Effect of high energy ball milling on solid state reactions in Al-25 at.-%Ni powders

The effect of high energy ball milling on the solid state reactions between aluminium and nickel in Al-25 at.-%Ni powders has been investigated using scanning electron microscopy, thermal analysis techniques, and X-ray diffractometry. It has been observed that the microstructure of the powder particles evolves in three stages: stage I is the formation of entrapped nickel particles in the aluminium matrix structure; stage II is the formation of an Al-Ni multilayered structure; and stage III is the formation of Al3Ni single phase. The temperature required to activate the reaction between aluminium and nickel during heating decreases by more than 200 K as the powder particle microstructure evolves from the entrapped particle structure to the multilayered structure, and then it decreases gradually with decreasing nickel layer thickness. The nucleation and lateral growth of Al3Ni phase at the Al/Ni interfaces occurs at much lower temperatures than those required for the transverse growth of Al3Ni. The fraction of Al3Ni formed through nucleation and lateral growth at the interface is almost linearly proportional to the interfacial area. The activation energy for nucleation and lateral growth of Al3Ni at the Al/Ni interfaces is independent of nickel layer thickness, but the activation energy for transverse growth of AIN decreases substantially with decreasing nickel layer thickness. The latter is attributed to the observation that the nickel layers are thinned by plastic deformation and thus contain an increasingly higher density of dislocations. MST/4752.