Al-RE-Ni非晶質合金受到高臨界冷卻速率的限制，只能以薄帶或粉末型態存在，必須再經過二次製程將薄帶或粉末溫擠型成為塊材之後，才能成為高溫應用之高強度奈米結構鋁合金，其強度可以超越傳統鋁合金的極限，可惜由於製程成本高昂，不易大量生產。本研究則以粉末冶金技術「噴覆成型」角度切入，直接由熔湯到成品單一步驟製作塊狀非晶/奈米晶合金，結果發現產品具有新穎之顯微結構與良好機械性質。
研究結果顯示噴覆成型Al-RE-Ni複材是「部分結晶」，特徵是「初晶」與「非晶質基地」同時存在，非晶質含量36％–64％之間，其餘為結晶相。噴覆成型對Al-RE-Ni非晶/結晶複材的影響，主要是「平行缺陷」的形成以及初晶相的「圓鈍化」。缺陷的成因是初晶在非晶質基地中成長產生的熱膨脹係數差異，加上噴覆成型製程時的溫度梯度與劇烈攪拌撞擊力量，為了消除內應力而在初晶上形成平行缺陷。圓鈍化的成因則是由於多重方位（接近60o）的缺陷會調整介金屬中間相的成長方向，例如在本研究中Al89La6Ni5試片中的Al11La3(Ni)初晶就可以有效圓鈍化；但是有些合金就無法在初晶上形成多重方位缺陷，例如本研究中的Al85Nd5Ni10試片，其Al7NdNi2初晶上的缺陷常常保持平行而彼此不交會，或者交會角度接近90o，型態保持樹枝狀。
噴覆成型製作非晶質合金之定性機構可分三個階段：第一階段，由霧化產生的液滴，保持「完全過冷液體」、「初晶+單純液體」、「非晶固體」以及「完全結晶固體」四種可能型態；第二階段，當液滴撞擊到基板或沉積體自由表面，形成半固態薄層，包括過冷液體+液體+初晶、經過撞擊變形的含有初晶之固體、經過撞擊變形的非晶質固體、非晶質固體以及結晶固體；第三階段，非晶質相受熱分解形成二次結晶，半固態薄層凝固成初晶、二次晶與非晶質基地的混合體。
與塊材同成分之熔融旋淬薄帶是完全非晶質，加熱時會分解形成奈米晶，由於成核成長反應速率較緩慢，很適合做為探討非晶質中固態成核成長反應的材料。在Tg溫度以下恆溫，Al89La6Ni5薄帶傾向於奈米鋁與介金屬中間相幾乎同時形成；Al85Nd5Ni10薄帶則傾向於奈米鋁的「單獨結晶」反應。當銅輪轉速（冷卻速率）下降時，均會使兩種薄帶硬度增加，但是前者之同時析出反應容易引發脆化，後者之奈米鋁單獨結晶反應則相對穩定。
噴覆成型非晶/結晶複材在高溫動態拉伸測試時，發現在過冷液體區域，黏性流動受到初晶抑制，而且初晶比例越高，黏性流動越少，對應之損失模數增加量也越少，而且試片長度不易延伸，延伸率僅約1％。另外也觀察到熔融旋淬薄帶在過冷液體區域之前的熱收縮係數很大，進入該區域更大幅上升四倍，但是噴覆成型複材在過冷液體區域之前的熱收縮係數非常小，進入該區域後雖然大幅上升，但是相較於薄帶仍僅為十分之一，而且初晶含量越高，越不易收縮。
總而言之，噴覆成型Al-RE-Ni非晶/奈米晶複材具有高溫應用潛力，而且由於初晶的存在，不但可以提高硬度與彈性模數，而且同時可以調整並降低非晶質基地之熱收縮現象，配合非晶質基地中的奈米晶析出硬化，提供Al-RE-Ni非晶質合金工業製程開發另一種可能性，未來應用方向包括耐高溫精密機械零件、耐磨耐蝕表面塗層、運動器材等。

Owing to the requirement of high critical cooling rate, Al-RE-Ni amorphous alloy can only be generated in the form of ribbons or powders. After secondary processing step, like warm extrusion, ribbons or powders can then be consolidated into a bulk material and act as a nano-structured aluminum alloy with strength much higher than the conventional aluminum alloys. However, the high processing cost makes it not feasible for mass production. In this study, a powder metallurgy technique, spray forming, was employed to produce a bulk amorphous/nanocrystalline alloy in one step without any precursor. The unique microstructure and improved mechanical properties are also observed.
The results show that spray-formed Al-RE-Ni composites, in which 36–64% amorphous phase combined with retained crystalline phase, are characteristic of "primary crystal" coexisting with "amorphous matrix". The influence of spray forming process on the Al-RE-Ni alloy are "parallel defects generation" and "blunt-shaped primary crystals". During spray forming, the severe temperature gradients and the large stirring and impacting stress during droplets depositing, together with the mismatch of the thermal expansions between the primary crystals and adjacent amorphous matrix, are sufficiently large to trigger the formation of defects in the primary crystals. Additionally, the growth of primary crystals can also be adjusted by multi-direction (about 60o) defects and end up with a blunt-shaped form, for example the Al11La3(Ni) primary crystals in Al89La6Ni5 specimen. However, some alloy (e.g. Al85Nd5Ni10) can only generate defects without intersection or at 90o intersection in the primary crystals. Therefore, the Al7NdNi2 primary crystals in the Al85Nd5Ni10 specimen are still dendritic in shape.
The spray forming process can be divided into three stages. In the first stage, droplets are generated by atomization in the form of completely undercooled liquid, primary crystals in liquid, amorphous solid particles and completely crystallized particle. In the second stage, upon droplets impacting on the substrate or free surface of deposit, a semi-solid layer is formed consisting of undercooled liquid+liquid+primary crystal, solidified particles with primary crystals being deformed upon impacting, solidified amorphous particles and completely crystallized particle. In the third stage, amorphous phase devitrifies to form secondary crystals and semi-liquid layers solidifies into a mixture of amorphous phase, primary and secondary crystals.
The corresponding melt-spun ribbons are completely amorphous, and can devitrify to nanocrystals upon heating. Because the sluggish crystallization mechanism, it is suitable for the investigation of nucleation and growth reaction in the amorphous solid. Upon isothermally held at sub-Tg temperature, Al89La6Ni5 ribbon prefers concurrent precipitation of fcc-Al nanocrystals and intermetallic intermediate phases; Al85Nd5Ni10 ribbons prefers primary crystallization of fcc-Al nanocrystals. While produced at lower wheel velocity, both ribbons become harder. Concurrent precipitates in the former induces embrittlement, but primary crystallization in the later remains relatively stable.
As subjecting the spray-formed amorphous/crystalline nanocomposite to high temperature dynamic tensile test, viscous flow of supercooled liquid is inhibited by the primary crystals. More primary crystals provide increased resistance to flow, as well as decreased loss modulus. The extension of specimen length is also difficult and the maximum value achieved is only 1%. Moreover, it is also observed that the thermal extraction coefficient of melt-spun ribbons are large at sub-Tg temperature, and dramatically increases four times at supercooled liquid region. However, the coefficient of spray-formed nanocomposite is extremely small at sub-Tg temperature, and slightly increases at supercooled region, about one-tenth of the one for ribbons. More primary crystals will retard further extraction.
In summary, spray-formed Al-RE-Ni amorphous/nanocrystalline nanocomposites are of great potential for high temperature application. In addition, due to the presence of primary crystals together with the nanocrystal precipitate in the matrix, hardness and modulus of the composites are improved and the thermal extraction behavior is also adjusted. It makes another process route for manufacturing Al-RE-Ni amorphous alloy possible. In the future, applications can be thermal-resistant precision parts, wear and corrosion resistance surface coating or sporting goods, etc.

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