Randall M. German Fundamentals and Applications
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Randall M. German Particulate Composites Fundamentals and Applications Particulate Composites Randall M. German Particulate Composites Fundamentals and Applications Randall M. German San Diego State University San Diego, CA, USA ISBN 978-3-319-29915-0 ISBN 978-3-319-29917-4 (eBook) DOI 10.1007/978-3-319-29917-4 Library of Congress Control Number: 2016933672 © Springer International Publishing Switzerland 2016 This work is subject to copyright. All rights are reserved by the Publisher, whether the whole or part of the material is concerned, specifically the rights of translation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in any other physical way, and transmission or information storage and retrieval, electronic adaptation, computer software, or by similar or dissimilar methodology now known or hereafter developed. The use of general descriptive names, registered names, trademarks, service marks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use. The publisher, the authors and the editors are safe to assume that the advice and information in this book are believed to be true and accurate at the date of publication. Neither the publisher nor the authors or the editors give a warranty, express or implied, with respect to the material contained herein or for any errors or omissions that may have been made. Printed on acid-free paper This Springer imprint is published by Springer Nature The registered company is Springer International Publishing AG Switzerland Dedicated to John Lee Johnson Preface Engineering materials continue to encounter challenges for new property combi- nations, and these challenges are leading to many hybrid materials known as composites. Particulate composites are formed using powders to create property combinations not available in traditional engineering compositions. This book provides engineers with information relevant to meeting the challenges on synthe- sis, selection, fabrication, and design associated with applying composites to demanding applications. Growth in the field is accelerating as we learn more about how to deliver novel property combinations. Further, the shaping flexibility associated with particles provides compelling economic benefit. Growth in the particulate composites is evident in patents, journal publications, and press releases. For example, a new composite of gold and titanium nitride is employed in the newest smart watches. The 18-karat watch has exceptional wear resistance beyond that of traditional jewelry. The 75 wt% Au (46 vol.%) gives elegance, while the hard, gold-colored TiN provides 400 HV hardness, tenfold higher than pure gold. This is just one of many ideas. Millions of formulations are possible, with tremendous flexibility in composition, microstructure, properties, and performance. Although the field is challenging to master, at the same time the performance gains are most attractive. Only now are we appreciating the full spectrum of opportunities. Although particulate composites are everywhere, the field is poorly organized. Predictive calculations are ignored or missing. Consequently, product development efforts rely on the empirical approach to see what works. In this book, the underlying principles are emphasized with attention to the critical factors. Important aspects are detailed with regard to the relations between phases, composition, powder charac- teristics, microstructure, fabrication, and properties. The resulting composites are isotropic, unlike long fiber graphite and fiberglass composites. Accordingly, a wide array of products are treated as part of this book. The intent is to introduce particulate composites in a manner relevant to training the next generation of innovators. San Diego, CA, USA Randall M. German vii Acknowledgements I am grateful to several individuals for support on this project. The idea for the book arose in discussions with a number of individuals associated with the Center for Innovative Sintered Products at Penn State University. But it took several years to realize the end product. I am especially appreciative of the help from the following experts: Sundar Atre, Animesh Bose, Louis Campbell, Robert Dowding, Zak Fang, Arun Gokhale, Mark Greenfield, Anthony Griffo, Ozkan Gulsoy, Anita Hancox, John Johnson, John Keane, Young Sam Kwon, Todd Leonhardt, Jason Liu, Yixiong Liu, Kathy Lu, Hideshi Muira, Neal Myers, Seong Jin Park, Leo Praksh, Joe Sery, Ivi Smid, Jose Torralba, Anish Upadhyaya, Ridvan Yamanoglu, and Rudy Zauner. A draft copy of this book was used by students at SDSU who provided useful comments, especially helpful were detailed comments from Hamood Almoshawah, Carolos-Jose Andallo, Sonny Birtwistle, Jonathan Briend, Vanessa Bundy, Justin Camba, Jeremiah Cox, Sam Delaney, Michael Diomartich, Abhi Dhanani, Natalia Ermolaeva, Britney Finley, Ian Gardner, Rebecca Gloria, Deanna Key, Akash Khatawate, Adam Lane, Leo Malmeryd, Falon Mannus, Robert McClellan, Cesar Ocampo, Nicholas Schwall, Nika Sedghi, Lauren Parrett, Nathan Reed, Matthew Revie, Marc Schumacher, Amritpal Singh, Arturo Sotomayorgayosso, Meena Wasimi. Oleg Usherenko, and Wes Yeagley. ix Contents 1 Introduction ......................................... 1 Context ............................................. 1 Composites . 2 Laminates, Fibers, Whiskers, Particles ...................... 7 History ............................................. 8 Shorthand Notations ................................... 10 Phase Connectivity . ................................... 12 Novel Properties ...................................... 13 Summary . 18 Study Questions . ..................................... 19 References . 20 2 Background Definitions ................................. 23 Key Terms Used in Composites . 23 Study Questions . ..................................... 32 References . 33 3 Analysis Techniques ................................... 35 Introduction ......................................... 35 Dimensional Testing . 36 Property Distributions . 38 Tests for Composition and Phases . 41 Density and Porosity Tests . .................. 43 Archimedes Technique ............................... 44 Pycnometry Technique ............................... 46 Hardness ............................................ 47 Brinell Hardness ................................... 47 Vickers Hardness . 48 Rockwell Hardness . 49 Tests for Mechanical Properties . 50 Nondestructive Tests ................................ 50 Strength Tests . 51 xi xii Contents Fatigue Tests . ............................ 56 Impact Tests . ................................... 58 Fracture Toughness ................................. 59 Magnetic Property Tests . 62 Tests for Thermal Properties . 64 Electrical Property Tests . .............................. 66 Environmental Degradation, Corrosion, and Wear Tests ......... 67 Biocompatibility ...................................... 69 Microstructure Quantification . .......................... 70 Sample Preparation ................................. 70 Optical Imaging . 71 Electron Imaging . ................................ 73 Other Imaging ..................................... 75 Standards and Specification Bodies ........................ 76 Comments on Accuracy and Precision . .................... 76 Study Questions . ..................................... 78 References . 80 4 Property Models ...................................... 83 Introduction ......................................... 83 Density ............................................. 85 Hardness ............................................ 86 Elastic Modulus . .................................... 91 Poisson’sRatio....................................... 95 Strength . 96 Failure Distributions . ................................. 102 Ductility . ................................... 104 Deformation and Fracture . 106 High Temperature . ................................... 112 Heat Capacity ........................................ 115 Thermal Expansion .................................... 116 Thermal Conductivity . ................................. 119 Thermal Shock Resistance ............................... 121 Thermal Fatigue . .................................... 122 Electrical Conductivity . ............................. 122 Magnetic Behavior .................................... 125 Wear Properties ....................................... 126 Sound Attenuation . .................................. 127 Comments on Property Models . ........................ 127 Study Questions . ..................................... 130 References . 132 5 Constituents .......................................... 137 Leading Candidates . 137 Constituent Selection Protocol . 140 Contents xiii Illustrated Definition Document: Thermal Management .......... 142 Illustrated Selection Protocol: Thermal Management ............ 143 Example Definition Documents . 146 Materials for Wire Drawing Dies ....................... 146 Self-Winding Watch Weights . ......................... 147 Frangible Ammunition ............................... 148 Radiation Containment . .............................. 150 Concrete Saw Segments .............................. 151 Stereo Headset Speaker Magnets ....................... 152 Electric Bicycle Motor Sectors . 152 Hot Sheet-Steel Descaling Abrasive . 153 Jet Engine Rotating Bearing . ........................ 154 Chromatography Filters