Int. Journal of Refractory Metals and Hard Materials 32 (2012) 33–38 Contents lists available at SciVerse ScienceDirect Int. Journal of Refractory Metals and Hard Materials journal homepage: www.elsevier.com/locate/IJRMHM Effects of Al2O3 addition on the microstructure and properties of Ni activated sintered W matrix composites Ö. Utku Demirkan, Aziz Genç ⁎, M. Lütfi Öveçoğlu Particulate Materials Laboratories, Department of Metallurgical and Materials Engineering, Istanbul Technical University, Maslak, 34469, Istanbul, Turkey a r t i c l e i n f o Article history: Received 31 October 2011 Accepted 21 January 2012 Keywords: Activated sintering Mechanical alloying W Al2O3 a b s t r a c t In the present investigation, fabrication of high dense (> 97.8%) W matrix composites with increased microhardness values were investigated. W and W–1 wt.% Ni powders were mechanical alloyed for 18 h and sintered at 1400 °C for 1 h under Ar, H2 gas flowing conditions in order to investigate the effects of 1 wt.% Ni addition on the densification and properties of W. The effects of Al2O3 particles additions on the microstructural and physical properties of the sintered W–1 wt.% Ni sample were investigated. A 92.59% relative density value of the sintered W sample increased to 99.47% with the addition of 1 wt.% Ni. Moreover, despite the observed grain growth, microhardness values significantly increased from 2.81 ± 0.34 GPa to 4.07 ± 0.16 GPa with the addition of 1 wt.% Ni. The relative density values of the sintered W–1 wt.% Ni sample slightly decreased with increasing Al2O3 additions, a relative density value of 97.81% was measured for the W–1 wt.% Ni sample reinforced with 2 wt.% Al2O3 particles. As the average grain size of W in the sintered W–1 wt.% Ni sample decreased from 4.41 ± 1.71 μm to 1.29 ± 0.39 μm with the addition of 2 wt.% Al2O3 particles, the microhardness of the sample increased to 5.98 ± 0.31 GPa. © 2012 Elsevier Ltd. All rights reserved. 1. Introduction Tungsten (W) and its alloys are attractive candidate materials for various elevated temperature structural applications due to their excellent properties such as high melting point, high modulus, high resistance of thermal shock and low coefficient of thermal expansions (CTE) [1,2]. However, alloying of monolithic W is mandatory for applications which require high strengths at elevated temperatures since mechanical properties of monolithic W decreases significantly with increasing temperature [1–3]. In order to overcome improve the mechanical properties of W, W matrix composites reinforced TiC, ZrC, HfC, SiC, B4C, La2O3, Y2O3, HfO2, Sm2O3, ThO2 and TiB2 were developed over the years [2–16]. Oxide dispersion strengthened tungsten matrix composites and alloys, with their high strength at elevated temperatures and controlled fracturing mechanism depending on their oxide content, are one of the promising materials for high temperature applications [10,16,17]. Although W and its alloys exhibit a combination of very unique properties, fabrication of W is a difficult task due to its high melting point and low ductility [1]. High sintering temperatures as high as 2500 °C [7] are used in order to get fully dense W fabricated using conventional, pressureless, sintering techniques which can be lowered to the range of 1680–1770 °C with the applied mechanical alloying technique followed by conventional sintering [12,13]. It is ⁎ Corresponding author. Tel.: + 90 2122857347; fax: + 90 2122853427. E-mail address: [email protected] (A. Genç). 0263-4368/$ – see front matter © 2012 Elsevier Ltd. All rights reserved. doi:10.1016/j.ijrmhm.2012.01.004 very well known that, activated sintering, which involves small additions of some transition metals such as Pd, Pt, Ni, Co and Fe, enables major reductions in the sintering temperature of W even when the conventional sintering techniques are used [18–32], owing to the enhanced grain boundary diffusions through the nanoscale Ni-rich, quasi-liquid, interfacial layers [29–32]. The coupled effects of mechanical alloying and Ni activated sintering on the densification of W matrix composites fabricated via conventional sintering at 1400 °C for 1 h have been reported previously [14,15]. In the present study, the efficiency of Ni activated sintering technique applied along with the mechanical alloying and its effects on the densification and properties of W are investigated by the addition of 1 wt.% Ni to the W powders MA'd for 18 h followed by sintering at 1400 °C for 1 h, which compared with the pure W compacts fabricated with the same procedure. The effects of Al2O3 particles on the microstructural and mechanical properties of Ni activated sintered W matrix composites were evaluated. 2. Experimental procedures W (Eurotungstene™, 99.9% purity, 4.5 μm average particle size), Ni (Alfa Aesar™, 99.9% purity, 3–7 μm average particle size) and Al2O3 (Sulzer Metco™, 99.99% purity, 44 μm average particle size) powders were used in the present study. Blended powder batches with a total amount of 20 g powders having the compositions of W, W–1 wt.% Ni, W–1 wt.% Ni–0.5 wt.% Al2O3, W–1 wt.% Ni–1 wt.% Al2O3, W–1 wt.% Ni–1.5 wt.% Al2O3 and W–1 wt.% Ni–2 wt.% Al2O3 (hereafter referred to be as the W, W1Ni, W1Ni–0.5 34 Ö.U. Demirkan et al. / Int. Journal of Refractory Metals and Hard Materials 32 (2012) 33–38 Al2O3, W1Ni–1Al2O3, W1Ni–1.5Al2O3, W1Ni–2Al2O3 samples, respectively) were mechanically milled/alloyed (MM'd/MA'd) for 18 h using a Spex™ Duo Mixer/Mill 8000D with a speed of 1200 rpm in a tungsten carbide (WC)–cobalt (Co) vial with WC–Co balls having a diameter of 6.35 mm (1/4 inch.). Preliminary studies on the effect of MA durations on the properties of W1Ni samples (not presented here) showed that longer MA durations than 18 h have no significant effects on relative density and microhardness values of the sintered samples. Therefore, MM/MA duration is fixed as 18 h for all samples. Vials were sealed inside a Plaslabs™ glove box under purified Ar gas (99.995% purity) to prevent oxidation during MA. The ball-to-powder weight ratio (BPR) was 7:1. The amount of WC contamination in the MM'd/MA'd powders was determined via measuring the amount of Co by using a Thermo Scientific™ XL3t Niton X-ray fluorescence (XRF). MM'd/MA'd powders were compacted in a 10 t capacity APEX™ 3010/4 uni-action hydraulic press to obtain cylinder type compacts with a diameter of 6.5 mm under an uniaxial pressure of 400 MPa. The compacts were sintered in a Linn™ high temperature hydrogen furnace at 1400 °C under inert Ar (introduced between 20–650 °C and 900–1400 °C) and reducing H2 (introduced between 650–900 °C) gas flowing conditions for 1 h. Microstructural characterizations of sintered samples were carried out using a Bruker™ D8 Advance X-ray diffractometer (XRD) (CuKα radiation) and a Hitachi™ TM-1000 scanning electron microscope (SEM). EDS analyses are conducted using a JEOL™ JEM 7000F SEM equipped with an Oxford™ EDS detector. W grain sizes in the as-sintered surface SEM micrographs were measured by drawing two perpendicular lines crisscrossing the equiaxed W grains. The size of each grain is the arithmetic mean of these two measurements and grain size results are arithmetic means of about 50 equiaxed W grains. Sintered densities were measured by using the Archimedes' method. The relative density results are the arithmetic mean of measurements taken from at least 2 different samples for each composition. Vickers microhardness tests were conducted on sintered samples using a Shimadzu™ microhardness tester under a load of 100 g for 15 s. Microhardness test result for each sample is the arithmetic mean of 10 successive indentations and standard deviations. 3. Results and discussions 3.1. Ni activated sintering In order to investigate the effects of Ni addition on the sinterability of MA'd W powders, pure W and W–1 wt.% Ni powders were respectively MM'd and MA'd for 18 h and sintered at 1400 °C for 1 h. X-ray diffraction (XRD) patterns taken from the sintered W and W1Ni samples are given in Fig. 1. Fig. 1a is an XRD pattern taken from the sintered W sample, revealing the presence of diffraction peaks belonging only to the W phase, which has a b.c.c. Bravais lattice and Im3− m space group with the lattice parameter of a = 0.316 nm [33]. The XRD pattern taken from the sintered W1Ni sample (Fig. 1b) is also very similar to Fig. 1a, where all peaks belong to the reflections from the W phase. Fig. 2a–d are the back scattered SEM micrographs taken from the sintered W and W1Ni samples. As seen in Fig. 2, two different types of SEM investigations are conducted for each sample, one is the investigation of the surface of the as-sintered sample without no further sample preparations and the other one is the SEM investigations of the polished surface after routine metallographic sample preparations. SEM micrographs of the as-sintered surfaces reveal the grain structure with a mechanism similar to the process called thermal etching, where grains with different orientations have different thermal expansion coefficients [34]. Fig. 2a shows the SEM micrograph taken from the as-sintered surface of the W sample revealing a microstructure with some secondary phases and some open pores throughout the microstructure. SEM/EDS investigations confirmed that light Fig. 1. XRD patterns taken from the sintered (a) W and (b) W1Ni samples. contrast grains are W with W contents higher than 99.4 wt.% and the secondary phases are WC particles comprising of 94.75 ± 1.50 wt.% W and 5.25 ± 1.50 wt.%C, which inherited by the milling media during MA. Although contaminated WC particles are not quite visible in the SEM micrograph taken from the polished surface of the sintered W sample (Fig. 2b), similar microstructural features with Fig. 2a, i.e. some open pores, can be observed in this micrograph. Fig. 2c is the back scattered SEM micrograph taken from the as-sintered surface of the W1Ni sample and reveals the presence of some dark gray grains unlike Fig. 2a. On the basis of EDS scans, these dark gray grains are composed of 86.71 ± 8.50 wt.% W, 12.14 ± 2.43 wt.% Ni and 1.15 ± 0.71 wt.% Co. The presence of Co can be explained by the contamination during MA in which WC–Co vials and balls are used as milling media. XRF measurements are conducted on the MM'd/MA'd powders in order to reveal the amount of WC contamination during MA by tracing the amounts of Co in the MA'd powders. XRF measurements revealed the presence of 0.11 wt.% and 0.08 wt.% Co for the W and W1Ni powders MM'd/MA'd for 18 h, respectively. By taking into account that WC–Co vials and balls are comprised WC–6 wt.% Co, the amount of milling media contamination during MM/MA can be calculated as about 1.8 wt.% for the W powders MM'd for 18 h and as about 1.36 wt.% for the W1Ni powders MA'd for 18 h. Moreover, on the basis of EDS analyses, which revealed that dark gray grains contain about 12 wt.% Ni in their microstructures, it is possible to state that a homogeneous distribution of Ni could not be obtained after MA for 18 h. However, this un-homogeneous distribution for Ni does not seem to have detrimental effects on the sinterability of W (see discussions about the relative density values). Same dark gray regions can be seen in the micrograph taken from the polished surface of the sintered W1Ni sample (Fig. 2d). Indications about the effects of the Ni addition on the densification of W can be interpreted by comparing the microstructures presented in Fig. 2a–b and Fig. 2c–d, i.e. the SEM micrographs taken from the sintered W1Ni sample (Fig. 2c–d) reveals the absence of open pores throughout the microstructure. The average grain size measurements reveal that the average grain size of 2.56 ± 1.29 μm for the sintered W sample becomes 4.41 ± 1.71 μm for the sintered W1Ni sample. The growth of W grains with the addition of 1 wt.% Ni can be explained by two different viewpoints: (i) the activation of the sintering process is based on the enhanced diffusion during sintering [19,22], which increases the growth of W grains during the final stage of sintering process [28], (ii) consequently, the pores present in the microstructure of the sintered W sample, which have a pinning effect on the grain growth, are no longer present in the microstructure of the sintered W1Ni sample. The difference between microstructures is also reflected on the relative density values, in which a relative density value of 92.59 ± Ö.U. Demirkan et al. / Int. Journal of Refractory Metals and Hard Materials 32 (2012) 33–38 35 Fig. 2. SEM micrographs taken from the as-sintered and polished surfaces of the sintered W ((a) and (b)) and W1Ni ((c) and (d)) samples. 0.09% for the sintered W sample increased to 99.47 ± 0.40% with the addition of 1 wt.% Ni (W1Ni sample). This increase in the relative density value is unambiguously contributed by the positive effects of Ni addition, Ni activated sintering, on the sinterability of W. Activated sintering of refractory metals such as W is a very well documented technique since the Vajek 's first report in 1959 [18], and over the years many researchers have conducted investigations using the activated sintering technique [19–32]. In these studies, a Ni containing precursor (chloride, nitrate, etc.) is used for coating of W particles with desired Ni amounts, except Kravchik et al. [25] used a vibrational milling equipment for uniform distribution of 0.5 wt.% Ni in W powders. They [25] reported that the addition of Ni into W increases the rate of pore reduction by the order of two compared to the pure W compacts, however, no specific relative density values were presented in their study. Diliberto et al. [35] reported on the activated sintering of mechanically alloyed refractory metal powders, they investigated the sintering behavior of Mo–W–Cr alloys activated with the Pd, Ni and Ru additions [35]. The possibility of fabricating high dense W compacts with mechanical alloying and Ni activated sintering were reported by the present authors [14,15], but there were no sintered compacts from pure W powders enabling the comprehensible comparison about the effects of the Ni addition in these studies. In this study, the effects of Ni addition on the sinterability of MM'd W powders have been clearly established. As mentioned above, SEM micrographs contain some grains with higher Ni contents indicating inhomogeneous distribution of Ni throughout the W grains. Nevertheless, the obtained relative density results undoubtedly indicate that this has no detrimental effects on the densification of W compacts, which can be explained by the critical amount of Ni necessary for the activated sintering of W. In the studies about activated sintering by Ni-coated W powders, it is reported that a few monolayer thick Ni coatings are enough for the activated sintering of W compacts [23,26,27], which is about 0.3–0.4 wt.% Ni depending on the particle size of starting W powders. Here, it is possible to state that the amount of Ni used for activated sintering, 1 wt.%, can tolerate the observed inhomogeneous distribution of Ni. Moreover, reported relative density value of 92.59 ± 0.09% for the sintered W sample is quite high by comparing the reported results about conventional sintering of pure W [7] and this higher relative density value of the MM'd and sintered W can be attributed to the grain refinements during MM and the presence of Co, which is also known as an activator agent for sintering of W [19,23,24]. Moreover, despite the observed grain growth with the addition of 1 wt.% Ni, microhardness value significantly increases with the addition of 1 wt.% Ni, where a microhardness value of 2.81 ± 0.34 GPa measured for the sintered W sample increased to 4.07 ± 0.16 GPa for the sintered W1Ni sample. This increase in the microhardness values can be correlated with the increased relative density values, in which the detrimental effects of the porous structure of the sintered W sample on the microhardness no longer prevailed. 3.2. The effects of Al2O3 addition Following the fabrication of fully dense W1Ni sample, different amounts of Al2O3 particles were added as reinforcements to the W1Ni matrix. This section comprises the experimental results and relevant discussions about the effects of Al2O3 particles addition on the properties of the W1Ni sample. Fig. 3. XRD patterns taken from the sintered W1Ni samples reinforced with different amounts of Al2O3 particles: (a) W1Ni–0.5Al2O3, (b) W1Ni–1Al2O3, (c) W1Ni–1.5Al2O3 and (d) W1Ni–2Al2O3 samples. 36 Ö.U. Demirkan et al. / Int. Journal of Refractory Metals and Hard Materials 32 (2012) 33–38 Fig. 3 shows the XRD patterns taken from the sintered W1Ni samples reinforced with different amounts of Al2O3 particles. XRD pattern of the sintered W1Ni-0.5Al2O3 sample (Fig. 3a) reveals only the characteristic peaks of the matrix W phase, where no other diffraction peaks from Ni and Al2O3 phases are observed. Likewise, matrix W phase is the only phase observed in the XRD patterns taken from the sintered W1Ni–1Al2O3 (Fig. 3b), W1Ni–1.5Al2O3 (Fig. 3c) and W1Ni–2Al2O3 (Fig. 3d) samples. Fig. 4 shows back scattered SEM micrographs taken from the sintered W1Ni samples reinforced with different amounts of Al2O3 particles. As in Fig. 4, two types, as-sintered and polished surfaces, of SEM investigations are conducted for each sample. Fig. 4a–b shows SEM micrographs taken from the sintered W1Ni–0.5Al2O3 sample revealing the presence of black particles having diameters of smaller than 1 μm, which are mainly located at the grain boundaries. SEM/EDS analyses suggested that these black particles are Al2O3 particles having compositions of about 55.77 ± 8.85 wt.% W, 14.34 ± 4.92 wt.% Al and 29.89 ± 4 wt.% O. It should be noted here that the presence of high amounts of W determined via EDS does not necessarily reveals the formation of Al–W–O particles. More likely, the obtained high W amounts can be attributed to the spread of X-ray beam, which collects data around the submicron sized Al2O3 particles. As seen in SEM micrographs taken from the sintered W1Ni–1Al2O3 sample (Fig. 4c–d), increasing the Al2O3 amount decreases the grain size of W, which is also observed in the SEM micrographs taken from the sintered W1Ni–1.5Al2O3 (Fig. 4e–f) and W1Ni–2Al2O3 (Fig. 2g–h) samples. SEM micrographs taken from the surfaces of the as-sintered samples (Fig. 4a, c, e and g) suggest that the clustering of Al2O3 particles take place with increasing Al2O3 content, however the SEM micrographs taken from the polished surfaces of the same samples clearly indicate that clustering of Al2O3 particles doesn't take place for the bulk of the samples (Fig. 4b, d, f and h). Yet, as the amount of the Al2O3 increases, Fig. 4. SEM micrographs taken from the sintered W1Ni sample reinforced with different amounts of Al2O3 particles: (a–b) W1Ni–0.5Al2O3, (c–d) W1Ni–1Al2O3, (e–f) W1Ni–1.5Al2O3 and (g, h) W1Ni–2Al2O3 samples. Ö.U. Demirkan et al. / Int. Journal of Refractory Metals and Hard Materials 32 (2012) 33–38 the distribution of Al2O3 particles get more homogeneous and their diameters get smaller due to the increased fracturing mechanism during MA. Simultaneously, the size of W grains systematically decreases with the increasing Al2O3 contents. The amount of WC contaminated via measuring the amount of Co suggested that the Co contents between 0.08 wt.% and 0.12 wt.% are present in the W1Ni–Al2O3 powders MA'd for 18 h suggesting the presence of WC–Co contamination between 1.36 wt.% and 2 wt.%, whereas no comparative trend was observed in the WC–Co contamination with increasing Al2O3 amount. Fig. 5 shows the relative density evolution of the sintered W1Ni sample after reinforcing with different amounts of Al2O3 particles and reveals a slight decrease with increasing Al2O3 content, where 99.47 ± 0.40% relative density value of the sintered W1Ni sample decreases to 97.81 ± 0.33% for the sintered W1Ni–2Al2O3 sample. Even after the addition of Al2O3 particles, the high relative density value of the W1Ni sample is preserved. As seen in the SEM micrographs presented in Fig. 4, no open pores can be observed in the surfaces of the sintered W1Ni–Al2O3 samples. However, as revealed by the relative density measurements, these samples contain some pores in their microstructures and it can be interpreted that these pores are mainly closed pores and their fractions vary between 0.7% and 2.2%. Fig. 6 shows the evolution of microhardness values and average W grain sizes with increasing Al2O3 contents. As seen in Fig. 6, microhardness of the sintered W1Ni sample increases with increasing Al2O3 contents, where a microhardness value of 4.07 ± 0.16 GPa for the sintered W1Ni sample increases to 5.98 ± 0.31 GPa for the sintered W1Ni–2Al2O3 sample. With the addition of 0.5 wt.% Al2O3, the microhardness value slightly increases to 4.24 ± 0.12 GPa, however, it significantly increases and becomes 5.33 ± 0.21 GPa with the addition of 1 wt.% Al2O3 particles. The evolution of average W grain sizes is also presented in Fig. 6, as observed in the SEM micrographs in Fig. 4, the size of W grains decrease with increasing Al2O3 contents. A mean grain size of 4.41 ± 1.71 μm of W grains for the sintered W1Ni sample (Fig. 2c–d) decreases to 1.29 ± 0.39 μm for the sintered W1Ni–2Al2O3 sample (Fig. 4g–h). Moreover, as the distribution of Al2O3 particles becomes more homogeneous with increasing contents, the standard deviation of the average grain sizes decreases. Fig. 6 clearly shows that the evolution of microhardness values and grain sizes are in great consistency with each other, in which the decreases in the grain size are accompanied with increases in microhardness. A significant increase in the microhardness value of the sintered W1Ni–1Al2O3 sample can also be correlated with its microstructure, in which the size of W grains declines to 1.99 ± 0.88 μm. Fig. 5. Relative density evolution vs. Al2O3 content for the sintered samples. 37 Fig. 6. Evolution of microhardness values and average W grain size with the addition of Al2O3 particles. 4. Summary and conclusions In the first instance, the effects of addition of 1 wt.% Ni on the densification of W powders, namely Ni activated sintering of W, are investigated. W and W–1 wt.% Ni powders were respectively MM'd and MA'd for 18 h and sintered at 1400 °C for 1 h. Along with the increased the relative density values, a significant increase in the microhardness values is observed with the addition of 1 wt.% Ni, revealing the coupled effects of mechanical alloying and Ni activated sintering for the fabrication of W compacts at a lower sintering temperature of 1400 °C using conventional sintering routes. Following the fabrication of fully dense W1Ni samples, different amounts (0.5, 1, 1.5 and 2 wt.%) of Al2O3 particles are used for dispersion strengtheners for the sintered W1Ni sample. Although the relative density of the W1Ni sample slightly decreased with the increasing Al2O3 addition, microhardness values are systematically increased. Homogeneously distributed dispersoids throughout the W matrix with smaller grain sizes are achieved by increasing the Al2O3 addition. On the basis of the results of the present investigations, the following conclusions can be drawn: 1) XRD patterns of the sintered samples revealed the presence of only W phase, no other peaks from the Ni and Al2O3 phases are observed. 2) SEM micrographs of the sintered W sample revealed the existence of some pores in its microstructure, whereas no open pores were observed in the microstructure of W1Ni sample. SEM micrographs taken from the samples containing different amounts of Al2O3 particles revealed that these particles are mainly located at W grain boundaries and distribution of Al2O3 particles in the matrix became more homogeneous and their size became smaller with increasing content. 3) Average size of W grains increased with the addition of 1 wt.% Ni and increasing amount of Al2O3 decreased the size of W grains. Grain size of 2.56 ± 1.29 μm for the sintered W sample became 4.41 ± 1.71 μm for the sintered W1Ni sample, which decreased to 3.23 ± 1.35 μm, 1.99 ± 0.88 μm, 1.44 ± 0.45 μm and 1.29 ± 0.39 μm for the W1Ni–0.5Al2O3, W1Ni–1Al2O3, W1Ni–1.5Al2O3 and W1Ni–2Al2O3 samples, respectively. 4) A relative density value of 92.59% for the sintered W sample increases to 99.47% for the sintered W1Ni sample, whereas the relative density values slightly decreased with increasing amount Al2O3. The relative density values of the samples containing Al2O3 particles varied between 97.81% and 99.26%. 5) The microhardness of the W sample significantly increased with the addition of 1 wt.% Ni and increasing amount of Al2O3 particles further increased the microhardness values. 2.81 ± 0.34 GPa 38 Ö.U. Demirkan et al. / Int. Journal of Refractory Metals and Hard Materials 32 (2012) 33–38 microhardness value of the sintered W sample increased to 4.07 ± 0.16 GPa with the addition of 1 wt.% Ni and W1Ni–2Al2O3 sample had a microhardness value of 5.98 ± 0.31 GPa. Overall, based on the relative density and microhardness values of the sintered samples, it is possible to state that activated sintering technique applied along with the mechanical alloying treatment is a very promising route to fabricate fully dense W products at a relatively low sintering temperature of 1400 °C. Using Al2O3 particles as reinforcements is also an efficient way to increase the properties of W matrix composites with no detrimental effects on relative densities. 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