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Carbon Nanotube Reinforced Composites: Metal and Ceramic ...

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Figure 5.13 (a) FTIR of amorphous Al2O3/MWNT composite<br />

powders before <strong>and</strong> after calcination process; (b) SEM<br />

micrograph of the composite powder surface showing<br />

homogeneous dispersion <strong>and</strong> incorporation of CNTs into<br />

amorphous Al2O3 powder. Reproduced with permission<br />

from [72]. Copyright Ó (2005) Elsevier.<br />

5.4 Oxide-Based Nanocompositesj147<br />

nanocomposites inherit the beneficial properties of reinforcing MWNTs <strong>and</strong> SiC<br />

nanoparticles, leading to improvement in fracture toughness, bending strength <strong>and</strong><br />

hardness of the hybrids. Figure 5.15(a) shows a SEM fractograph of the Al2O3/(1 vol%<br />

MWNT þ 1 vol% SiC) hybrid nanocomposite. MWNTs are mainly dispersed along<br />

grain boundaries of alumina, forming a network microstructure. SiC nanoparticles<br />

can only be seen in the TEM micrograph as shown in Figure 5.15(b). The fracture<br />

mode of hybrid is mixed intergranular <strong>and</strong> transgranular mode.<br />

5.4.1.3 Plasma Spraying<br />

Very recently, Agarwal s group employed the plasma spraying process to form Al 2O 3/<br />

4 wt% MWNT <strong>and</strong> Al2O3/8 wt% MWNT nanocomposite coatings [76, 77]. They<br />

indicated that the Al2O3 nanopowder (150 nm) cannot be plasma sprayed because<br />

it has a high tendency to form clogs at the plasma gun nozzle. To facilitate the<br />

flowability of the nanopowder, a spray-drying pretreatment for nanopowder was<br />

needed. Spray-drying involves the dispersion of nanopowder in an aqueous organic<br />

binder to form a slurry followed by atomization. Spray-drying of Al2O3 nanopowder<br />

results in the formation of spherical agglomerates of 35 mm (designated as A-SD).<br />

A-SD powder was then blended with 4 wt% MWNT in a jar mill to form the powder<br />

feedstock (designated as A4C-B) for plasma spraying (Figure 5.16). In another<br />

approach, mixed alumina nanopowder <strong>and</strong> MWNT of different contents were<br />

spray-dried to form the A4C-SD or A8C-SD feedstock. Figure 5.17(a) <strong>and</strong> (c) show<br />

SEM micrographs of A4C-B, A4C-SD <strong>and</strong> A8C-SD powders. Apparently, MWNTs are<br />

dispersed only on the surface of A4C-B powder, but are dispersed throughout<br />

the powder agglomerates of A4C-SD <strong>and</strong> A8C-SD.

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