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One of the current problems concerning the re-use of aluminium alloys is the recycling of aluminium alloys with increased content of iron. One of the recent trends is the processing by powder metallurgy, producing completely new grades of aluminium alloys. The aim of the present work was to test the properties of Al–Si–Fe alloy, which can be manufactured from the high-irony scrap, as a possible material for elevated temperature applications. Since chromium and nickel accompany the iron in the scrap when stainless steels are admixed, the effect of chromium and nickel on thermal stability and mechanical properties at room and elevated temperature was also studied. Al–Si–Fe–X alloys were rapidly solidified by using melt spinning technique. The rapidly solidified ribbons were pulverized by planetary ball mill and the obtained powders were used for compaction by means of Spark Plasma Sintering. It was found that nickel improves the thermal stability as well as the mechanical properties at the elevated temperature. On the other hand, the effect of chromium on the mechanical properties at elevated temperature was almost detrimental. [ABSTRACT FROM AUTHOR]

Powder metallurgy is a group of advanced processes for the synthesis, processing, and shaping of various kinds of materials. Initially inspired by ceramics processing, the methodology comprising of the production of a powder and its transformation to a compact solid product has attracted great attention since the end of World War II. At present, there are many technologies for powder production (e.g., gas atomization of the melt, chemical reduction, milling, and mechanical alloying) and its consolidation (e.g., pressing and sintering, hot isostatic pressing, and spark plasma sintering). The most promising ones can achieve an ultra-fine or nano-grained structure of the powder, and preserve it during consolidation. Among these methods, mechanical alloying and spark plasma sintering play a key role. This Special Issue gives special focus to the advancement of mechanical alloying, spark plasma sintering and self-propagating high-temperature synthesis methods, as well as to the role of these processes in the development of new materials. [ABSTRACT FROM AUTHOR]

Fe–Al–Si alloys have been previously reported as an interesting alternative to common high-temperature materials. This work aimed to improve the properties of FeAl20Si20 alloy (in wt.%) by the application of powder metallurgy process consisting of ultrahigh-energy mechanical alloying and spark plasma sintering. The material consisted of Fe3Si, FeSi, and Fe3Al2Si3 phases. It was found that the alloy exhibits an anomalous behaviour of yield strength and ultimate compressive strength around 500 °C, reaching approximately 1100 and 1500 MPa, respectively. The results also demonstrated exceptional wear resistance, oxidation resistance, and corrosion resistance in water-based electrolytes. The tested manufacturing process enabled the fracture toughness to be increased ca. 10 times compared to the cast alloy of the same composition. Due to its unique properties, the material could be applicable in the automotive industry for the manufacture of exhaust valves, for wear parts, and probably as a material for selected aggressive chemical environments. [ABSTRACT FROM AUTHOR]

This work presents the possibilities of producing a substitute for a commercial matrix material for sintered metal–diamond tools which is characterized by increased tribological properties required in machining natural stones and concrete. In this study, the improvement in wear behavior of sintered pre-alloyed matrix caused by a thermal treatment was investigated. Several mixtures made of commercially available powders were homogenized by ball milling and consolidated at 900 °C using the spark plasma sintering (SPS) method. During cooling down, the specimens were subjected to isothermal holding at 350 or 250 °C for 1 h. After consolidation, all specimens were tested for density and hardness, whereas selected specimens were characterized by scanning electron microscopy (SEM) and flexural strength tests. The specimens made of BDCM50 powder (a mixture of the base and pre-alloyed powders in 50:50 proportion) shows excellent properties including σ0.2 = 1045 MPa in the three-point bending test and HV10 ≈ 380. Resistance to abrasive wear evaluated in both three-body and two-body conditions in the MWT abrasion test was estimated at A i 3 = 18.1 ± 3.9 μm/20 m and   A i 2 = 95.9 ± 11.8 μm/20 m, respectively. A series of diamond-impregnated specimens (segments) was also produced and tested for wear rate on abrasive concrete. The potential graphitization of the diamond grits was investigated using Raman spectroscopy and X-ray diffraction. As a reference, both the base Fe-Mn-Cu-Sn-C and commercially available Co+20%WC alloy were used to compare selected properties of the investigated materials. It has been proved that heat-treated specimens made of the base mixture modified with pre-alloyed powders are characterized by increased hardness and resistance to abrasive wear. The BDCM50 matrix has a negligible effect on diamond graphitization and shows excellent field performance, which makes it a good potential substitute for replacing Co+20%WC in sintered diamond-impregnated tools. [ABSTRACT FROM AUTHOR]

This work is devoted to the preparation of alloys based on intermetallic compounds in the Ti-Al-Si system by powder metallurgy using mechanical alloying and the spark plasma sintering (SPS) method. The aim was to describe the formation of intermetallic phases during mechanical alloying of TiAl15Si15 (wt-%) alloy and to consolidate the powder prepared by optimised conditions. Phase composition, microstructure and hardness of compacted alloy were determined. Four hours of mechanical alloying is sufficient time for preparation of pure elements free material composed only of intermetallic phases. After consolidation, the TiAl15Si15 alloy has a homogeneous structure composed of silicide (Ti5Si3) in aluminide (TiAl) matrix. The hardness of the material reaches 865 ± 42 HV 5. [ABSTRACT FROM AUTHOR]

The microstructure, phase composition, and microhardness of both gas-atomized and mechanically milled powders of the Al7075 + 1 wt % Zr alloy were investigated. The gas-atomized powder exhibited a cellular microstructure (grain size of a few µm) with layers of intermetallic phases along the cell boundaries. Mechanical milling (400 revolutions per minute (RPM)/8 h) resulted in a grain size reduction to the nanocrystalline range (20 to 100 nm) along with the dissolution of the intermetallic phases. Milling led to an increase in the powder's microhardness from 97 to 343 HV. Compacts prepared by spark plasma sintering (SPS) exhibited negligible porosity. The grain size of the originally gas-atomized material was retained, but the continuous layers of intermetallic phases were replaced by individual particles. Recrystallization led to a grain size increase to 365 nm in the SPS compact prepared from the originally milled powder. Small precipitates of the Al3Zr phase were observed in the SPS compacts, and they are believed to be responsible for the retainment of the sub-microcrystalline microstructure during SPS. A more intensive precipitation in this SPS compact can be attributed to a faster diffusion due to a high density of dislocations and grain boundaries in the milled powder. [ABSTRACT FROM AUTHOR]

Ni-Ti alloys are considered to be very important shape memory alloys with a wide application area including, e.g., biomaterials, actuators, couplings, and components in automotive, aerospace, and robotics industries. In this study, the NiTi46 (wt.%) alloy was prepared by a combination of self-propagating high-temperature synthesis, milling, and spark plasma sintering consolidation at three various temperatures. The compacted samples were subsequently heat-treated at temperatures between 400 °C and 900 °C with the following quenching in water or slow cooling in a closed furnace. The influence of the consolidation temperature and regime of heat treatment on the microstructure, mechanical properties, and temperatures of phase transformation was evaluated. The results demonstrate the brittle behaviour of the samples directly after spark plasma sintering at all temperatures by the compressive test and no transformation temperatures at differential scanning calorimetry curves. The biggest improvement of mechanical properties, which was mainly a ductility enhancement, was achieved by heat treatment at 700 °C. Slow cooling has to be recommended in order to obtain the shape memory properties. [ABSTRACT FROM AUTHOR]

FeAlSi intermetallics are materials with promising high-temperature mechanical properties and oxidation resistance. Nevertheless, their production by standard metallurgical processes is complicated. In this study, preparation of powders by mechanical alloying and properties of the samples compacted by spark plasma sintering was studied. Various initial feedstock materials were mixed to prepare the material with the same chemical composition. Time of mechanical alloying leading to complete homogenization of powders was estimated based on the microstructure observations, results of XRD and indentation tests. Microstructure, phase composition, hardness and fracture toughness of sintered samples was studied and compared with the properties of powders before the sintering process. It was found that independently of initial feedstock powder, the resulting phase composition was the same (Fe3Si + FeSi). The combination of hard initial powders required the longest milling time, but it led to the highest values of fracture toughness. [ABSTRACT FROM AUTHOR]

The compact samples of an Al7075 alloy were prepared by a combination of gas atomization, high energy milling, and spark plasma sintering. The predominantly cellular morphology observed in gas atomized powder particles was completely changed by mechanical milling. The continuous-like intermetallic phases present along intercellular boundaries were destroyed; nevertheless, a small amount of Mg(Zn,Cu,Al)2 phase was observed also in the milled powder. Milling resulted in a severe plastic deformation of the material and led to a reduction of grain size from several µm into the nanocrystalline region. The combination of these microstructural characteristics resulted in abnormally high microhardness values exceeding 300 HV. Consolidation through spark plasma sintering (SPS) resulted in bulk samples with negligible porosity. The heat exposition during SPS led to precipitation of intermetallic phases from the non-equilibrium microstructure of both gas atomized and milled powders. SPS of the milled powder resulted in a recrystallization of the severely deformed structure. An ultra-fine grained structure (grain size close to 500 nm) with grains divided primarily by high-angle boundaries was formed. A simultaneous release of stored deformation energy and an increase in the grain size caused a drop of microhardness to values close to 150 HV. This value was retained even after annealing at 425 °C. [ABSTRACT FROM AUTHOR]