In this study, acoustic and viscosity data are collected in real time during the ball milling process and analyzed for correlation. After fast Fourier transformation (FFT) of the acoustic data, changes in the signals are observed as a function of the milling time. To analyze this quantitatively, the frequency band is divided into 1 kHz ranges to obtain an integral value. The integrated values in the 2–3 kHz range of the frequency band decrease linearly, confirming that they have a high correlation with changes in viscosity. The experiment is repeated four times to ensure the reproducibility of the data. The results of this study show that it is possible to estimate changes in slurry properties, such as viscosity and particle size, during the ball milling process using an acoustic signal.

Macro-porous carbon foams are fabricated using cured spherical phenolic resin particles as a matrix and furfuryl alcohol as a binder through a simple casting molding. Different sizes of the phenolic resin particles from 100– 450 μm are used to control the pore size and structure. Ethylene glycol is additionally added as a pore-forming agent and oxalic acid is used as an initiator for polymerization of furfuryl alcohol. The polymerization is performed in two steps; at 80oC and 200oC in an ambient atmosphere. The carbonization of the cured body is performed under Nitrogen gas flow (0.8 L/min) at 800oC for 1 h. Shrinkage rate and residual carbon content are measured by size and weight change after carbonization. The pore structures are observed by both electron and optical microscope and compared with the porosity results achieved by the Archimedes method. The porosity is similar regardless of the size of the phenolic resin particles. On the other hand, the pore size increases in proportion to the phenol resin size, which indicates that the pore structure can be controlled by changing the raw material particle size.

This study demonstrates the effect of addition of Fe particles of different sizes on the critical properties of the superconductor MgB2. Bulk MgB2 is synthesized by ball milling Mg and B powders with Fe particles at 900oC. When Fe particles with size less than 10 μm are added in MgB2, they easily react with B and form the FeB phase, resulting in a reduction in the amount of the MgB2 phase and deterioration of the crystallinity. Accordingly, both the critical temperature and the critical current density are significantly reduced. On the other hand, when larger Fe particles are added, the Fe2B phase forms instead of FeB due to the lower reactivity of Fe toward B. Accordingly, negligible loss of B occurs, and the critical properties are found to be similar to those of the intact MgB2.

In this study, a process is developed for 3D printing with alumina (Al2O3). First, a photocurable slurry made from nanoparticle Al2O3 powder is mixed with hexanediol diacrylate binder and phenylbis(2,4,6- trimethylbenzoyl) phosphine oxide photoinitiator. The optimum solid content of Al2O3 is determined by measuring the rheological properties of the slurry. Then, green bodies of Al2O3 with different photoinitiator contents and UV exposure times are fabricated with a digital light processing (DLP) 3D printer. The dimensional accuracy of the printed Al2O3 green bodies and the number of defects are evaluated by carefully measuring the samples and imaging them with a scanning electron microscope. The optimum photoinitiator content and exposure time are 0.5 wt% and 0.8 s, respectively. These results show that Al2O3 products of various sizes and shapes can be fabricated by DLP 3D printing.

MgB2 bulk superconductors are synthesized by the solid state reaction of (MgB4+xMg) precursors withexcessive Mg compositions (x=1.0, 1.4, 2.0 and 2.4). The MgB4 precursors are synthesized using (Mg+B) powders. Thesecondary phases (MgB4 and MgO) present in the synthesized MgB4 are removed by HNO3 leaching. It is found thatthe formation reaction of MgB2 is accelerated when Mg excessive compositions are used. The magnetization curves ofMg1+xB2 samples show that the transition from the normal state to the superconducting state of the Mg excessive sam-ples with x=0.5 and x=0.7 are sharper than that of MgB2. The highest Jc-B curve at 5 K and 20 K is achieved forx=0.5. Further addition of Mg decreases the Jc owing to the formation of more pores in the MgB2 matrix and smallervolume fraction of MgB2.