科技英语文献翻译英文资料原文

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Strategiesfordevelopingbulkmaterialsnanotechnology(BMN)intoindustrialproducts

D.J.Branagan*,A.V.Sergueeva,S.Cheng,J.K.Walleser,T.F.Weznel,J.V.Costa,W.Kiilunen,B.E.MeachamandC.D.Tuffile

mercialdevelopmentofbulkmaterialsnanotechnology(BMN)isenabledthroughnewdiscoveriesovercomingageoldproblemsspecifically:(1)openingupofprocesswindowtoenablenanoscalestructureformationinindustrialproductsand(2)utilisationofnewnanoscaleductilitymechanismstoachievecombinationsofhighstrengthwithductility.StrategiesforusingBMNaseitherasurfacetechnologyorasastandalonemonolithictechnologyaredependentontheoperableductility/toughnessmechanismswhichareoverridingfactorsforsuccessfulcommercialisation.Foreachroute,thepathwayformicrostructuralformation,thetargetednanoscalestructuresandtheprocesswindowgoalsaredescribedalongwithmainstreamexamplesofeachtechnologyforamultitudeofrealworldindustrialapplications.

Keywords:Nanotechnology,Metallicglass,Devitrification,Nanomaterials,Tensileproperties,Bulkmaterialsnanotechnology

ThispaperispartofaspecialissueonNanoengineeringintheModernSteelIndustry

Introduction

arecreatedarethemselvesinherentlybrittlesinceasReducedlengthscalematerialshavegrainsizeisdecreasedtothenanoscale,dislocation1,2beenusedfordecadesforsoftmagneticapplications,suchasme-pileupsbecomeincreasinglylesslikelyanddislocationtallicglassesastransformercores,andhardmagneticmotionbecomesincreasinglymoredif cult.Thus,inapplications,3,4includingdevitri ednanocompositesasnanomaterials,dislocationsbecomeeffectivelyimmobilehighenergydensitypermanentmagnets.However,induetothelargefractionofgrainandphaseboundaries,ordertoutilisethisclassofmaterialsinnewtypesofresultinginlowvaluesoftensileductilityandbrittleindustrialproducts,theweaklinkintheseclassesofresponse.

materialsmustbeovercome,whichistheabilitytoAfteryearsofresearch,extensive eldtrialsanddeformatroomtemperature.Atambienttemperature,successfulindustrialimplementationinamultitudeofmetallicglassescandeformbutdosoinhomogeneouslymainstreammarkets,TheNanoSteelCompanyhasthroughshearbanding.5,6Atunconstrainedloadingdevelopedspeci cstrategiestowarddevelopingironconditions,thepropagationofaslowasasingleshearbasedbulkmaterialsnanotechnology(BMN)intobandcanleadtocatastrophicfailure.6Notethatwhileindustrialproductsforcommercialmarkets,whicharesomeglassescanexhibitsigni cantductilitythroughdescribedbytheoverviewinFig.1.Thestartingpointhomogeneousviscous owatelevatedtemperatureina(1)inBMNistostartwithironbasedglassformingnarrowtemperaturerangecalledthesupercooledliquidalloysthatexhibitsuf cientlylowcriticalcoolingratesformetallicglassformationcorrespondingtothechosenregion,5afterdeformationandreturningtoambientindustrialprocessingmethod.Forsurfacetechnologytemperatures,theresultingglassisbrittle,limitingits(2a),theglassformingalloywillbeappliedoverausefulness.Themetallicglassstructurecanalsobeusedsurface/substrate.Thismeansthatsystemtoughnesscanasaprecursorfordevelopingawholerangeofderivedbedeveloped,andinherentmaterialtoughnessisnotananoscalestructuresthroughhistorydependantglassnecessarycriterion.Duringsolidi cationofthecoating,devitri cationtransformation,whichcanbein uencedtheglassstructureisformedandcanbeused;however,bythetransformationalpathwaysuchasrelaxation,thegeneralrouteistodevitrifytheglassandthusformrecoveryandrecrystallisation.7However,inallcases,anenablingstructuretype,whichiscalledadevitri edtheresultingdevitri ednanocompositestructuresthat

nanocompositestructure.Formonolithic(i.e.standalone)technology(2b),thereisnosubstrate,whichmeansthatthematerialmustdevelopinherentintrinsicTheNanoSteelCompany,Providence,RI,USA

toughness.Intrinsictoughnessarisesfromconventional*Correspondingauthor,emailDBranagan@plasticzonesinfrontofacracktipinhibitingcrack

ß2013InstituteofMaterials,MineralsandMiningPublishedbyManeyonbehalfoftheInstitute

Received4September2012;accepted7November2012DOI10.1179/1743284712Y.0000000161

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1Successfulstrategiestoprocessglassformingliquidmelts(1)into(2a)surfacetechnologyand(2b)monolithictechnology

propagation.Inordertodeveloptensileductility,devi-tri cationmustbeavoided,andtheenablingstructuretypeisfoundtobeaspinodalglassmatrixmicrocon-stituent(SGMM).Inthesubsequentsections,thesuccessfulcommercialapproachesillustratedinFig.1willbedescribedinadditionaldetail.

Surfacetechnology

Forsurfacetechnology,theglassformingalloyisutilisedasacoating,whichbyitsnatureisalwaysappliedontoasubstrateandnotutilisedinapplicationswherethecoatingisgoingtocarryastructuralload.Throughcarefulmanipulationoftheapplicationprocessandsubstrateselection,highsystemtoughnesscanbedevel-opedwithouttheneedforintrinsicmaterialtoughnessofthecoating.8,9Inthermalspraycoatings,hightoughnesscoatingscanbedevelopedduetothenatureofthethermalsprayprocesswherethecoatingcanbedepositedinacompressivestressstateduetotheshotpeeningeffectofthecontinuousbuildingupofsemimoltenparticlesintoindividuallayersathighvelocity.Inweldoverlayhardfacing,ductilehightoughnessbackingmaterialsincludingplaincarbon(i.e.A36)andlowalloyhightoughnesssteels(i.e.4140)canbeutilisedwithfullmetallurgicalbondingachievedtotheductilesubstratematerial.

Owingtothedevelopmentofsystemtoughness,bothmetallicglassanddevitri ednanocompositestructurescanbeutilisedcommerciallythroughthesolidi cationpathwaysshownbythemodelcontinuouscoolingtransformation(CCT)diagraminFig.2.Asshownbycoolingrate1(CR1),thegoalistosolidifyatahighenoughcoolingrate,whichmissesthenoseoftheglasstocrystallineCcurve,representingtheglasstocrystal-linetransformation.Bythisroute,auniformmetallicglassstructurecanbedeveloped,which,dependingonthecriticalcoolingrateformetallicglassformation,canprovideawideoperationalwindow.Atcoolingrate2(CR2),itispossibletoundercoolsuf ciently,followedbyrapidnucleationfromthesupercooledliquidmeltto

formthecompletelycrystallinedevitri ednanocom-positestructure.Theprocesswindowtoproduceadevitri ednanocompositestructuredirectlyfromthemeltissmallanddif culttoachieveonanindustrialscale.Thus,amorescalableapproachistooverquenchintothemetallicglassstateandthenheattreattocompletelydevitrifyasshownbythehorizontalarrow.Thiselevatedtemperatureexposurecanbeaccomplishedbyasinglestageheattreatmentasindicatedorcanoccurinsituinelevatedtemperatureapplications,forexamplecoatingsappliedforerosion/corrosioninanoperatingcoilorbiomassboilers.10

Forsurfacetechnologyapplications,dependingontheenvironmentandtherequiredproperties,thecoatingcanbeutilisedinametallicglassstate,apartiallydevitri edorafullydevitri edcondition.Paramountpropertiesofperformancethatcanbedevelopedarehardnesslevelsintherangeofmanyceramics,11–13wearanderosionresistanceperformancelikehardmetals(i.e.WC)8,14,15andcorrosionresistancelikenickelbasedsuperalloys16–18inselectedenvironments.

InFig.3,thetechnologicaldevelopmentofmetallicglassesintoaplatformsurfacetechnologyisshown.Thedevelopmentbeganwithinitiallyverythin(,1mm)physicalvapourdepositioncoatingsappliedthroughlaserablationorsputteringandwithonlyanarrowprocesswindowrequiringextremelyhighcoolingratesaty109Ks21.Throughcontinuousalloydevelopment,thecriticalcoolingrateformetallicglassformationwasreducedordersofmagnitudetothe,104Ks21range(Fig.3b),whichenabledthermalsprayapplicationtechniques.Typicalthermalspraycoatingthicknessesarefrom0?1to1mmandappliedthroughtechniquessuchasplasmaspray,highvelocityoxyfuelsprayandtwinrollwirearcspray.Furtherreductionincriticalcoolingratestothey102Ks21range(Fig.3c)enabledthick(typicallyfrom3to10mm)weldoverlayhard-facingapplicationtechniquesincludinggasmetalarcwelding,plasmatransferredarcwelding,openarcweldingandsubmergedarcweldingforweld

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2Structuralformationmodelutilisedtodevelopsurfacetechnologysolutions

wearplate.Onenoteisthatthedevelopmentofweldresistanceofthecoatings,whichhasbeensuccessfullyoverlaytechnologytookauniquepathsinceweldingutilisedatanumberofoperatingpowerplants.Figure4b(otherthanlaserweldingwherethedilutionislow)19showsweldoverlayhardfacing/hardbandingappliedtoainvolvesintimatemixingwiththecrystallinesubstrate.tooljointaspartofthetoolstemforoilandgaswellThus,itwasfoundthatitwasverydif culttoretainthedrillingillustratingthehighwearresistanceandlowglassstructureindependentofthecriticalcoolingrateforfrictiontribologicalcouplethatcanbeproduced.metallicglassformationduetothepresenceofcrystallineFigure4cisanexampleofawearpackageutilisingweldheterogeneousnucleationsites.Nevertheless,itwasfoundoverlaytoprovideextremewearprotectiontoalargethattheglassformingnatureofthealloysresultedinhigh26yard3(y20m3)shoveldipper.Figure4disa240tonundercoolingbeforenucleationasshownbythenuclea-(,217metrictons)haultruckwithwearplatesinstalledtionpointtninFig.3c,whichallowedahighnucleationinthebedofthetruckwithover10milliontonsofhardfrequencyandlimitedtimeforgrowthresultinginrockoreprocessed,illustratingresistancetoextrememetallurgicalre nementoftheresultingweldoverlayimpact,highstressabrasionandploughing/gouging.

structure.ThecreationofnovelnearnanoscalestructuresdirectlyduringtheweldingprocesshasresultedincompellingcombinationsofpropertiesincludinglowMonolithictechnology

frictionandhighwear/abrasionresistance.14,20

Inmonolithictechnology,nosubstrateisutilised,soExamplesofsurfacetechnologyapplicationsforBMNthereisnomethodologytodevelopsystemtoughness.arewidespread,andselectedcommercialexamplesofThisnecessitatesinherentmaterialtoughnessrequiringsurfacetechnologyareprovidedinFig.4.Figure4atensileplasticitysoaneffectiveplasticzonecanbeshowsanexampleofawirearccoatingbeingappliedformedaheadofa aworcracktip.Asdiscussedontotheheatexchangetubesofabiomassboilerandispreviously,reducedlengthscalematerialshaveveryillustrativeofthehightemperatureerosionandcorrosion

limitedabilitytodeformatroomtemperature.

Metallic

aphysicalvapourdeposition;bthermalspraycoating;cweldoverlayhardfacing

3ModelCCTdiagramsforsurfacetechnologyshowingtechnologicalexploitationofBMNtonewapplicationtechniques

atincreasinglevelsofthicknesscorrespondingtoreductionsinnecessarycooling

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aboilertubecoatingappliedinpowerplant;bweldoverlayhardfacing/hardbandingontooljoint;cweldoverlayhardfa-cingappliedtolargeshoveldipper;dwearplateinhaultruckbedliners

4ExamplesofindustrialproductsbasedonsurfacetechnologyapplicationofBMN

glassesdoexhibitaroomtemperaturedeformationmechanism;however,whenexposedtoatensileload,itexperiencescatastrophicfailureduetoshearbandfor-mation,freevolumecreation,shearsofteningandrunawayshearpropagation.5Recently,wehavereportedaspeci cstructuretypecalledaSGMMstructure,whichhastheabilitytodeformwithoutrunawayshearpro-pagationresultingintheachievementofsigni cantlevelsofglobalplasticityandusableductility.21–24

ThestructuralformationmodelfortheSGMMstructurerequiredformonolithictechnologyisshowninFig.5.Thekeytoformingthisenablingstructureisasolidi cationpathwaywherebyglassdevitri cationisavoided,whichisshownbythecoolingcurvesmissingthenoseoftheglassdevitri cationtransformation.Thisisbecauseglassdevitri cation,whetherornotitisper-formedinsingleormultiplestages,orwhetherinvolvingrecovery,relaxationorrecrystallisation,resultsinthecreationofbrittlestructures.Theglassformingnatureofthealloyisparamounttoformasupersaturatedglassmatrixduetothehighsolubilityofelementsinthemetallicglassstructure.Keytosubsequenttransformationistheabilityofthemulticomponentalloytoexhibiteitherastableormetastablemiscibilitygapatasuf cientlylowtemperaturerangetoallowtransformationinametallicglassmatrixthroughspinodaldecomposition.Unlikedevitri cation,spinodaltransformationisnotnucleationcontrolledbutinsteadinvolvesphaseseparationfromfreeenergydrivencompositionalgradientsduetothepresenceofeitherastableormetastablemiscibilitygap.Duringcooling,afterametallicglassisformed,thissupersaturatedsolutionthenundergoesspinodaldecompositiontocreateadistributionofvery nenanoscale(typically1–10nm)precipitatesintheglassmatrix.AsshowninFig.5,dependingonthecoolingrate,thespinodalstructurecanbeobservedtobehaveasexpectedforaspinodaldecompositiontransformation,andearlystage(CR4),middlestage(CR5)andlatestage(CR6)spinodalstructurescanbeobserved.Notethattheearlystagespinodalphasesareverysmallat,2nmandwheninitiallyformsappeartobesemicrystalline,butinlaterstages,oncetheycoarsengreaterthany6nmbecomecompletelycrystalline.

OncetheSGMMstructureisformed,ithastheuniqueabilitytodeformunderatensileload.InFig.6a,ahighdensityofshearbandscanbeobservedinasampleproducedwiththeSGMMstructureandthentensiletesteduntilfailure.Twotypesofinteractionsareobserved,whicharecalledinducedshearbandblunting(smallcircles)andshearbandarrestinginteractions(SBAI)(largecircles).21–24InFig.6b,additionaldetailsoftheinducedshearbandbluntingprocessareshownasapropagatingshearbandisinteractingwiththeSGMMstructureandisbluntedduetocomplexmultifoldinteractionsoftheshearbandwiththeSGMMstructurethroughlocaliseddeformationinducedchangesinclud-ingphasetransformation,phasegrowthandinsitunanocrystallisation.21–24InFig.6c,additionaldetailsoftheSBAIprocessareshown,whichshowthataftershearbandsarecreated,theyinteractwithexistingshearbandsandareoftensplitandbluntedafterashortdistance.Theresultistheformationofhighdensitiesofshearbandsupto105–106linespervolume,analogoustodislocationsincrystallinemetals,leadingtosigni -cantlevelsofglobalplasticity.

ThetargetedSGMMstructurehasbeensuccessfullyproducedinmanyproductformsincludingmicrowiresthroughTaylor–Ulitovskywireproduction, bresthroughvariationsofindustrialscalemeltspinningprocessesandfoilsthroughplanar owcasting.In

these

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5Structuralformationmodeltodevelopthinmonolithictechnology

solutions

productforms,theabilitytoachievecombinationsoffabricshavebeenusedwithimprovementsinpropertiesstrength(2?5upto4?0GPa)andductility(3–7%)issuchasabrasion/cutresistance,temperaturestability,enablingforawholehostofpotentialapplications.EMI/RFIshielding,resistanceheatingandsignaltrans-ExamplesofproductformsmadefrommonolithicmissionalongwithimprovedenvironmentalstabilityduetechnologyareshowninFig.7.Figure7ashowshightoresistancetowatervapourandUVabsorption.

strength bresaddedataloadingrateof30kgm23inFormonolithictechnology,productdevelopmentisordertodevelopconcretewithhigherresistancetocrackcontinuingasindustrylearnstoworkwithanewclassofformationandtomaintainresidualstrengthafterthematerials.However,thefutureimplementationofthiscrackforms.InFig.7b,ahoneycombstructureisshowntechnologymaybeexpectedtoprogresswithincreas-madefromfoil,whichhasahigherspeci cstrengthinglythickerproductsanalogoustothedevelopmentalandspeci cstiffnessthanexistinghoneycombstructurespathwaytosurfacetechnologyasshowninFig.8.Oneaswellasgreater reandheatresistance.Figure7candkeytechnologicalhurdletoovercomeisprocesswindowdshowsexamplesoffabricproducedbyweavingnarrowexpansionfromtheexistingcoolingraterequirementsof lamentsofSGMMfoil(Fig.7c)oraramidserved104Ks21downtothe103–100Ks21rangedependingSGMMfoil lamenthybridyarns(Fig.7d).Thefabricsonthecommercialproductionstrategy.Inaccordancecanbeappliedwheretraditionalhighstrengthpolyamidewithglassformingabilityrequirements,two

potential

aimage(SEM)showinghighdensityofshearbandsincludinginducedshearblandblunting(smallcircles)andSBAI(largecircles);bTEMimageshowinginteractionofshearbandwithSGMMstructureleadingtoblunting;cTEMimageshowingSBAI

6Micrographsofshearbandinginmeltspunribbonafterexperiencingtensileload

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a bresutilisedinconcreteundergoingthree-pointbendtesting;bhoneycombstructuresmadefromfoil;cbidirectionalhybridfabric;dfabricmadebyweavinghybridSGMMfoilaramidyarn7ExamplesofproductformswithSGMM

structure

pathwaysforfuturedevelopmentareanticipated.Inpathwayone,asshowninFig.8b,thespinodaldecom-positionisdecoupledfromtheglassdevitri cationprovidingalargeprocesswindow.However,thisneces-sitateslowtemperaturesforspinodaldecompositiontransformation,whichmaynotallowsuf cientdiffusionduringtheinitialcooling.InFig.8c,asecondpathwayisanticipatedwherebythespinodaldecompositionremainscoupledtotheglassdevitri cationtransformation.Inthiscase,thereisanarrowprocesswindowtoformthetargetedSGMMstructuredirectly,butitmaybedevelopedthroughoverquenchingandthencarefulannealingthroughthespinodaldecompositiontransfor-mationwhileavoidingdevitri cationoftheglassmatrix.

Conclusions

TheNanoSteelCompanyhasbeenapplyingBMNasamainstreamtechnologyforamultitudeofrealworld

industrialapplicationsforoveradecade.Speci cnewstrategiesforthecommercialexploitationofthisnovelclassofmaterialshavebeendevelopedonthebasisoftheinherentmaterialpropertiesandresultingchallengesfortheapplication.Forsurfacetechnologyapplications,glassformingalloyscanbeappliedasacoating,andtheresultingmetallicglassstructurecanbedevitri edtodevelophighwear,abrasion,erosionandcorrosionresistanceandenabledbyhighsystemtoughness.Formonolithictechnologyapplications,devitri cationofthemetallicglassprecursormustbeavoided,andthedevelopmentofaspeci cmicrostructuralconstituent,SGMM,isfoundtobeenablingfortheachievementofglobalplasticityandinherentmaterialtoughnessneces-saryforstructuralapplications.Challengesyetremainespeciallyinforminghightensilestrength(.2GPa)thick(.1mm)industrialproductsincorporatingtheSGMM

structure.

athinmonolithic;bpotentialpathway1;cpotentialpathway2

8ModelCCTdiagramstoallowtechnologicalexploitationofSGMMstructuresatincreasingthickness

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