Segregation band formation in Al-Si die castings

Banded defects are often found in high-pressure die castings. These bands can contain segregation, porosity, and/or tears, and changing casting conditions and alloy are known to change the position and make-up of the bands. Due to the complex, dynamic nature of the high-pressure die-casting (HPDC) process, it is very difficult to study the effect of individual parameters on band formation. In the work presented here, bands of segregation similar to those found in cold-chamber HPDC aluminum alloys were found in laboratory gravity die castings. Samples were cast with a range of fraction solids from 0 to 0.3 and the effect of die temperature and external solid fraction on segregation bands was investigated. The results are considered with reference to the rheological properties of the filling semisolid metal and a formation mechanism for bands is proposed by considering flow past a solidifying immobile wall layer.     

Review on testers for measuring flow properties of bulk solids

 The author was asked by the International Fine Particle Research Institue (IFPRI) to write a critical review on shear testers for IFPRI-members. The review was delivered to IFPRI in summer 1999. Following the contract with IFPRI it was not allowed to publish the review elsewhere for at least two years. Granular Matter invited the author to submit the review in the original form; during the refereeing process (besides other changes) it turned out that some remarks should be added here for clarification: - Since 1999, the author is not aware of a really new device for testing bulk solid properties, which could lead to a change of the general comments and conclusions provided in the review. It was argued, that the review is referring too much to the work of Jenike, while the works of Johanson and Peschl were not adequately cited. Both are excellent engineers with a lot of experience, but their basic ideas are not available in published form, and if, they are not set in relation to alternative approaches so that an objective comparison in detail would be a future research issue rather than a topic in this report. A discussion on the influence of electrostatic charges was missing. There hardly is an influence, since the particles are in continuous contact. Only with non-conducting plastic particles electrostatic charges could cause problems. But no relevant experiments and results are known. In closed systems, the effect of electric charges is thus mainly neglected, but it is clear that electrostatic forces are eminent in flows with a free surface – an issue not addressed in this review. Received: 1 November 2002     

Effect of deformation route on microstructural development in aluminum processed by equal channel angular extrusion

Aluminum has been deformed by equal channel angular extrusion (ECAE) to obtain submicron-grained structures under different deformation routes. The deformation routes were varied by rotating billets through 0, 90, and 180 deg between each extrusion pass, and were designated as route A, B_C, and C, respectively. Based on quantitative microstructural analysis, the effectiveness of the deformation route is shown to depend upon the different definition used. The order of effectiveness is (a) A > B_C > C for both 90 and 120 deg dies, in terms of the generation of high-angle grain boundaries (HAGBs); (b) B_C > C > A for both 90 and 120 deg dies, in terms of the formation of equiaxed shape of grains; and (c) B_C > A > C for 90 deg die and B_C ∼ A > C for 120 die, in terms of reducing grain size. It is suggested that the generation of HAGBs can be related to the accumulation of nonredundant strain, while the shape and orientation of grains may be linked to the shearing patterns of the deformation route.     

Copper-zirconium tungstate composites exhibiting low and negative thermal expansion influenced by reinforcement phase transformations

A fully-dense Cu-75 vol pct ZrW₂O₈ metal matrix composite was fabricated by hot isostatic pressing of Cu-coated ZrW₂O₈ particles. A small amount of the high-pressure γ-ZrW₂O₈ phase was created during the cooldown and depressurization following densification; near complete transformation to γ-ZrW₂O₈ was achieved by subsequent cold isostatic pressing. The thermal expansion behavior of the composite between 25°C and 325°C was altered by the cold isostatic pressing treatment, and also depended on the length of time that had passed between thermal cycles. The measured thermal expansion coefficients within specific temperature ranges varied from −6·10⁻⁶ K⁻¹ to far above the thermal expansion coefficient of the copper matrix. The complex temperature-dependent expansion/contraction behavior could be justified by considering the evolution of phase transformations taking place in the ZrW₂O₈ phase, which were observed by in-situ synchrotron X-ray diffraction measurements.     

Midplane-symmetry breaking in the flow between two counter-rotating disks

This paper considers the axisymmetric steady flow driven by exact counter rotation of two co-axial disks of finite radius. At the edges of the rotating disks one of three conditions is (typically) imposed: (i) zero velocity, corresponding to a stationary, impermeable, cylindrical shroud (ii) zero normal velocity and zero tangential fluid traction, corresponding to a (confined) free surface and (iii) an edge constraint that is consistent with a similarity solution of von Kármán form. The similarity solution is valid in an infinite geometry and possesses a pitchfork bifurcation that breaks the midplane symmetry at a critical Reynolds number. In this paper, similar bifurcations of the global (finite-domain) flow are sought and comparisons are made between the resulting bifurcation structure and that found for the similarity solution. The aim is to assess the validity of the nonlinear similarity solutions in finite domains and to explore the sensitivity of the solution structure to edge conditions that are implicitly neglected when assuming a self-similar flow. It is found that, whilst the symmetric similarity solution can be quantitatively useful for a range of boundary conditions, the bifurcated structure of the finite-domain flow is rather different for each boundary condition and bears little resemblance to the self-similar flow.     

Preparation and characterization of cuprous iodide nanoparticles

A new technique for the preparation of CuI nanoparticles from CuSO₄ and KI ethanol solutions has been developed. Preparation conditions were optimized through a series of experiments. Under these conditions, the yield of CuI reached 95.39%. The product was characterized and the reaction kinetics was studied. The results show that the product takes a roughly spherical shape with an average particle size of less then 50 nm. The activation energy of the formation of CuI is found to be E _a = 0.58 × 10² kJ/mol, and the preexponential factor in the Arrhenius equation is k ₀ = 7.43 × 10¹⁶ mol/(l s). The text was submitted by the authors in English.     

The effect of solidification time and heat treatment on the fatigue properties of a cast 319 aluminum alloy

Solidification time and heat treatment are known to have a large effect on the microstructure of cast aluminum alloys. This study was conducted to quantify how the fatigue properties of a 319-type aluminum alloy are affected by solidification time and heat treatment. Both porosity-containing (non-hot isostatically pressed (HIP)) and porosity-free (HIP) samples in the T6 (“peak aged”) or T7 (“overaged”) heattreated conditions were tested. As the solidification time increased, the average initiating pore diameter increased and stress-controlled fatigue life decreased. Heat treatment was observed to have a large effect on fatigue properties of the HIP samples. However, in the non-HIP fatigue samples, heat treatment did not significantly change the fatigue life or fatigue strength of the cast 319-type alloy. The absence of an influence of heat treatment on fatigue response is attributed to the predominance of the microporosity in fatigue crack initiation in cast aluminum.     

Analytical results for the plectonemic response of supercoiled DNA

The DNA molecule is modeled as an elastic rod with bending and twisting rigidities, subjected to external tension and twist applied at one end, the other end being clamped. We study the plectonemic equilibrium of such a rod, taking into account the impenetrability constraint. Numerical solutions of this boundary value problem have previously shown that purely elastic models can reproduce the supercoiling response of the DNA molecule. Using a variational approach, we derive analytical formulae for the elastic response of the filament, and extend former numerical results.