Full length articleMechanics and energetics modeling of ball-milled metal foil and particle structures
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Introduction and prior work
Over the past three decades the materials community has made groundbreaking progress in mechano-chemistry research addressing mechanical alloying (MA) of metals and non-metallic materials. On the one hand, this has enabled a variety of transformative and impactful applications, as e.g. in ball milling (BM) fabrication of bimetallic and multi-material micro- and nano-structures, such as of nickel, iron and titanium aluminides etc., used for self-propagating high-temperature synthesis [1]. Such
Model framework and assumptions
Morphological observation of ball-milled bimetallic particulate sections reveals a multi-scale self-similar microstructure (Fig. 1a) composed of lamellar network (branching tree) formations, which have evolved by deformation of globular agglomerates (Apollonian packs) of the original metal powders (Fig. 1b). This fractal microstructure transformation during the BM process can be described by the deformation and joining of these individual monometallic particle domains as warped ellipsoid (WE)
Calibration tests on foils
Laboratory testing of the model is performed on a low-energy planetary BM system (Fritsch Mono Mill Pulverisette 6) in nitrogen inert atmosphere, with five balls of Rball = 5 mm radius in a rounded cylindrical 80 ml vial rotating at 300 rpm and made of stainless steel. The bimetallic Al-Ni reactive system is employed for model calibration and validation, with material properties shown in Table 1 [45], and with ball energetics described by s = 1 m/s in Eq. (1) (Fig. 5). In addition, the contact
Conclusions
The computational model established in this article introduces several original contributions to the wealthy literature of MA simulation. These include: the warped ellipsoid (WE) as universal domain primitive, from spheroidal powders to lamellar particulate layers; implementation of experimentally calibrated kinetic theory-based motion of the ball impactors; ideal elastic-to-inelastic dissipative energetic material transformations of surface friction slip and bulk Castigliano deformation;
Acknowledgment
This research was supported in part by a Khalifa University Internal Research Fund (Level 1) award and by the US Department of Energy, National Nuclear Security Administration under Award Number DENA0002377. KU students Khatera Farzanah, Mira Hassan and Rauda Al Mheiri are gratefully acknowledged for laboratory work in calibration tests. The authors also wish to thankfully acknowledge particularly constructive suggestions on this article context and references by one anonymous reviewer.
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