Production of nanocrystalline aluminum alloy powders through cryogenic milling and consolidation by dynamic magnetic compaction.

摘要

Nanopowders and bulk nanostructred materials have gained large interest in recent years. Bulk nanostructured materials exhibit properties that are far superior in comparison to conventional micron grained alloys. The fabrication of large scale nano-grained materials has been achieved in a two step process: (1) the production of nanostructured aluminium alloy powders and (2) the consolidation of the powder using a electromagnetic shockwave process.;The first part consists of cryo-milling; the milling of powder in an attritor filled with liquid nitrogen. This causes successive welding and fracturing events as the powder is milled, thereby creating the nano-structure. The low temperature prevents the possibility of recrystallization and grain growth. The alloy used for this work was Al 5356 (Al-5%Mg). Two different types of raw source materials were investigated: pre-alloyed powders and a mixture of aluminum with pure magnesium or an Al12Mg17 intermetallic. Experiments have been conducted in order to determine the optimum milling parameters that will simultaneously give a grain size smaller than 100 nm; equiaxed milled particles and mechanically alloyed powder (in the case of the mixture). The optimum milling parameters were established at 15 hours of milling time with a rotational speed of 300 RPM and ball to powder weight ratio of 24:1 in the case of the pre-alloyed powders. For the mixture of pure aluminum with pure magnesium the parameters were 15 hours, 300RPM and 32:1. The parameters for the mixture with the intermetallic were 18 hours, 300RPM and 32:1.;The dynamic magnetic compaction technique was done with a peak pressure of 1.1 GPa. This ultra-high strain rate process minimizes the exposure of the powders to high temperature and therefore reduces the possibility of recrystallization and grain growth. Relative densities of compacted pieces obtained ranged from 86.39% to 97.97%. However consolidation characterized by particle to particle bonding with a melted layer was not accomplished.