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Chapter and Conference Paper
Energy Balance Investigation of Close-Coupled Optimized-Pressure Gas Atomization Pour-Tube Design Geometry to Prevent Melt Freeze-Off
Metal additive manufacturing (AM) is an evolving technology, and the supply of quality feedstock material needs to follow suit. Closed-coupled optimized-pressure gas (CCOPGA) narrow size distribution, sphe...
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Chapter and Conference Paper
Numerical Simulation and Validation of Gas and Molten Metal Flows in Close-Coupled Gas Atomization
Molten metal atomization in close-coupled gas atomization dies can operate between two limiting conditions, jetting and filming, together with several complex mechanisms: liquid-gas drafting, downward/upward s...
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Article
Role of the Applied Magnetic Field on the Microstructural Evolution in Alnico 8 Alloys
Improving performance of permanent magnet (PM) alloys is a complex optimization of microstructure through control of chemistry and processing. Alnico alloys represent a class of chemically complex alloys whose...
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Article
Advances in Characterization of Non-Rare-Earth Permanent Magnets: Exploring Commercial Alnico Grades 5–7 and 9
The magnetic domain structure of commercial alnico grades 5–7 and 9 was investigated using a magneto-optical Kerr effect (MOKE) to gain an understanding of their coercivity mechanisms at the micron to millimet...
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Article
Advanced gas atomization processing for Ti and Ti alloy powder manufacturing
A multi-layer ceramic composite melt pour tube for superheating and pouring of molten Ti-6Al-4V (wt.%) was tested using an existing Ti atomization system. Free fall gas atomization was conducted with the pour ...
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Article
Characterization of Hypereutectic Al-Si Powders Solidified under Far-From Equilibrium Conditions
The rapid solidification microstructure of gas-atomized Al-Si powders of 15, 18, 25, and 50 wt pct Si were examined using scanning electron microscopy (SEM) and transmission electron microscopy (TEM). In order...
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Article
Suppression of void coalescence in thermal aging of tin-silver-copper-X solder joints
Addressing the potential for drop impact failure of Pb-free interconnects, the shear ductility after extensive aging of Sn-Ag-Cu (SAC) solders has been improved radically by Co or Fe modifications. Several oth...
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Article
Elevated temperature aging of solder joints based on Sn-Ag-Cu: Effects on joint microstructure and shear strength
The shear strength behavior and microstructural effects after aging for 100 h and 1,000 h at 150°C are reported for near-eutectic Sn-Ag-Cu (SAC) solder joints (joining to Cu) made from Sn-3.5Ag (wt.%) and a se...
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Article
Isothermal aging of near-eutectic Sn-Ag-Cu solder alloys and its effect on electrical resistivity
Solder joints were prepared from seven eutectic and near-eutectic Sn-based compositions and characterized for electrical resistivity after 100 h and 1,000 h of isothermal aging at 423 K. The solder joint sampl...
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Article
Effect of heat treatment on the electrical resistivity of near-eutectic Sn-Ag-Cu Pb-Free solder alloys
The electrical resistivity of solder joints prepared from Sn-Ag, Sn-Ag-Cu, and Sn-Ag-Cu-X alloys (where X = Co, Fe, or Bi) was characterized by a four-point probe technique and interpreted in terms of microstr...
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Article
Microstructural modifications and properties of Sn-Ag-Cu solder joints induced by alloying
Slow cooling (1–3°C/sec) of Sn-Ag-Cu and Sn-Ag-Cu-X (X = Fe, Co) solder-joint specimens, made by hand soldering, simulated reflow in a surface-mount assembly to achieve similar as-solidified joint microstructu...
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Article
Sn-Ag-Cu solders and solder joints: Alloy development, microstructure, and properties
Slow cooling of Sn-Ag-Cu and Sn-Ag-Cu-X (X = Fe, Co) solder-joint specimens made by hand soldering simulated reflow in surface-mount assembly to achieve similar as-solidified joint microstructures for realisti...
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Article
Shear deformation in Sn-3.5Ag and Sn-3.6Ag-1.0Cu solder joints subjected to asymmetric four-point bend tests
The shear deformation behavior of two lead-free solder compositions, Sn-3.5Ag (wt.%) and Sn-3.6Ag-1.0Cu (wt.%), both on copper substrates, was studied using an asymmetric four point bend technique. Four test j...
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Article
Application of an asymmetrical four point bend shear test to solder joints
The asymmetrical four-point bend shear (AFPB) test method was used to measure the shear strength and creep properties through the stress relaxation experiments using three different Pb-free solder joint compos...
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Article
Alloying effects in near-eutectic Sn-Ag-Cu solder alloys for improved microstructural stability
This study included a comparison of the baseline Sn-3.5Ag eutectic to one near-eutectic ternary alloy, Sn-3.6 Ag-1.0Cu and two quaternary alloys, Sn-3.6Ag-1.0Cu-0.15Co and Sn-3.6Ag-1.0 Cu-0.45 Co, to increase ...
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Article
Gas Atomization Processing of LaNi5−xMm, Modified with Silicon and Tin
A high pressure gas atomization (HPGA) process has been employed to study microsegregation in LaNi4.75 Sn0.25 and LaNi4.6Si0.4 alloy powders to serve as a basis for further investigations of low cost production o...
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Article
Benefits of Rapid Solidification Processing of Modified LaNi5 Alloys by High Pressure Gas Atomization for Battery Applications
A high pressure gas atomization approach to rapid solidification has been employed to investigate simplified processing of Sn modified LaNi5 powders that can be used for advanced Ni/metal hydride (Ni/MH) batterie...
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Article
A numerical investigation of gas flow effects on high-pressure gas atomization due to melt tip geometry variation
A parametric numerical study is presented on how melt feed tube geometry influences the gas flow field of a high-pressure gas atomizer (HPGA). The axisymmetric, turbulent, compressible Navier-Stokes equations ...
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Chapter
Processing and Testing of the Low-Temperature Stage Er6Ni2Sn Cryogenic Regenerator Alloy
Low temperature heat capacity measurements have shown that Er6Ni2Sn might be a useful low temperature, <20 K, cryocooler regenerator material. Here we report on (1) our efforts to prepare small particles for use ...
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Article
Particle size effects on chemistry and structure of Al-Cu-Fe quasicrystalline coatings
Gas atomized Al63Cu25Fe12 powders of varying size fractions were plasma sprayed onto hot (~600 °C) and cool (~25 °C) substrates using Mach I and subsonic plasma gun configurations. The chemical composition and ph...