Wear properties and effect of molds on microstructure of graphite reinforced copper alloy composites made by centrifugal casting

Graphite reinforced copper alloy composites were cast using gravity and centrifugal casting techniques to identify the effect of graphite particles on microstructural formation and the effect of the casting techniques on the distribution of the particles. Melt containing either 5 or 120 μm size graphite particles were gravity cast in both steel and graphite molds. Melts containing 5 μm graphite particles were also cast in a horizontal centrifugal casting machine. Samples cast in the graphite molds exhibited much greater pore size than that found in the samples cast in the steel molds. Graphite particles moved to the inner periphery when influenced by centrifugal force, resulting in the formation of graphite-rich and graphite-free zones. The volume fraction of graphite particles near the inner periphery was 13%, which is higher than the initial volume fraction of graphite particles (7 vol.%) added into the melt. The results of wear testing showed that the friction coefficient of the pin from the graphite-rich zone is 0.49 and 0.69 for the pin from the graphite-free zone. The size of the machining chips from the graphite-rich zone was much smaller than those from the graphite-free zone. These results suggest that this composite may be an attractive substitute for copper alloys containing lead.     

半固态过共晶高铬铸铁浆料在离心力作用下的凝固组织

对于倾斜冷却体法制备的半固态过共晶高铬铸铁浆料，采用离心铸造法将其制备成环形铸件，并观察和分析该铸件组织。结果表明，首先在半固态组织中初生碳化物出现偏析现象，且存在明显的偏析分界线，分界线位于距离环形铸件径向外侧面约6mm处。其次，在本试验条件下，离心力的作用只能部分消除半固态过共晶高铬铸铁组织中的缩松倾向，而且在组织中也存在缩松出现的分界线，即小于距环形铸件径向外侧面约6mm的径向区域内无缩松产生，大于距环形铸件径向外侧面约6mm的径向区域产生缩松。     

Strain Rate Dependency of Bronze Metal Matrix Composite Mechanical Properties as a Function of Casting Technique

Strain rate dependency of mechanical properties of tungsten carbide (WC)-filled bronze castings fabricated by centrifugal and sedimentation-casting techniques are examined, in this study. Both casting techniques are an attempt to produce a functionally graded material with high wear resistance at a chosen surface. Potential applications of such materials include shaft bushings, electrical contact surfaces, and brake rotors. Knowledge of strain rate-dependent mechanical properties is recommended for predicting component response due to dynamic loading or impact events. A brief overview of the casting techniques for the materials considered in this study is followed by an explanation of the test matrix and testing techniques. Hardness testing, density measurement, and determination of the volume fraction of WC particles are performed throughout the castings using both image analysis and optical microscopy. The effects of particle filling on mechanical properties are first evaluated through a microhardness survey of the castings. The volume fraction of WC particles is validated using a thorough density survey and a rule-of-mixtures model. Split Hopkinson Pressure Bar (SHPB) testing of various volume fraction specimens is conducted to determine strain dependence of mechanical properties and to compare the process-property relationships between the two casting techniques. The baseline performances of C95400 bronze are provided for comparison. The results show that the addition of WC particles improves microhardness significantly for the centrifugally cast specimens, and, to a lesser extent, in the sedimentation-cast specimens, largely because the WC particles are more concentrated as a result of the centrifugal-casting process. Both metal matrix composites (MMCs) demonstrate strain rate dependency, with sedimentation casting having a greater, but variable, effects on material response. This difference is attributed to legacy effects from the casting process, namely, porosity and localized WC particle grouping.     

Prediction of powder particle behavior during high-velocity oxyfuel spraying

A mathematical model is developed to predict particle velocity and temperature during high-velocity oxyfuel (HVOF) spraying. This model accounts for internal heat conduction in powder particles; particle heating, fusion, cooling, and solidification; the influence of particle morphology on thermal behavior; and the composite structure of the particles. Analytical results are obtained that describe particle velocity and temperature variations. The dependence of fluid velocity on particle density and volume fraction is shown. The results agree with empirically established HVOF spraying practice. Physical Metal-lurgy—Materials Science     

Evolution of primary phases and high-temperature compressive behaviors of as-cast AuSn20 alloys prepared by different solidification pathways

The as-cast AuSn20 eutectic alloys prepared by four different solidification pathways have been investigated in terms of the microstructure and the high-temperature compressive behaviors. The primary phases appeared in the four alloys are very sensitive to the cooling rate, which decrease in the size and the volume fraction as the cooling rate increases. The morphologies of the primary ζ′-Au₅Sn phase are in dendritic at low cooling rate and change to rosette-like at high cooling rate. When the cooling rate is about 3.5 × 10⁴ K/min, the primary ζ′-Au₅Sn can be suppressed but small δ-AuSn particles appear instead as the primary phase. The compressive behaviors at 220°C exhibit a low yielding stress and a long stress platform for the alloy prepared by injection casting with a copper crucible, which indicates an advantageous processing route for the production of the AuSn20 strips or foils.     

离心铸造WCp/钢基复合材料的组织及断口特征

研究了离心铸造工艺制备的WCp/钢基复合材料的显微组织及断口形貌.结果表明:离心铸造显著的细化了基体材料的组织结构,WC颗粒在复合材料中均匀分布,复合材料断口特征主要表现为脆性断裂,在断口上可以观察到WC颗粒开裂和界面脱粘现象.     

离心铸造原位初生Si/Al3Ni颗粒增强铝基复合材料

采用离心铸造制备原位初生Si和Al3Ni颗粒混合增强铝基复合材料的筒状铸件。通过光学显微镜(OM)、XRD、SEM、EDS以及洛氏硬度计等研究了复合材料的组织和性能。结果表明,所制备的复合材料铸件外层偏聚少量初生Si和大量Al3Ni颗粒,内层偏聚大量初生Si和少量Al3Ni颗粒,中间层没有增强颗粒。从铸件的外层到内层,增强颗粒的含量先降低后升高,复合材料的硬度也呈现出相应的变化规律。分析了离心场中多相流体的运动规律,发现复合材料中增强颗粒的分布与高重力系数G参数条件下初生Si和Al3Ni颗粒的密度以及它们的相互碰撞、粘结等作用有关。     

Influence of time evolution of particle shape on rheological behavior of semisolid slurries of magnesium alloy AZ91D

To gain the insights into the influence of the morphology of solid particles on rheological behavior of semisolid metal slurries, the time evolution of Hausdorff dimensionality describing the particle morphology is deduced in order to quantitatively analyze the time evolution of the particle morphology. In consideration of the role of the liquid entrapped by non-spherical solid particles, the non-spherical solid particles with the entrapped liquid are treated as spherical solid particles, and the equivalent solid volume fraction is defined as the sum of solid volume fraction and the volume fraction of the entrapped liquid. This model could be used to analyze the rheological behavior of the semisolid metal slurries containing the non-spherical particles with Hausdorff dimensionality less than 3. Moreover, the rheological behavior of semisolid magnesium alloy AZ91D is theoretically analyzed by this model during isothermal shearing and continuous cooling. The calculated results are found coinciding with the experimental results and the calculated results also reveal that the shear rate and cooling rate could influence the rheological behavior of semisolid metal slurries by changing the morphology of solid particles except by affecting agglomeration degree.     

Fluidity and microstructure formation during flow of Al- SiC particle composites

This article presents the results of casting and spiral fluidity in a Al-7 wt% Si alloy reinforced with 10,15, and 20 vol% SiC particles in permanent molds. The fluidity of the Al-SiC slurry increases linearly with temperature up to about 760 °C. Above this temperature, the casting fluidity of the Al-SiC particle slurry does not change significantly with an increase in temperature. In several cases, the fluidity decreased at temperatures above 760 °C. The fluidity of Al-SiC melts containing 9-μm SiC particles decreased with an increase in volume percentage of SiC up to 15 vol% (the range studied), presumably due to an increase in the viscosity of the melt with increasing volume percentage of dispersoid and changes in thermophysical properties of the composite. However, the fluidity of Al-20 vol% SiC of 14-μm particle size is higher than the fluidity of Al-15 vol% SiC 9-μm particles, indicating the role of particle size and surface area in de-creasing fluidity. Composite slurries travel farther in a channel of larger cross sections compared to channels of smaller cross sections under similar conditions. Casting fluidity increases linearly with an in-crease in cross section of the channel. A model has been proposed to calculate the values of fluidity of the composite as a function of particle volume percent, superheat, flow velocity of the melt, and the cross sec-tion of the flow channel. Experimental observations have been compared with the predictions of the model, and some deviations have been attributed to settling and segregation of SiC particles observed through microstructural examination. (on leave from Dept. of Metallurgy, University of Roorkee, Roorkee (U.P.)-247667, India)     

Modeling of eutectic macrosegregation in centrifugal casting of thin walled ZA8 zinc alloy

The maximum segregation zone and microstructure formation during the solidification of thin walled ZA8 zinc–aluminum alloy produced by centrifugal casting are investigated. From the results obtained, it is seen that the maximum segregation zone of the eutectic through the part section corresponds to the zone of final solidification point. The concentration of eutectic through the section changes depending on the initial mold temperature, pouring temperature, and cooling rate. A high cooling rate reduces the rate of change in eutectic concentration across the section. The distance separating the maximum segregation zone from the inner and outer faces of the casting can be controlled by controlling the ratio between the speeds of the solidification fronts advancing from opposite sides. The microstructure obtained becomes finer as the cooling rate increases. The structure of eutectic changes according to the cooling rate, and may be granular or lamellar.     

THEORETICAL ANALYSIS OF PARTICLE DISTRIBUTION IN GRADIENT COMPOSITE BY CENTRIFUGAL CASTING

A theoretical analysis was presented to produce gradient composite by centrifugal casting.particle movement in liquid metal is described and gradient distribution of particles in com-posite is calculated in a centrifugal field.The factors affected the gradient distribution are discussed in detail .There exist composite zone and blank zone in(?)radient composite.whichwas proved by experiments. Finally,a theoretical analysis is given to explain the abovementioned particle distribution.     

Numerical simulation and experimental verification of gravity and centrifugal investment casting low pressure turbine blades for high Nb–TiAl alloy

Gravity and centrifugal investment casting processes of low-pressure turbine blades with high Nb–TiAl alloy were simulated by Procast software. Actual blade components were poured by vacuum induction suspended furnace with Ar protection. The experimental verification indicated that the simulation results were in good agreement with the experimental results. Comparative results had shown that the surface of centrifugal casting blade was more complete than that of gravity casting one. In gravity casting process, molten metal filled the thinnest trailing edge at last, resulting in the generation of misrun defects. Furthermore, the shrinkage porosity and crack defects of gravity casting were much more and dispersive. The internal and external quality of centrifugal casting was much better than that of gravity casting. Microstructures from edge to center of gravity casting blade had no significant change. The microstructure for centrifugal casting blade is finer than that for gravity casting blade, however, a large number of dentritic γ segregation appeared in the blade edge of centrifugal casting, which resulted from the fast cooling rate of centrifugal casting surface.     

Microstrucmral characteristics and properties in centrifugal casting of SiCp/Zl104 composite

The microstructural characteristics and Brinell hardness of a cylinder produced by centrifugal casting were investigated using 20% (volume fraction) SiC_p/Zl104 composites. Macrostructure and XRD analysis show that most of SiC particles segregate to the external circumference of the cylinder, the other SiC particles maintain in the inner circumference of the cylinder, and a free particle zone is left in the middle circumference of the cylinder. Microstructural characteristics and quantitative assessment of SiC particles show that most of congregated SiC particles in 20%SiC_p/Zl104 composites are dispersed by centrifugal force, and the other congregated SiC particles and most of alumina oxide are segregated to the inner circumference of the cylinder. The SiC particles in aluminum melt can promote the refinement of primary α(Al) during solidification, and fine primary α(Al) grains can also promote the uniform distribution of SiC particles. Brinell hardness of SiC_p/Zl104 composites is connected with not only the volume fraction of SiC particles, but also the distribution of SiC particles in matrix alloy.     

Centrifugal casting processes of manufacturing <Emphasis Type="Italic">in situ</Emphasis> functionally gradient composite materials of Al-19Si-5Mg alloy

Cylindrical components of in situ functionally gradient composite materials of Al-19Si-5Mg alloy were manufactured by centrifugal casting. Microstructure characteristics of the manufactured components were observed and the effects of the used process factors on these characteristics were analyzed. The results of observations shows that, in thickness, the components possess microstructures accumulating lots of Mg₂Si particles and a portion of primary silicon particles in the inner layer, a little Mg₂Si and primary silicon particles in the outer layer, and without any Mg₂Si and primary silicon particle in the middle layer. The results of the analysis indicate that the rotation rate of centrifugal casting, mould temperature, and melt pouring temperature have evidently affected the accumulation of the second phase particles. Also, the higher the centrifugal rotation rate, mould temperature, and melt pouring temperature are, the more evident in the inner layer the degree of accumulation of Mg₂Si and primary silicon particles is.     

Centrifugal casting processes of manufacturing in situ functionally gradient composite materials of Al-19Si-5Mg alloy

Cylindrical components of in situ functionally gradient composite materials of Al-19Si-5Mg alloy were manufactured by centrifugal casting. Microstructure characteristics of the manufactured components were observed and the effects of the used process factors on these character-istics were analyzed. The results of observations shows that, in thickness, the components possess microstructures accumulating lots of Mg2Si particles and a portion of primary silicon particles in the inner layer, a little Mg2Si and primary silicon particles in the outer layer, and without any Mg2Si and primary silicon particle in the middle layer. The results of the analysis indicate that the rotation rate of centrifugal casting, mould temperature, and melt pouring temperature have evidently affected the accumulation of the second phase particles. Also, the higher the centrifugal rotation rate, mould temperature, and melt pouring temperature are, the more evident in the inner layer the degree of accumulation of Mg2Si and primary silicon particles is.     

Rheological behavior of molten Al-SiC slurries and comparison of their behavior with metallic slurries

In this study a new precise rotational viscometer was developed and used to measure the viscosity of molten A356 alloy containing 5, 15, and 25vol.% of 90–106 μm SiC particles at 650 and 690 °C. Three types of typical curves viscosity (η) versus volume fraction of SiC particles, shear time (t), and shear rate (γ) were derived advantage from the results of viscosity measurements. It would present the viscosity got lowered by decreasing particle volume fraction and by increasing the amounts of shear time and shear rate. In the next step, the influence of the number of aggregates on apparent viscosity was studied by the special tests, developed in this research. Also the formation of aggregates in Al-SiC composite slurries was explained and compared with metallic slurries. It concluded that the origin of aggregation in Al-SiC slurries was long range electrical forces while in metallic slurries it was micro welds between particles. it would show the rheological behavior of Al-SiC slurries could be justified according to the nature and the numbers of their aggregates. At the end, the implications of findings in order to predict the gradient of particles in functionally graded Al-SiC composites, produced by casting, were discussed.     

Process of graphitization in gray cast iron under pressure

Conclusions  

Aluminum alloy pistons reinforced with SiC fabricated by centrifugal casting

Hypereutectic Al-Si alloy-based composite pistons reinforced with SiC particles locally at the head were fabricated by centrifugal casting. The effects of various technique parameters, i.e., the slurry temperature of the alloy, the mold temperature and the rotation speed of the mold, on the particle segregation were investigated, and the macromorphologies and microstructures of pistons were observed. The mechanical properties, such as hardness and wear resistance along the axis of the piston and the thermal expansion coefficient at the piston head, were measured. The results showed that, (1) centrifugal casting can be used as a new and effective method in manufacturing pistons, and reasonable parameters were 850 °C, 600 °C and 800 rpm for the slurry temperature of the alloy, the mold temperature and the rotation speed of the mold, respectively; (2) the hardness values of pistons fabricated by centrifugal casting gradually increased from the piston skirt to the piston head, and the average hardness value in piston heads was improved by 23.7HRB over that of pistons fabricated by gravity permanent mold casting; (3) the piston heads showed excellent wear resistance, and the wear rate of piston heads decreased by 70.3% over that of the piston fabricated by gravity permanent mold casting; and (4) the average linear expansion coefficient of the piston head was 15.3 × 10⁻⁶ K⁻¹ and decreased by 23.1% over that of pistons fabricated by gravity permanent mold casting.     

Effect of powder synthesis atmosphere on the characteristics of iron nanopowder in a plasma arc discharge process

To investigate the effect of the powder synthesis atmosphere on the characteristics of iron nano powder in a plasma arc discharge process, the hydrogen volume fraction in the powder synthesis atmosphere was changed from 10 to 50%. The particle size, phase structure, and magnetic property of the synthesized iron powder were studied using FE-TEM, XRD, XPS, and a vibration sample magnetometer at room temperature. The particle size increased simultaneously with the increase in the hydrogen volume fraction, and the particle size ranged from about 20 to 100 nm with the change in the hydrogen volume fraction from 10 to 50%. The synthesized iron powder particles had a two-layered shell-core structure composed of α-Fe in the core, Fe₃O₄ in the inner shell, and FeO(OH) in the outer shell. The thickness of the oxide shells decreased with increasing hydrogen volume fraction in the powder synthesis atmosphere.     

Centrifugal casting of in-situ Al-Mg2Si(1-x)Snx composites: a study of radial segregation

During centrifugal casting of Al-Mg₂Si hypereutectic cylinders, the light Mg₂Si particles are commonly segregated in centripetal direction towards the inner periphery. In order to change this inevitable centripetal segregation of Mg₂Si particles, some amounts of tin up to 8 wt pct were added to Al-15wt.% Mg₂Si alloy to enhance the formation of Mg₂Si_(1?x)Sn_x particles with variant stoichiometry thus variant density. XRD, EDS, optical metallography and hardness measurements were used to evaluate the stoichiometry and segregation patterns of in situ formed Mg₂Si_(1?x)Sn_x particles. According to the results, the cylinder containing 6 wt pct Sn illustrates a rather uniform distribution of particles thus hardness in all radial sections. However, the cylinders with higher amounts of Sn exhibit a radial segregation of Mg₂Si_(1?x)Sn_x particles in centrifugal direction towards the outer periphery. The results are interpreted in view of the Stokes’ law and the difference in density of the particles and the melt.