Synthesis, and characterization of metallic glassy Cu-Zr-Ni powders decorated with big cube Zr2Ni nanoparticles for potential antibiofilm coating applications.

Biofilms, are significant component that contributes to the development of chronic infections, especially when medical devices are involved. This issue offers a huge challenge for the medical community since standard antibiotics are only capable of eradicating biofilms to a very limited degree. The prevention of biofilm formation have led to the development of a variety of coating methods and new materials. These methods are intended to coat surfaces in such a way as to inhibit the formation of biofilm. Metallic glassy alloys, in particular, alloys that include copper and titanium metals have gained popularity as desirable antibacterial coating. Meanwhile, there has been a rise in the use of the cold spray coating technique due to the fact that it is a proper approach for processing temperature-sensitive materials. The present study was carried out in part with the intention of developing a new antibiofilm metallic glassy consisting of ternary Cu-Zr-Ni using mechanical alloying technique. The spherical powders that comprised the end-product were utilized as feedstock materials for cold spray coatings to stainless steel surfaces at low temperature. When compared to stainless steel, substrates coated with metallic glassy were able to significantly reduce the formation of biofilm by at least one log.

Phase Transformations from Nanocrystalline to Amorphous (Zr70Ni25Al5)100-xWx (x; 0, 2, 10, 20, 35 at. %) and Subsequent Consolidation.

Glasses, which date back to about 2500 BC, originated in Mesopotamia and were later brought to Egypt in approximately 1450 BC. In contrast to the long-range order materials (crystalline materials), the atoms and molecules of glasses, which are noncrystalline materials (short-range order) are not organized in a definite lattice pattern. Metallic glassy materials with amorphous structure, which are rather new members of the advanced materials family, were discovered in 1960. Due to their amorphous structure, metallic glassy alloys, particularly in the supercooled liquid region, behave differently when compared with crystalline alloys. They reveal unique and unusual mechanical, physical, and chemical characteristics that make them desirable materials for many advanced applications. Although metallic glasses can be produced using different techniques, many of these methods cannot be utilized to produce amorphous alloys when the system has high-melting temperature alloys (above 1500 °C) and/or is immiscible. As a result, such constraints may limit the ability to fabricate high-thermal stable metallic glassy families. The purpose of this research is to fabricate metallic glassy (Zr70Ni25Al5)100-xWx (x; 0, 2, 10, 20, and 35 at. %) by cold rolling the constituent powders and then mechanically alloying them in a high-energy ball mill. The as-prepared metallic glassy powders demonstrated high-thermal stability and glass forming ability, as evidenced by a broad supercooled liquid region and a high crystallization temperature. The glassy powders were then consolidated into full-dense bulk metallic glasses using a spark plasma sintering technique. This consolidation method did not result in the crystallization of the materials, as the consolidated buttons retained their short-range order fashion. Additionally, the current work demonstrated the capability of fabricating very large bulk metallic glassy buttons with diameters ranging from 20 to 50 mm. The results indicated that the microhardness of the synthesized metallic glassy alloys increased as the W concentration increased. As far as the authors are aware, this is the first time this metallic glassy system has been reported.

Mechanical Milling: A Superior Nanotechnological Tool for Fabrication of Nanocrystalline and Nanocomposite Materials.

Throughout human history, any society's capacity to fabricate and refine new materials to satisfy its demands has resulted in advances to its performance and worldwide standing. Life in the twenty-first century cannot be predicated on tiny groupings of materials; rather, it must be predicated on huge families of novel elements dubbed "advanced materials". While there are several approaches and strategies for fabricating advanced materials, mechanical milling (MM) and mechanochemistry have garnered much interest and consideration as novel ways for synthesizing a diverse range of new materials that cannot be synthesized by conventional means. Equilibrium, nonequilibrium, and nanocomposite materials can be easily obtained by MM. This review article has been addressed in part to present a brief history of ball milling's application in the manufacture of a diverse variety of complex and innovative materials during the last 50 years. Furthermore, the mechanism of the MM process will be discussed, as well as the factors affecting the milling process. Typical examples of some systems developed at the Nanotechnology and Applications Program of the Kuwait Institute for Scientific Research during the last five years will be presented in this articles. Nanodiamonds, nanocrystalline hard materials (e.g., WC), metal-matrix and ceramic matrix nanocomposites, and nanocrystalline titanium nitride will be presented and discussed. The authors hope that the article will benefit readers and act as a primer for engineers and researchers beginning on material production projects using mechanical milling.

Cold Gas-Dynamic Spray for Catalyzation of Plastically Deformed Mg-Strips with Ni Powder.

Magnesium hydride (MgH2) has received significant attention due to its potential applications as solid-state hydrogen storage media for useful fuel cell applications. Even though MgH2 possesses several attractive hydrogen storage properties, it cannot be utilized in fuel cell applications due to its high thermal stability and poor hydrogen uptake/release kinetics. High-energy ball milling, and mechanically-induced cold-rolling processes are the most common techniques to introduce severe plastic deformation and lattice imperfection in the Mg/MgH2. Furthermore, using one or more catalytic agents is considered a practical solution to improve both the de-/rehydrogenation process of MgH2.These treatments are usually dedicated to enhance its hydrogen storage properties and deduce its thermal stability. However, catalyzation of Mg/MgH2 powders with a desired catalytic agent using ball milling process has shown some disadvantages due to the uncontrolled distribution of the agent particles in the MgH2 powder matrix. The present study has been undertaken to employ a cold gas-dynamic spray process for catalyzing the fresh surfaces of mechanically-induced cold-rolled Mg ribbons with Ni powder particles. The starting Mg-rods were firstly heat treated and forged 200 times before cold rolling for 300 passes. The as-treated ribbons were then catalyzed by Ni particles, using cold gas-dynamic spray process. In this catalyzation approach, the Ni particles were carried by a stream of Ar gas via a high-velocity jet at a supersonic velocity. Accordingly, the pelted Ni particles penetrated the Mg-substrate ribbons, and hence created numerous micropores into the Mg, allowed the Ni particles to form a homogeneous network of catalytic active sites in Mg substrate. As the number of coating time increased to three times, the Ni concentration increased (5.28 wt.%), and this led to significant enhancement of the Mg-hydrogen storage capacity, as well as improving the de-/rehydrogenation kinetics. This is evidenced by the high value of hydrogen storage capacity (6.1 wt.% hydrogen) and the fast gas uptake kinetics (5.1 min) under moderate pressure (10 bar) and temperature (200 °C). The fabricated nanocomposite MgH2/5.28 wt.% Ni strips have shown good dehydrogenation behavior, indicated by their capability to desorb 6.1 wt.% of hydrogen gas within 11 min at 200 °C under 200 mbar of hydrogen pressure. Moreover, this system possessed long cycle-life-time, which extended to 350 h with a minimal degradation in the storage and kinetics behavior.

From gangue to the fuel-cells application.

Hydrogen, which is a new clean energy option for future energy systems possesses pioneering characteristics making it a desirable carbon-free energy carrier. Hydrogen storage plays a crucial role in initiating a hydrogen economy. Due to its low density, the storage of hydrogen in the gaseous and liquids states had several technical and economic challenges. Despite these traditional approaches, magnesium hydride (MgH2), which has high gravimetric and volumetric hydrogen density, offers an excellent potential option for utilizing hydrogen in automobiles and other electrical systems. In contrast to its attractive properties, MgH2 should be mechanically and chemically treated to reduce its high activation energy and enhance its modest hydrogen sorption/desorption kinetics. The present study aims to investigate the influence of doping mechanically-treated Mg metal with 5 wt% amorphous Zr2Cu abrasive nanopowders in improving its kinetics and cyclability behaviors. For the first time, solid-waste Mg, Zr, and Cu metals were utilized for preparing MgH2 and amorphous Zr2Cu alloy (catalytic agent), using hydrogen gas-reactive ball milling, and arc melting techniques, respectively. This new nanocomposite system revealed high-capacity hydrogen storage (6.6 wt%) with superior kinetics and extraordinary long cycle-life-time (1100 h) at 250 °C.

Top-Down Reactive Approach for the Synthesis of Disordered ZrN Nanocrystalline Bulk Material from Solid Waste.

Transition metal nitrides possess superior mechanical, physical, and chemical properties that make them desirable materials for a broad range of applications. A prime example is zirconium nitride (ZrN), which can be obtained through different fabrication methods that require the applications of high temperature and pressure. The present work reports an interesting procedure for synthesizing disordered face centered cubic (fcc)-ZrN nanoparticles through the reactive ball milling (RBM) technique. One attractive point of this study is utilizing inexpensive solid-waste (SW) zirconium (Zr) rods as feedstock materials to fabricate ZrN nanopowders. The as-received SW Zr rods were chemically cleaned and activated, arc-melted, and then disintegrated into powders to obtain the starting Zr metal powders. The powders were charged and sealed under nitrogen gas using a pressurized milling steel vial. After 86 ks of milling, a single fcc-ZrN phase was obtained. This phase transformed into a metastable fcc-phase upon RBM for 259 ks. The disordered ZrN powders revealed good morphological characteristics of spherical shapes and ultrafine nanosize (3.5 nm). The synthetic ZrN nanopowders were consolidated through a spark plasma sintering (SPS) technique into nearly full-density (99.3% of the theoretical density for ZrN) pellets. SPS has proven to be an integral step in leading to desirable and controlled grain growth. Moreover, the sintered materials were not transformed into any other phase(s) upon consolidation at 1673 K. The results indicated that increasing the RBM time led to a significant decrease in the grain size of the ZrN powders. As a result, the microhardness of the consolidated samples was consequently improved with increasing RBM time.

Synthesizing of Novel Bulk (Zr67Cu33)100-xWx(x; 5-30 at%) Glassy Alloys by Spark Plasma Sintering of Mechanically Alloyed Powders.

Metallic glassy alloys with their short-range order have received considerable attention since their discovery in 1960's. The worldwide interest in metallic glassy alloys is attributed to their unique mechanical, physical, and chemical properties, which cannot be found together in long-range order alloys of the same compositions. Traditional preparation methods of metallic glasses, such as rapid solidification of melts, always restrict the formation of glassy alloys with large atomic fraction (above 3-5 at%) of high melting point metals (Ta, Mo, W). In this study, (Zr67Cu33)100-xWx(x; 5-30 at%) metallic glassy alloys were fabricated through a mechanical alloying approach, which starts from the elemental powders. This system shows excellent glass forming ability in a wide range of W (0 ≤ x ≥ 30 at%). We have proposed a spark plasma sintering technique to prepare nearly full-dense large sized (20 × 20 mm) bulk metallic glassy alloys. The as-consolidated bulk metallic glassy alloys were seen to possess high thermal stability when compared with the other metallic glassy systems. This is implied by their high glass transition temperature (722-735 K), wide range of supercooled liquid region (39 K to over 100 K), and high values of crystallization temperature (761 K to 823 K). In addition, the fabricated ternary systems have revealed high microhardness values.

Environmentally friendly nanocrystalline magnesium hydride decorated with metallic glassy-zirconium palladium nanopowders for fuel cell applications.

A new solid-state hydrogen storage system of magnesium hydride (MgH2) doped with 5 wt% of metallic glassy (MG) zirconium palladium (Zr2Pd) nanopowder was fabricated using a high-energy ball milling technique. The end-product obtained after 50 h of milling was consolidated into bulk buttons, using a hot-pressing technique at 350 °C. The results have shown that this consolidation step, followed by the repetitive pressing at ambient temperature did not affect the nanocrystalline characteristics of pressed powders. Recycling pressing demonstrated beneficial effects of plastic deformation and lattice imperfections on Mg, leading to its enhanced hydrogenation/dehydrogenation kinetics and cycle-life-time performance compared with untreated samples. The results elucidated that spherical, hard, nanopowder of MG-Zr2Pd were forced to penetrate the Mg/MgH2 matrix to create micro/nanopore structures upon pressing for 50 cycles. These ultrafine spherical metallic glassy particles (∼400 nm in diameter) acted as a micro-milling media for reducing the particle size of MgH2 powders into submicron particles. In addition, they played a vital role as grain growth inhibitors to prevent the undesired growth of Mg grains upon the application of a moderate temperature in the range of 50 °C to 350 °C. The apparent activation energy for the decomposition of this new consolidated nanocomposite material was measured to be 92.2 kJ mol-1, which is far below than the measured value of pure nanocrystalline MgH2 powders (151.2 kJ mol-1) prepared in the present study. This new binary system possessed superior hydrogenation kinetics, indicated by the rather low temperature (200 °C) required to uptake 6.08 wt% H2 within 7.5 min. More importantly, the system revealed excellent dehydrogenation kinetics at 225 °C as implied by the limited time needed to release 6.1 wt% H2 in 10 min. The MgH2/5 wt% MG-Zr2Pd system showed a high performance for cyclability, implied by the achievement of continuous cycles (338 cycles) at 225 °C without degradation over 227 h.

Synthetic nanocomposite MgH2/5 wt. % TiMn2 powders for solid-hydrogen storage tank integrated with PEM fuel cell.

Storing hydrogen gas into cylinders under high pressure of 350 bar is not safe and still needs many intensive studies dedic ated for tank's manufacturing. Liquid hydrogen faces also severe practical difficulties due to its very low density, leading to larger fuel tanks three times larger than traditional gasoline tank. Moreover, converting hydrogen gas into liquid phase is not an economic process since it consumes high energy needed to cool down the gas temperature to -252.8 °C. One practical solution is storing hydrogen gas in metal lattice such as Mg powder and its nanocomposites in the form of MgH2. There are two major issues should be solved first. One related to MgH2 in which its inherent poor hydrogenation/dehydrogenation kinetics and high thermal stability must be improved. Secondly, related to providing a safe tank. Here we have succeeded to prepare a new binary system of MgH2/5 wt. % TiMn2 nanocomposite powder that show excellent hydrogenation/dehydrogenation behavior at relatively low temperature (250 °C) with long cycle-life-time (1400 h). Moreover, a simple hydrogen storage tank filled with our synthetic nanocomposite powders was designed and tested in electrical charging a battery of a cell phone device at 180 °C through a commercial fuel cell.

In-situ catalyzation approach for enhancing the hydrogenation/dehydrogenation kinetics of MgH2 powders with Ni particles.

One practical solution for utilizing hydrogen in vehicles with proton-exchange fuel cells membranes is storing hydrogen in metal hydrides nanocrystalline powders. According to its high hydrogen capacity and low cost of production, magnesium hydride (MgH2) is a desired hydrogen storage system. Its slow hydrogenation/dehydrogenation kinetics and high thermal stability are the major barriers restricting its usage in real applications. Amongst the several methods used for enhancing the kinetics behaviors of MgH2 powders, mechanically milling the powders with one or more catalyst species has shown obvious advantages. Here we are proposing a new approach for gradual doping MgH2 powders with Ni particles upon ball milling the powders with Ni-balls milling media. This proposed is-situ method showed mutually beneficial for overcoming the agglomeration of catalysts and the formation of undesired Mg2NiH4 phase. Moreover, the decomposition temperature and the corresponding activation energy showed low values of 218 °C and 75 kJ/mol, respectively. The hydrogenation/dehydrogenation kinetics examined at 275 °C of the powders milled for 25 h took place within 2.5 min and 8 min, respectively. These powders containing 5.5 wt.% Ni performed 100-continuous cycle-life time of hydrogen charging/discharging at 275 °C within 56 h without failure or degradation.

Metallic glassy Zr70Ni20Pd10 powders for improving the hydrogenation/dehydrogenation behavior of MgH2.

Because of its low density, storage of hydrogen in the gaseous and liquids states possess technical and economic challenges. One practical solution for utilizing hydrogen in vehicles with proton-exchange fuel cells membranes is storing hydrogen in metal hydrides. Magnesium hydride (MgH2) remains the best hydrogen storage material due to its high hydrogen capacity and low cost of production. Due to its high activation energy and poor hydrogen sorption/desorption kinetics at moderate temperatures, the pure form of MgH2 is usually mechanically treated by high-energy ball mills and catalyzed with different types of catalysts. These steps are necessary for destabilizing MgH2 to enhance its kinetics behaviors. In the present work, we used a small mole fractions (5 wt.%) of metallic glassy of Zr70Ni20Pd10 powders as a new enhancement agent to improve its hydrogenation/dehydrogenation behaviors of MgH2. This short-range ordered material led to lower the decomposition temperature of MgH2 and its activation energy by about 121 °C and 51 kJ/mol, respectively. Complete hydrogenation/dehydrogenation processes were successfully achieved to charge/discharge about 6 wt.%H2 at 100 °C/200 °C within 1.18 min/3.8 min, respectively. In addition, this new nanocomposite system shows high performance of achieving continuous 100 hydrogen charging/discharging cycles without degradation.

Contamination Effects on Improving the Hydrogenation/Dehydrogenation Kinetics of Binary Magnesium Hydride/Titanium Carbide Systems Prepared by Reactive Ball Milling.

Ultrafine MgH2 nanocrystalline powders were prepared by reactive ball milling of elemental Mg powders after 200 h of high-energy ball milling under a hydrogen gas pressure of 50 bar. The as-prepared metal hydride powders were contaminated with 2.2 wt. % of FeCr-stainless steel that was introduced to the powders upon using stainless steel milling tools made of the same alloy. The as-synthesized MgH2 was doped with previously prepared TiC nanopowders, which were contaminated with 2.4 wt. % FeCr (materials of the milling media), and then ball milled under hydrogen gas atmosphere for 50 h. The results related to the morphological examinations of the fabricated nanocomposite powders beyond the micro-and nano-levels showed excellent distributions of 5.2 wt. % TiC/4.6 wt. % FeCr dispersoids embedded into the fine host matrix of MgH2 powders. The as-fabricated nanocomposite MgH2/5.2 wt. % TiC/4.6 wt. % FeCr powders possessed superior hydrogenation/dehydrogenation characteristics, suggested by the low value of the activation energy (97.74 kJ/mol), and the short time required for achieving a complete absorption (6.6 min) and desorption (8.4 min) of 5.51 wt. % H2 at a moderate temperature of 275 °C under a hydrogen gas pressure ranging from 100 mbar to 8 bar. van't Hoff approach was used to calculate the enthalpy (DH) and entropy (DS) of hydrogenation for MgH2, which was found to be -72.74 kJ/mol and 112.79 J/mol H2/K, respectively. Moreover, van't Hoff method was employed to calculate the DH and DS of dehydrogenation, which was found to be 76.76 kJ/mol and 119.15 J/mol H2/K, respectively. This new nanocomposite system possessed excellent absorption/desorption cyclability of 696 complete cycles, achieved in a cyclic-life-time of 682 h.