Synthesis of Nanostructured Materials by Mechanical Milling: Problems and Opportunities
Synthesis of Nanostructured Materials by Mechanical Milling: Problems and Opportunities
Synthesis of Nanostructured Materials by Mechanical Milling: Problems and Opportunities
1997
Elsevia Science Ltd
Q 1997 Acta Mdallurgica Inc.
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C. C. Koch
MamialsscienceandEngineeringDepartment
North Carolina State University, Raleigh, N. C. 27695, USA
INTRODUCI’ION
13
14 CC KOCH
26
16 Al \\
16 I
\ Ni
14 ‘ii%
12
10
6i
ot I I I I I
1000 2000 3000 4000 5000
Figure 1. Minimum grain size for nc elements vs. their melting temperatures (open
symbols (10,11,12); fiiled circles (17); Si (13.14); C (15)).
(17) that the minimum nanocrystalline grain sizes for a number of elements milled in a low
energy mill are comparable to those milled in a high energy mill (10,11,12) is contrary to
conclusions made previously on the minimum grain size in milled TiNi (19). The
nanocrystalline grain size was compared after milling TiNi in a high energy Spex shaker mill
and a lower energy vibratory mill. After about 10h in the Spex mill the grain size (determined
by TEM and x-ray line broadening analysis) decreased to about 4-5 nm. At longer milling
times an amorphous structure was observed. Milling for 1OOhin the vibratory mill resulted in a
grain size of about 15 nm. We originally assumed this value represented a saturation to the
minimum grain size obtainable in the lower energy mill. However, in light of the work of
Oleszak and Shingu (17) it is likely that the &. was not obtained at 1OOhin the lower energy
mill and that continued milling may have reduced the grain size further. These new results
suggest that total strain, rather than milling energy or ball-powder-ball collision frequency, is
responsible for determining the nanocrystalline grain size. This is different from amorphization
(20,21) or disordering (22) induced by ball miIling where it appears the energy and frequency of
ball-powder-ball collisions determine the final structures formed in “driven systems”. It is,
however, consistent with observations of nanocrystallites formed by high strain values using
other non-cyclic deformation methods (23-32).
Mill Energy
As pointed out above, in elemental powders, similar ultimate nanocrystalline grain sizes
have been achieved in high energy shaker mills (lOJl.12) and conventional low energy ball
mills (17). These results suggest mill energy per se is not critical to the final microstructure
16 CC KOCH
but of course the kinetics of the process are dependent on the energy, and times for attaining the
same microstructure can be several orders of magnitude longer in the low energy mills than in
high energy mills.
MillingTemperature
Milling temperature has been observed to affect the rate at which the nanocrystalline
structure develops. The milling time at which a given grain size was attained in a TiNi
intermetallic compound was a function of milling tempemnue (19). In this case amorphization
occnrmd at a “critical”grain size of about 4-5 nm so the final nanocrystalline grain size at each
milling temperature could not be determined. Shen and Koch (33) also observed smaller nc
grain sizes in both Cu and Ni milled at -85°C compared to samples milled at room
temperature. For example for Cu d = 26 f 3 nm for room temperature milling and d = 17 f 2
nm for milling at -85°C. Evidence for smaller nanocrystalline grain size at low milling
temperatures was also obtained on the intermetalliccompound CoZr (34).
Alloy Eflects
It has been suggested that the ultimate grain size achievable by milling is determined by
the minimum grain size that can sustain a dislocation pile-up within a grain and by the rate of
recovery during milling (12). To estimate the composition dependence of grain size after
milling one may use the formula suggested by Nieh and Wadsworth (35). The minimum
distance L between dislocations is L = 3Gb/n(l-v)h with shear modulus G. Burgers vector b.
Poisson ratio v, and hardness h. If this is indeed related to the formation of a minimum nc
grain size, then this nc grain size is inversely proportional to hardness. In fact, a decreasing nc
grain size with solute concentration is observed in nc alloy systems which exhibit solid
solution hardening such as Cu(Fe) (36,37). Ti(Cu), Nb(Cu), Cu(Ni), and Cu(Co) (37). Also
consistent with this is the essentially constant nc grain size in Ni(Co) where hardness does not
change significantly (33) and the increased grain size in nc Ni(Cu), Fe(Cu), and Cr(Cu) which
exhibit a solid solution softening effect (36).
From evidence of the atomic level lattice strain and the stored enthalpy as a function of
reciprocal grain size (or milling time) it was concluded that two different regimes can be
distinguished i.e. dislocation versus grain boundary deformation mechanisms (9). The lattice
strain in the fee elements studied by Eckert et al (12). (milled in a high energy shaker mill) was
found to increase continuously with decreasing grain size and reached a maximum value at the
smallest grain size. This is in contrast to the earlier observation on Ru and AlRu which
indicated a maximum in strain vs. l/d (10) and the recent study of Olesxakand Shingu (17) in a
low energy mill which also shows a broad maximum in strain vs. l/d for a number of elements
including several fee elements. The lattice strain values availablefrom the literature are plotted
against reciprocal grain size, l/d, in Figure 2. With the exception of Ru, the data for
l.l_
l.O_
0.9_
0.6_
k
3 0.7,
= 0.6_
2
z 0.6_
0.4 _
0.3 -
0.2 -
0.1 -
l/d (nm-1)
Figure 2. Lattice strain vs. reciprocal grain size. (Al, Ni, Fe, W (17); Ru (10); Pd (12); Ti
(56)).
increasing lattice strain with l/d appear to fall on a common relatively narrow band before
decreasing from the maximum strain values. However, these data are from several groups
using mills with various energy levels and possible differences in milling temperature. It has
been demonstrated (33) that lower milling temperature resulted in larger values for lattice strain
for Cu and Ni. However, the data from the low energy mill (17) should be self-consistent and
18 CC Kow
exhibits interesting behavior. That is, the strain rises with decrea&g grain sire, reaches a
maximum, and then decreases to low values for the smallest nanocrystalline grain sizes. A
maximum in strain with l/d was explained previously by either a change in deformation
mechanism from dislocation generation and movement to grain botmdary sliding, grain rotation
(lo), or, in brittle intermetallics to fmctnre after the strain maximum is reached (10,38). The
f~tmechanismisunlikelyinthiscasesincethencgrainsizecontinuestodecreaseaftertbe
strain maximum is reached and grahr boundary sliding, grain rotation presumably cauuot result
in grain size reduction. lhere is no clear evidence at present in the elements for the fracture
mechauism which would also presumably result in a finer particulate distribution.
Additional information to help explain the mechankm of nanocrystallite formation comes
from measurements of stored enthalpy. Maxima in stored enthalpy vs. l/d are typically
observed (10,12,17). However, the maximum in stored entbalpy is usually found at smaller
grain sixes than the strain maximum, as illustrated for W (17) in Figure 3. Here the maximum
insaainoccursatd=8.3nmwhilethemaximuminstoredenthalpyisatd=5.5nm. Several
suggestions have been offered to explain the maxima in stored enthalpy with l/d including
decreasing strain (10,17) or impurity pick-up during milling (10). The latter is unlikely for the
samples from low energy milling (17) where metallic impurity contmnination is negligible. It
is stated that the stored enthalpy comes mainly from grain boundaries (12.17) and grain
boundary strains. Stress relaxation may be responsible for the maxima (17) but, as above, the
ti and stored enthalpy maxhua don’tnecessarilycoincide.
0.1
l/d (nm-1)
Figure 3. Stored enthalpy (AI-I)and lattice strain (c) vs. reciprocal gmin size for w (17).
microscopy (TEM) deformation studies have been carried out on UC thin film Au or Ag
specimens (39,40,41). Samples with 100 mu grain sixes exhibited the usual deformation
mechanisms including extensive dislocation activity, ligament formation, and ductile fracture
within a given grain. However, 10 nm grain size samples did not exhibit dislocations within
the grains. Instead, evidence was seen for grain boundary rotation and sliding (which can result
in 3096 strains at the crack tip) as well as opening of small pores at grain boundary triple
junctions. Such studies and their analysis should help us better understaud the formation of
nanocrystalline structures by mechanical attrition.
Most of the studies of the microstructural evolution of a nc structure during ball milling
have been carried out on single phase mate&Is such as elements or compounds. However,
nanocrystalline grains are also observed during the mechanical alloying (MA) of multi-
component powders. Klassen et al (42) followed the phase formation and microstructural
development during MA of Ti and Al powder blends of overall composition Ti+lz. TEM
revealed mmocrystalli.ne grains of the partiahy otdered L12 phase with a crystalhte size of 10-30
nm in the alloy layers at the interface between Ti and Al lamellae at very early stages of the
milling process. The alloy phase which develops between the pure powder components
consists of nc grains presumably because of the multiple nucleation events and the slow
growth which occur at relatively low temperahues (lOO-200°C above ambient) during milling.
Trudeau et al (38) prepared nc FeTi by both MA of elemental Fe and Ti powders and MM of
FeTi compound powders. The grain size of MM FeTi steadily decreases with milling time
while that for MA FeJTi fust increases and then decreases to values essentially identical to
those for the MM samples.
Crystallixation has been observed by ball milling certain amorphous materials and
nanocrystalline phases often result. In some cases, the crystallization is either clearly due to
impurity pick-up changing the composition and therefore crysWixation tempeaature Tx of the
alloy (43) or to large local temperature increases to above Tx in energetic mills (eg. 44).
However, there are other examples, first cited by Trudeau et al (45). which are not simply
explained by the above two effects. Trudeau and co-workers (45,46,47) and Huang et al (48)
have observed crystallization induced by ball milling in several Fe-base amorphous alloys in
this regard. Explanations offered for this crys&lhzation include: enhancement of diffusion by
the milling deformation which allows decomposition of the metastable amorphous phase (49);
local temperature rises associated with shear bands due to bending as well as wear processes
(48). This phenomenon of crystallization by ball milling in certain amorphous alloys (it is
composition dependent) is still not well understood, but may be related to the observation of
nanocrystal formation within shear bands of melt spun Al-based amorphous alloys induced by
bending the ribbon samples (50). It was suggested this nanocrystallixation is due to local
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atomic rearrangements within the shear bands which exhibit enormous plastic strain. Such
atom rearrangement depends on the topological order and the chemical bonding of the
amorphous alloy.
A serious problem with the milling of fine powders is the potential for significant
contamination from the milling media (balls and vial) or atmosphere. If steel balls and
containers are used, iron contamination can be a problem. It is most serious for the highly
energetic mills, eg. the Spex shaker mill, and depends on the mechanical behavior of the
powder being milled as well as its chemical affinity for the milling media. For example,
milling Ni to attain the minimum nc graht size in a Spex mill resulted in Fe contamination of
13 at.%, while the Fe contamination in nc Cu similarly milled is only 5 1 at.% (37). Lower
energy mills result is much less, often negligible, Fe contamination. Other milling media,
such as tungsten carbide or ceramics, can be used but contamination Tom such media is also
possible. Surfactants (process control agents) may also be used to minimize contamination.
Mishurda et al (51) studied the effect of several process control agents on Fe and interstitial
element contamhnttion during ball milling of prealloyed Ti&lssWz powders. Boric acid and
borox were quite effective in reducing Fe contamination (from 1.04 wt.96 to 0.44 wt.% and
0.26 wt.%, respectively). Using a “seasoned” vial - i.e. media coated with the alloy powder
- resulted in very low values for Fe contamination of 0.06 wt.% (with boric acid) and 0.09
wt.% (with borax). Interstitial contamination can be controlled by milling and subsequent
powder handling in a pure inert gas atmosphere with care taken that the milling vial is leak-fme
during processing. Goodwin and Ward-Close (52) have recently reported on a new production
scale mill which cau process reactive materials such as Ti-Al alloys with essentially no
metallic or interstitial element contamination. Such devices should generate increased interest
in the use of mechanical attrition for synthesis of nc materials.
Powder consolidation to theoretical density of nc materials prepared by mechanical
attrition without signikant coarsening is necessary for many properties eg. mechanical
behavior. There is not room in this paper to adequately review the increasing effort in this
area. However, a number of successes have been documented by both conventional, eg. hot
isostatic pressing (HIP) (53) and dynamic, eg., explosive compaction (54). While theoretical
densities have been achieved in many studies, tensile deformation has revealed that interparticle
debonding can still be a problem (55). Additional work is needed on this important problem.
ACKNOWLRDGRMRNTS
The author wishes to thank Prof. C. Suryanarayana for his unpublished data on the effect
of surfactauts on contamination in T&Al alloys. Thanks to T. Malow and T. D. Shen for
useful discussions. The author’s work described in this paper was supported by the U. S.
National Science Foundation under grant No. DMR-9508797.
SYNTHESIS
OF NANOSTRUCTURED
MATERIALS
BYMECHANGAL
MILLING 21
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