Mechanical alloying (MA) is a solid-state powder processng technique involving repeated welding, fracturing, and rewelding of powder particles in a high-energy ball mill. Originally developed to produce oxide-dispersion strengthened (ODS) nickel- and iron-base superalloys for applications in the aerospace industry, MA has now been shown to be capable of synthesizing a variety of equilibrium and non-equilibrium alloy phases starting from blended elemental or prealloyed powders. The non-equilibrium phases synthesized include supersaturated solid solutions, metastable crystalline and quasicrystalline phases, nanostructures, and amorphous alloys. Recent advances in these areas and also on disordering of ordered intermetallics and mechanochemical synthesis of materials have been critically reviewed after discussing the process and process variables involved in MA. The often vexing problem of powder contamination has been analyzed and methods have been suggested to avoid/minimize it. The present understanding of the modeling of the MA process has also been discussed. The present and potential applications of MA are described. Wherever possible, comparisons have been made on the product phases obtained by MA with those of rapid solidification processing, another non-equilibrium processing technique.

Mechanical Alloying And Milling

The search for new and advanced materials is the major preoccupation of metallurgists, ceramicists, and material scientists for the past several centuries. Significant improvements in mechanical, chemical, and physical properties have been achieved by alloying and through chemical modification and by subjection the materials to conventional thermal, mechanical, and thermo mechanical processing methods. Present paper deals with a brief review of the mechanical alloying questions focusing on the possible processes and apparatuses (mills).

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Mechanical Alloying and Milling

During the past decade, considerable research effort has been directed towards the development of in situ metal matrix composites (MMCs), in which the reinforcements are formed in situ by exothermal reactions between elements or between elements and compounds. Using this approach, MMCs with a wide range of matrix materials (including aluminum, titanium, copper, nickel and iron), and second-phase particles (including borides, carbides, nitrides, oxides and their mixtures) have been produced. Because of the formation of ultrafine and stable ceramic reinforcements, the in situ MMCs are found to exhibit excellent mechanical properties. In this review article, current development on the fabrication, microstructure and mechanical properties of the composites reinforced with in situ ceramic phases will be addressed. Particular attention is paid to the mechanisms responsible for the formation of in situ reinforcements, and for creep failure of the aluminum-based matrix composites.

Microstructural and mechanical characteristics of in situ metal matrix composites

http://www.crystallography.ru/MA/articles/!Self-sustaining_Takacs2002.pdf

Self-sustaining reactions induced by ball milling

An account is given of the research that has been carried out on mechanical alloying/milling (MA/MM) during the past 25 years. Mechanical alloying, a high energy ball milling process, has established itself as a viable solid state processing route for the synthesis of a variety of equilibrium and non-equilibrium phases and phase mixtures. The process was initially invented for the production of oxide dispersion strengthened (ODS) Ni-base superalloys and later extended to other ODS alloys. The success of MA in producing ODS alloys with better high temperature capabilities in comparison with other processing routes is highlighted. Mechanical alloying has also been successfully used for extending terminal solid solubilities in many commercially important metallic systems. Many high melting intermetallics that are difficult to prepare by conventional processing techniques could be easily synthesised with homogeneous structure and composition by MA. It has also, over the years, proved itself to be superior to rapid solidification processing as a non-equilibrium processing tool. The considerable literature on the synthesis of amorphous, quasicrystalline, and nanocrystalline materials by MA is critically reviewed. The possibility of achieving solid solubility in liquid immiscible systems has made MA a unique process. Reactive milling has opened new avenues for the solid state metallothermic reduction and for the synthesis of nanocrystalline intermetallics and intermetallic matrix composites. Despite numerous efforts, understanding of the process of MA, being far from equilibrium, is far from complete, leaving large scope for further research in this exciting field.

Novel materials synthesis by mechanical alloying/milling

(1991). NEW MATERIALS BY MECHANICAL ALLOYING TECHNIQUES. Materials and Manufacturing Processes: Vol. 6, No. 4, pp. 733-736.

L. Schultz

Papers

New materials by mechanical alloying techniques