Combustion synthesis in nanostructured reactive systems

Phase Formation during the Synthesis of the MAB Phase from Mo-Al-B Mixtures in the Thermal Explosion Mode

This work focused on the production of the MoAlB MAB phase through self-propagating, high-temperature synthesis in the thermal explosion mode. The influence of the method of a Mo-Al-B-powder reaction mixture preparation on the combustion temperature, mechanism, and stages of the MAB phase formation in the combustion process was investigated. The combustion temperatures of the mixtures obtained in the rotary ball mill and high-speed planetary ball mill were 1234 and 992 °C, respectively. The formation of intermediate compounds Mo3Al8 and α-MoB in the combustion front, along with MoAlB, was established using the time-resolved X-ray diffraction method. In the case of the mixture prepared in a ball mill, the primary interaction in the combustion front occurred through the Al melt, and in the case of using a planetary mill, solid-phase reactions played an important role. The mechanical activation of the mixture in a planetary mill also accelerated the processes of phase formation. The method of a reaction mixture preparation has virtually no effect on the MoAlB MAB phase content in combustion products (92-94%), but it does affect their structure. The synthesis products have a lamellar structure composed of MAB grains with a thickness of ~0.4 μm and a length of ~2-10 μm.

Nanoscale Dispersion of Carbon Nanotubes in a Metal Matrix to Boost Thermal and Electrical Conductivity via Facile Ball Milling Techniques

Carbon nanotube (CNT)/metal composites have attracted much attention due to their enhanced electrical and thermal performance. How to achieve the scalable fabrication of composites with efficient dispersion of CNTs to boost their performance remains a challenge for their wide realistic applications. Herein, the nanoscale dispersion of CNTs in the Stannum (Sn) matrix to boost thermal and electrical conductivity via facile ball milling techniques was demonstrated. The results revealed that CNTs were tightly attached to metal Sn, resulting in a much lower resistivity than that of bare Sn. The resistivity of Sn with 1 wt.% and 2 wt.% CNTs was 0.087 mΩ·cm and 0.056 mΩ·cm, respectively. The theoretical calculation showed that there was an electronic state near the Fermi level, suggesting its electrical conductivity had been improved to a certain extent. In addition, the thermal conductivity of Sn with 2 wt.% CNTs was 1.255 W·m-1·K-1. Moreover, Young's modulus of the composites with CNTs mass fraction of 10 wt.% had low values (0.933 MPa) under low strain conditions, indicating the composite shows good potential for various applications with different flexible requirements. The good electrical and thermal conductive CNT networks were formed in the metal matrix via facile ball milling techniques. This strategy can provide guidance for designing high-performance metal samples and holds a broad application potential in electronic packaging and other fields.

Preparation of Mesoporous Si Nanoparticles by Magnesiothermic Reduction for the Enhanced Reactivity

In this study, mesoporous silicon nanoparticles (M-Si) were successfully prepared by a magnesiothermic reduction of mesoporous silica nanoparticles, which were synthesized by a templated sol-gel method and used as the precursors. M-Si exhibited a uniform size distribution with an average diameter of about 160 nm. The measured BET surface area was 93.0 m² g^-1, and the average pore size calculated by the BJH method was 16 nm. The large internal surface area provides rich reaction sites, resulting in unique interfacial properties and reduced mass diffusion limitations. The mechanism of the magnesiothermic reduction process was discussed. The reactivity of prepared M-Si was compared with that of commercially available non-porous Si nanopowder (with the average diameter of about 30 nm) by performing simultaneous thermogravimetry and differential scanning calorimetry in the air. The results showed that the reaction onset temperature indicated by weight gain was advanced from 772 °C to 468 °C, indicating the promising potential of M-Si as fuel for metastable intermolecular composites.

The Synthesis of Cu–Mn–Al Mixed-Oxide Combustion Catalysts by Co-Precipitation in the Presence of Starch: A Comparison of NaOH with Organic Precipitants

Cu–Mn mixed oxides are well known as active combustion catalysts. The common method for their synthesis is based on co-precipitation, with NaOH as a precipitant, and is burdened with the possibility of introducing undesired Na contamination. This work describes the use of two organic bases, tetrabutylammonium hydroxide and choline hydroxide, as precipitating agents in a novel alkali-free route for Cu–Mn–Al catalyst synthesis. To obtain fine crystalline precursors, which are considered advantageous for the preparation of active catalysts, co-precipitation was carried out in the presence of starch gel. Reference materials prepared with NaOH in the absence of starch were also obtained. Mixed oxides were produced by calcination at 450 °C. The precursors contained MnCO3 doped with Cu and Al, and an admixture of amorphous phases. Those prepared in the presence of starch were less crystalline and retained biopolymer residues. The combustion of these residues during calcination enhanced the formation of larger amounts of the Cu1.5Mn1.5O4 spinel phase, with better crystallinity in comparison to catalysts prepared from conventionally synthesized precursors. Tests of toluene combustion demonstrated that the catalysts prepared with starch performed better than those obtained in starch-free syntheses, and that the mixed oxides obtained by the alkali-free route were more active than catalysts prepared with NaOH. Catalytic data are discussed in terms of property–performance relationships.

Novel Pathway for the Combustion Synthesis and Consolidation of Boron Carbide

A novel pathway for the magnesiothermic reduction of boron oxide and magnesium dodecaboride (MgB12) in the presence of carbon by a self-propagating high-temperature synthesis method was proposed that was aimed at the direct preparation of boron carbide nanopowder. The combined utilization of two boron sources, boron oxide and MgB12, allowed tailoring the overall caloric effect of the process, increasing the yield of the target product and lessening the laborious leaching process. In addition, it is an alternative way to utilize magnesium borides, which are inevitable side products at boron production. Multivariate thermodynamic calculations performed in the B2O3-MgB12-Mg-C system allowed estimating equilibrium compositions of the products and deducing the optimum composition of the initial mixture for obtaining B4C. For the latter, the adiabatic temperature (Tad) is 2100 °C, which is theoretically enough for the implementation of the self-propagating reaction. The combustion reaction was shown to be extremely sensitive to the initial mixture composition, external pressure, as well as sample diameter (heat losses). It proceeds in self-oscillatory mode and leads to the product of a layered macrostructure. The combustion product was then consolidated by the spark plasma sintering technique at different conditions. Vickers microhardness was measured, and the wear erosion behavior was examined. The variation in lattice parameters of boron carbide reflected the influence of synthesis, sintering and erosion conditions on the ordering/disordering of the boron carbide structure.

Materials Development Using High-Energy Ball Milling: A Review Dedicated to the Memory of M.A. Korchagin

High-energy ball milling (HEBM) of powders is a complex process involving mixing, morphology changes, generation and evolution of defects of the crystalline lattice, and formation of new phases. This review is dedicated to the memory of our colleague, Prof. Michail A. Korchagin (1946–2021), and aims to highlight his works on the synthesis of materials by self-propagating high-temperature synthesis (SHS) and thermal explosion (TE) in HEBM mixtures as important contributions to the development of powder technology. We review results obtained by our group, including those obtained in collaboration with other researchers. We show the applicability of the HEBM mixtures for the synthesis of powder products and the fabrication of bulk materials and coatings. HEBM influences the parameters of synthesis as well as the structure, phase composition, phase distribution (in composites), and grain size of the products. The microstructural features of the products of synthesis conducted using the HEBM precursors are dramatically different from those of the products formed from non-milled mixtures. HEBM powders are also suitable as feedstock materials for depositing coatings by thermal spraying. The emerging applications of HEBM powders and future research directions in this area are discussed.

Influence of Initial Temperature and Convective Heat Loss on the Self-Propagating Reaction in Al/Ni Multilayer Foils

A two-dimensional numerical model for self-propagating reactions in Al/Ni multilayer foils was developed. It was used to study thermal properties, convective heat loss, and the effect of initial temperature on the self-propagating reaction in Al/Ni multilayer foils. For model adjustments by experimental results, these Al/Ni multilayer foils were fabricated by the magnetron sputtering technique with a 1:1 atomic ratio. Heat of reaction of the fabricated foils was determined employing Differential Scanning Calorimetry (DSC). Self-propagating reaction was initiated by an electrical spark on the surface of the foils. The movement of the reaction front was recorded with a high-speed camera. Activation energy is fitted with these velocity data from the high-speed camera to adjust the numerical model. Calculated reaction front temperature of the self-propagating reaction was compared with the temperature obtained by time-resolved pyrometer measurements. X-ray diffraction results confirmed that all reactants reacted and formed a B2 NiAl phase. Finally, it is predicted that (1) increasing thermal conductivity of the final product increases the reaction front velocity; (2) effect of heat convection losses on reaction characteristics is insignificant, e.g., the foils can maintain their characteristics in water; and (3) with increasing initial temperature of the foils, the reaction front velocity and the reaction temperature increased.

Progress in Preparation of ZrB2 Nanopowders Based on Traditional Solid-State Synthesis

ZrB₂ is of particular interest among ultra-high temperature ceramics because it exhibits excellent thermal resistance at high temperature, as well as chemical stability, high hardness, low cost, and good electrical and thermal conductivity, which meet the requirements of high-temperature components of hyper-sonic aircraft in extreme environments. As raw materials and basic units of ultra-high temperature ceramics and their composites, ZrB₂ powders provide an important way for researchers to improve material properties and explore new properties by way of synthesis design and innovation. In recent years, the development of ZrB₂ powders’ synthesis method has broken through the classification of traditional solid-phase method, liquid-phase method, and gas-phase method, and there is a trend of integration of them. The present review covers the most important methods used in ZrB₂ nanopowder synthesis, focusing on the solid-phase synthesis and its improved process, including modified self-propagating high-temperature synthesis, solution-derived precursor method, and plasma-enhanced exothermic reaction. Specific examples and strategies in synthesis of ZrB₂ nano powders are introduced, followed by challenges and the perspectives on future directions. The integration of various synthesis methods, the combination of different material components, and the connection between synthesis and its subsequent application process is the trend of development in the future.

Hollow porous BiOCl microspheres assembled with single layer of nanocrystals: spray solution combustion synthesis and the enhanced photocatalytic properties

The hollow porous microspheres assembled with BiOCl nanocrystals were successfully synthesized via a facile spray solution combustion synthesis method. The microstructure, morphology, absorbance, optical properties of the samples were investigated in detail. The results show that hollow porous BiOCl microspheres have narrow band gaps (2.66-2.71 eV), and the degradation rate of rhodamine B (RhB) can reach 98% under visible light irradiation for 60 min. Furthermore, the mechanism of the photocatalytic degradation of RhB was proposed through the experiment of trapping active species. This excellent photocatalytic property can be ascribed to the larger specific surface area and the special microstructure.

Corrosion and transformation of solution combustion synthesized Co, Ni and CoNi nanoparticles in synthetic freshwater with and without natural organic matter

Pure metallic Co, Ni, and their bimetallic compositions of Co3Ni, CoNi, and CoNi3 nanomaterials were prepared by solution combustion synthesis. Microstructure, phase composition, and crystalline structure of these nanoparticles (NPs) were characterized along with studies of their corrosion and dissolution properties in synthetic freshwater with and without natural organic matter (NOM). The nanomaterials consisted of aggregates of fine NPs (3-30 nm) of almost pure metallic and bimetallic crystal phases with a thin surface oxide covered by a thin carbon shell. The nanomaterials were characterized by BET surface areas ranging from ~ 1 to 8 m2/g for the Ni and Co NPs, to 22.93 m2/g, 14.86 m2/g, and 10.53 m2/g for the Co3Ni, CoNi, CoNi3 NPs, respectively. More Co and Ni were released from the bimetallic NPs compared with the pure metals although their corrosion current densities were lower. In contrast to findings for the pure metal NPs, the presence of NOM increased the release of Co and Ni from the bimetallic NPs in freshwater compared to freshwater only even though its presence reduced the corrosion rate (current density). It was shown that the properties of the bimetallic nanomaterials were influenced by multiple factors such as their composition, including carbon shell, type of surface oxides, and the entropy of mixing.

Ethanol electrooxidation on high-performance mesoporous ZnFe2O4-supported palladium nanoparticles

As a catalyst for the electrooxidation of ethanol, a well-dispersed mesoporous ZnFe₂O₄ powder (ZnFe₂O₄MP) as a support for Pd nanoparticles (PdNPs) was fabricated using solution combustion synthesis, which is an easy and environmentally friendly method.

X-ray nanotomography and focused-ion-beam sectioning for quantitative three-dimensional analysis of nanocomposites

Knowing the relationship between three-dimensional structure and properties is paramount for complete understanding of material behavior. In this work, the internal nanostructure of micrometer-size (∼10 µm) composite Ni/Al particles was analyzed using two different approaches. The first technique, synchrotron-based X-ray nanotomography, is a nondestructive method that can attain resolutions of tens of nanometers. The second is a destructive technique with sub-nanometer resolution utilizing scanning electron microscopy combined with an ion beam and `slice and view' analysis, where the sample is repeatedly milled and imaged. The obtained results suggest that both techniques allow for an accurate characterization of the larger-scale structures, while differences exist in the characterization of the smallest features. Using the Monte Carlo method, the effective resolution of the X-ray nanotomography technique was determined to be ∼48 nm, while focused-ion-beam sectioning with `slice and view' analysis was ∼5 nm.