Development and evaluation of die and container materials

X = 0.75 Beta prime Sialon (a silicon aluminum oxynitride) and Sibeon (silicon beryllium oxynitride) are promising die materials. In sessile drop tests in contact with molten silicon, beryllium contamination was less than ppm and aluminum contamination 50 ppm. A shaping die of the Sialon material was successfully fabricated. Dry milling studies for the preparation of Si3N4-Al2O3-ALN mixtures were performed with butanol, acetic anhydride, oleic acid, and triethanolamine milling aids. Optimum mixing was achieved with 0.15 percent triethanolamine using a milling time of 8 hours. Preliminary evaluation of Sibeon materials indicates that they are more resistent to molten silicon attack than Sialon. Silicon contamination from the beryllium was less than aluminum contamination even though the aluminum impurity level in the Sibeon was only 450 to 1300 ppm. Work designed to produce an aluminum-free Sibeon is described

Improved toughness of refractory compounds

The concept of grain-boundary-engineering through elimination of the grain-boundary silicate phase in silicon nitride was developed. The process involved removal of the silica from the nitride powder via a thermal treatment coupled with the use of nitride additives to compensate the remaining oxygen. Magnesium and aluminum nitrides are found to be the most effective additive for use as oxygen compensators. Strength decreases at elevated temperatures are not observed in the alumina containing material. The creep rate of a dual additive sialon composition was two orders of magnitude lower at 1400 C than commercial silicon nitride. A cursory analysis of the creep mechanism indicate that grain-boundary sliding is avoided through elimination of the grain-boundary silicate phase

Two-phase densification of cohesive granular aggregates

When poured into a container, cohesive granular materials form low-density, open granular aggregates. If pressed upon with a ram, these aggregates densify by particle rearrangement. Here we introduce experimental evidence to the effect that particle rearrangement is a spatially heterogeneous phenomenon, which occurs in the form of a phase transformation between two configurational phases of the granular aggregate. We then show that the energy landscape associated with particle rearrangement is consistent with our interpretation of the experimental results. Besides affording insight into the physics of the granular state, our conclusions are relevant to many engineering processes and natural phenomena.Comment: 7 pages, 3 figure

Neutralization of Chloride in Concrete

DOT-FH-11-8133This study was concerned with one solution to the problem of deterioration of bridge decks due to corrosion of reinforcing steel caused by chloride from deicing salts. Flushing of salts by application of water to the underside of the concrete and electrochemical removal of the chlorides were investigated. Flushing was found to be ineffective and work on it was abandoned early. However, the electrochemical removal technique showed promise of success first in the laboratory and later in a small scale field trial. In the latter chloride present at the level of the top rebar mat was reduced to below the concentration that is known to cause corrosion in 24 hours of treatment, and active corrosion of the steel that was going on was completely stopped