Nanocrystalline TiAl powders synthesized by high-energy ball milling: Effects of milling parameters on yield and contamination

High-energy ball milling was employed to produce nanocrystalline Ti-Al powders. As sticking of the powders can be sufficiently severe to result in a near zero yield, emphasis was placed on varying milling conditions so as to increase the yield, while avoiding contamination of the powders. The effects of milling parameters such as milling tools, initial state of the powders and addition of process control agents (PCA's) were investigated. Cyclohexane, stearic acid and titanium hydride were used as PCA's. Milling was conducted either in a Cr-steel vial with C-steel balls, or in a tungsten carbide (WC) vial with WC balls, using either elemental or pre-alloyed powders. Powder samples were characterized using X-ray diffraction, scanning and transmission electron microscopy. In the absence of PCA's mechanical alloying in a WC vial and attrition milling in a Cr-steel vial were shown to lead to satisfactory yields, about 65-80%, without inducing any significant contamination of the powders. The results suggest that sticking of the powders on to the milling tools is correlated with the phase evolution occurring in these powders during milling.