fig. 5. Axial cross-sectional thicknesses of coated microtrusses cores at different strain levels starting from the centre of the node at increment of lOOum.

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