Progress in High Throughput Fabrication and Characterization of Metal Matrix Composites

doi:10.11900/0412.1961.2018.00307

Acta Metall Sin

2019, Vol. 55

Issue (1): 109-125 DOI: 10.11900/0412.1961.2018.00307

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Progress in High Throughput Fabrication and Characterization of Metal Matrix Composites

Xuexi ZHANG¹, Zhong ZHENG¹, Ying GAO², Lin GENG¹(

)

1 School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, China
2 Institute of Spacecraft System Engineering, Beijing 100086, China

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Xuexi ZHANG, Zhong ZHENG, Ying GAO, Lin GENG. Progress in High Throughput Fabrication and Characterization of Metal Matrix Composites. Acta Metall Sin, 2019, 55(1): 109-125.

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Abstract

The "material genetic engineering" plan, based on the large data, is to investigate the high throughput design, fabrication and characterization techniques with the aim to shift the material research from traditional mode to high throughput mode with low cost and fast response speed, and to accelerate the research and development of new materials and achieve the goal of "double reduction halves". As the metal matrix composites (MMCs) exhibit multi-components and a thermodynamically non-equilibrium state during fabrication, some key issues occur and need to be addressed including: (1) for high throughput fabrication, currently developed high throughput technologies based on thermodynamically equilibrium conditions, such as spray printing and multi-node diffusion methods, are not applicable for MMCs; (2) for high throughput characterization, there is a lack of multi- dimensional, field and scale acquisition technique for the composition, morphology, microstructure and property of MMCs. In order to solve these problems, the progress on the research and development of high throughput fabrication and characterization techniques of MMCs was reviewed, especially, in the field of gradient reinforced MMCs and their high throughput combination characterization methods, which may promote the application of high throughput fabrication and characterization techniques in MMCs. Finally, the bottlenecks and prospects in the high throughput fabrication and characterization of MM Cs are proposed.

Key words: metal matrix composites (MMCs) high throughput fabrication high throughput characterization gradient metal matrix composites (GMMCs) research status

Received: 03 July 2018

ZTFLH:

TG457

Fund: Supported by National Key Research and Development Program of China (No.2017YFB0703103)

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https://www.ams.org.cn/EN/10.11900/0412.1961.2018.00307 OR https://www.ams.org.cn/EN/Y2019/V55/I1/109

Fig.1 Comparison of two kinds of material development modes
(a) traditional single-step mode (b) high throughput mode

Technique	Application area	Advantage	Ref.
Co-deposition method	High throughput preparation of multi-component alloys	Precise control of composition and gradient distribution	[4,33]
Discrete template coating	Doping of epitaxial films with transition metals and synthesis of sulfuric semiconductor materials	Uniform, controllable and wide span composition and unlimited number of components	[4,5]
Continuous template coating	Preparation of dielectric materials and study of multi-alloy phase diagrams	Controllable component distribution and continuous linear distribution states	[35,36]
Spray printing	Preparing combined ceramic specimens	Repeated delivery of multiple components in a fast and precise way	[9~11]
Microfluidic structure method	Preparation and characterization of trace amount of catalysts	Fast response to stress, helpful in conducting efficient characterization	[37~39]
Multiple diffusion nodes	Drawing three element phase diagrams and quickly screening materials	Gaining alloys with gradient composition changes	[6~8]
Microelectromechani-cal structure	Studying mechanical properties and transformation enthalpies of alloys	Quickly examine many samples, high compatibility with high-throughput experiments	[16,17,21]
Chemical bath deposition	Preparation of array film materials	High efficiency for films, suitable for multi-component systems	[40]
Magnetron sputtering	Preparing film samples with various elements and contents	High efficiency in preparing multi-component films	[14]
Multi-flow pulse laser deposition	High-throughput synthesis of monolayer and multilayer thin films	Composite films have uniform composition and high performance	[41]
Direct atomization of oligomers	High throughput preparation of nano-scale hybrid membranes	Low defect density in nano hybrid membranes and high fabrication efficiency	[42]
Cooling rate controlling	Studying correlation between cooling rate and properties of polycrystalline nickel based alloys	High efficiently characterizing the correlation between microstructures and properties	[43]
High throughput sintering diffusion	Synthesis of magnetic materials	Study of the new phases and equilibrium phases in alloys	[44]
Linear friction welding	Fabrication of alloys with gradient element distribution state	Establishing the relationship among element content, microstructure and properties	[45]
Focused ion beam machining	Any area of interest can be collected in many kinds of materials	Preparing micron- or nano-samples for direct analysis of microstructure and properties	[46]
Laser additive manufacturing	Preparing alloys, composites and micron- or nano-structured materials	High precision in dimensions and wide range of application	[47~50]

Table 1 High throughput preparation techniques, applications and advantages in metal materials^{[4~11,14,16,17,21,33,35~50]}

Table 2 High throughput preparation methods and applications in metal matrix composites (MMCs)^{[12,13,51~54]}

Fig.2 SEM images of interface pillars before (a~c) and after (d~f) compressive deformation in a SiC_p/Al composite^[57]
(a, d) diameter 2.2 μm (b, e) diameter 1.0 μm (c, f) diameter 0.5 μm

Fig.3 Preparation of graphene gradient distributed graphene-Al composite powder compacts by self-assembly method
(a) schematic of the preparation setup
(b) gradient distribution of graphene in the powder compact
(c) graphene on an Al powder (GO—graphene oxide)

Fig.4 Processing and microstructure of GNP/Al composite wires prepared by multistep drawing (GNP—graphene nano-platelet)^[59]

Fig.5 Preparation schematic of the composite wires by hot extrusion and drawing using layered MMCs

Fig.6 SEM images of the network structure in TiC_p/Ti6Al4V composite with increasing magnifications from (a) to (d) (Inset shows a honeycomb structure)^[60]

Fig.7 High throughput fabrication technique of network titanium composites by powder metallurgy
(a) 32 samples in a composite layer separated by soft graphite paper
(b) multi-composite layers separated by hard graphite platelet

Fig.8 A high throughput technique for aluminum composites based on pressureless infiltration
(a) a unit in the composite array (b) multi-unit array (c) composite samples in the unit

Fig.9 Micro-sample arrays of a composite material fabricated by focused ion beam (FIB)

Technique	Applicable area	Reference
X-ray diffraction (XRD)	Phase information	[65]
Atomic force microscopy (AFM)	Surface roughness and three-dimensional image	[66]
Scanning probe	Characterizing electro-catalysts and electrodes with gradient component distribution	[67~69]
X-ray photoelectron spectroscopy	Quantitative analysis of surface compositions and functional groups	[70,71]
Secondary ion mass spectroscopy	Qualitative analysis of the surface compositions (acting as supplement of X-ray photoelectron spectrum using molecular ion segment spectrum)	[70,71]
In situ XRD	The evolution of the crystal structure in the stress field, temperature field and combination of these fields	[72,73]
X-ray absorption near edge spectrum	High resolution characterization of the large volume 2D and 3D morphologies (tens of nanometers) and chemical compositions	[74,75]
Neutron diffraction technique	Three dimensional spatial distribution of texture evolution, microstructure and residual stress in bulk materials	[76~78]
Decalescent microwave probe microscopy	Characterization of electrical (superconductivity, conductivity, dielectric constant etc.) and magnetic (magnetic susceptibility and spin resonance etc.) properties	[79,80]
Nano scanning calorimetry	Characterization of the thermodynamic parameters such as enthalpy, heat capacity and phase transition temperature	[21~23]
X-ray fluorescence technique	Chemical composition, elemental analysis and identification	[65]
Near edge X-ray absorption spectroscopy	Characterization of the element valence state	[65]
Ultraviolet-visible spectroscopy	The absorbance characteristics and molecular conjugation analysis	[31]
Infrared emission imaging	Screening organic and inorganic materials and hydrogen storage metal materials	[81]
Mass spectrometry	Mass ratio analysis and compound/molecular identification	[82]
Gas chromatography	Separation and identification of the complex	[83]
Resonance enhanced multiphoton ionization	Study of the spectrum and molecular rotation information of atoms and small molecules	[31]
In situ X-ray absorption spectroscopy	Characterization of the chemical evolution	[74,84]
In situ X-ray binding mass spectrometry	Characterization of the thermal stability	[74]
Cantilever beam array technology	Thermomechanical behavior analysis of thin films with wide component gradient	[85]
Nuclear magnetic resonance spectrum	Analyzing small stray magnetic field and relaxation phenomena of small magnets	[86,87]
Photoacoustic technology	Identification and characterization of parallel catalytic products	[88]

Table 3 Characterization techniques and applications for the microstructure of MMCs^{[21~23,31,65~88]}

Technique	Application area	Reference
Ion beam analysis	Automatic detection for abundant samples; promising for high throughput detection	[89]
High throughput transmission technology	Characterization of composition phases, development of new materials and construction of phase diagrams	[25]
In situ transmission electron microscopy (TEM)	Simultaneous in-situ imaging and electrical measurement, and observation of grain growth process induced by electric current	[90]
Differential aperture XRD technique	Low X-ray energy, sub-micron size of the spot, fairly high spatial resolution, and useful for analyzing deformation microstructures	[91]
Three dimensional XRD technique	High spatial and angular resolutions, suitable for studying recrystallization growth process	[24]
Automatic scanning nano-indentation technology	Mechanical properties of small volume materials, including strength and modulus	[18,85,92~94]
Optical microscopy combined with differential interference imaging	Three-dimensional surface topography and height information at re-melting lines	[26~28]
Laser induced fluorescence imaging technology	High throughput in-situ screening with micron scale spatial resolution and millisecond time resolution	[95]
Scanning X-ray fluorescence microscopy	Characterization of the element composition and crystal structure	[96]
High throughput screening sensor	A new high throughput characterization method for a variety of elements	[97]
In-situ tensile combined with digital image correlation (DIC)	Calculation of the local strain distribution using different strain images, with high spatial resolution and the stretching rate	[29]
Scanning electron microscopy (SEM) combined with DIC	Precise calculation of image gradients, strain and deformation fields	[30]
Femtosecond pulse laser technology	Imaging of the time domain thermal reflection for phase formation, with spatial resolution of 1 μm and test rate of 10000 pointsh^-1	[15]
Micromechanical testing technology	High throughput mechanical properties tests, potential for automatic micro area tests	[16~20]
In-situ statistical distribution analysis technique	High throughput screening and validation of material design, modification and optimization	[98~101]
Multi-dimensional and multi-scale high throughput characterization	Three-dimensional crystallographic orientation and reconstruction; material structures; three dimensional X-ray diffraction etc.	[102]
Microwave microscopy combined with AFM	High spatial resolution characterization of the dielectric/ferroelectric materials	[103]
Micro area electrochemical measurement technology	High positioning accuracy (resolution 50 nm) and automatic programming tests for high density composite material samples	[33]

Table 4 High throughput characterizing techniques and applications of metal matrix composites (MMCs)^{[15~20,24~30,33,85,89~103]}

Fig.10 Schematic of simultaneous characterization techniques for the microstructure, deformation and mechanical properties of layered MMCs (ND—normal direction, EBSD—electron backscattered diffraction^[29]

Fig.11 Modified X-ray diffractometer and its application (CCD—charge coupled device)^[104]
(a) geometric structure of X-ray beam
(b) structure of the XRD configuration in the invert space
(c) configuration diagram of the concurrent XRD
(d) diffraction intensity of [(SrTiO₃)_n/(SrTiO₃)_n]₃₀ (n=12,14,

?

, 30) superlattice

Fig.12 In-situ characterization technique based on synchrotron radiation for electrode composites^[105]
(a) in-situ time-resolved (TR) XRD (b) in-situ TR-XRD combined mass spectroscopy
(c) in-situ X-ray absorption spectroscopy (d) in-situ transmission X-ray microscopy

Fig.13 The principle (a) and accuracy analysis (b) of time-domain detection of probe test laser beam deflection (TD-PBD) (CTE—coefficient of thermal expansion)^[106]

Fig.14 High throughput characterization platform based on SEM for MMCs

Fig.15 High throughput characterization platform based on X-ray synchrotron radiation for (MMCs)
(a) schematic of the whole platform
(b) assembly of the three dimensional and loading modules including 1—temperature and loading module, 2—vacuum module, 3—remote control module

Fig.16 Schematics of the rapid characterization of array samples
(a) an array sample containing sixteen samples

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