In-situ synthesis of 15R-Sialon from Al-Si3N4-Al2O3 composite at 1500°C via liquid-phase sintering

In this study, alumina-based composite with 12 wt% Al and 16 wt% Si₃N₄ was designed to achieve the synthesis of 15R-Sialon reinforced alumina composite. To investigate the reaction mechanism, two-step sintered Al-Si₃N₄-Al₂O₃ samples at different temperatures ranging from 600°C to 1500°C were prepared and characterized via X-ray diffraction and scanning electron microscope (SEM). The results revealed that 15R-Sialon was synthesized at 1500°C through a novel liquid Si phase sintering and Si₃N₄ played as a precursor and a reactant. First, Si₃N₄ precursor reacted with Al to form intermediate phases AlN and Si, which were not further transformed below 1400°C. When the sintering temperature was 1500°C, the formed Si presented as a liquid phase, under the influence of which plate-like15R-Sialon was generated from Al₂O₃, residual Si₃N₄, and derived AlN. The obtained Si was also involved in the synthesis of 15R-Sialon and completely transformed. In addition to the AlN from Si₃N₄, the AlN deriving from the nitridation of Al may not react with liquid Si. Compared to 15R-Sialon from liquid Si, plate-like 15R-Sialon with smaller size was generated from AlN, SiO, and O₂.     

热处理工艺对22MnB5钢铝硅镀层氧化层厚度和组织演变的影响

目的探究奥氏体化工艺对铝硅镀层氧化层厚度和微观组织的影响规律及其演变机理。方法以热浸镀Al-10%Si的22MnB5为研究对象,采用扫描电子显微镜(SEM)、辉光放电光谱仪(GD-OES)和X射线衍射仪(XRD)等仪器,观察镀层在奥氏体化过程中氧化层厚度的变化和微观组织的演变规律。结果当试样以15℃/s的速率升温到900℃后立即水淬,镀层氧化层最薄,当试样升温到900℃保温5 min后水淬,镀层氧化层出现了不同程度的开裂,镀层表面出现孔洞和脱落的现象,氧化层厚度明显增加。结论奥氏体化保温时间比奥氏体化升温速率对镀层氧化层厚度的影响更大,保温时间越长,氧渗入镀层的深度越深,氧化层越厚,奥氏体化时间的延长不利于镀层氧化层保持完整性,影响镀层对钢基体的保护功能。镀层及其氧化层的微观组织演变规律为:镀层中首先形成Al2Fe3Si3(τ1)和Fe2Al5相,随后Fe2Al5相生长并伴随FeAl2相形成,而后FeAl2+Fe2Al5相生长且有FeAl析出,随后FeAl相生长,氧化层出现孔洞,最后氧化层破裂,镀层表面孔洞增加,最终组织为FeAl2+Fe2Al5+FeAl。     

喷涂功率对YSZ涂层的力学性能和抗铝硅熔体腐蚀性能的影响

热浸镀Al–Si合金涂层是一种有效的现代钢铁防腐涂层，但熔融Al–Si合金腐蚀已成为热浸镀Al–Si合金生产线沉没辊及其备件亟待解决的关键问题之一。本工作采用大气等离子喷涂技术制备Y2O3部分稳定ZrO2(YSZ)/NiCrAlY防护涂层，研究了喷涂功率对YSZ涂层组织和力学性能的影响和涂层在700℃下Al–Si熔体中的腐蚀行为。结果表明，YSZ涂层是由板条和层间柱状晶粒组成的典型层状结构，随着喷涂功率从37 kW增至46 kW，层间柱状结晶呈长大趋势；YSZ涂层主要由t-ZrO2相和少量m-ZrO2相组成，喷涂功率对涂层相组成无明显影响；喷涂功率为40 kW的YSZ涂层具有较高的显微硬度642.4 HV0.3和结合强度62 MPa。此外，当带有涂层的样品在700℃的Al–Si熔液中腐蚀240 h后，YSZ涂层与高温Al–Si熔液之间的界面没有反应层生成，同时Al–Si合金熔液中的Al和Si元素也未渗透进YSZ涂层内部，表明YSZ/NiCrAlY防护涂层有效地将Al–Si合金熔体阻挡在涂层表面。     

硅铝合金车削中切削力和切削温度的研究

研究金刚石刀具切削硅铝合金时切削力和切削温度的变化规律。结果表明，在金刚石刀具精车硅铝合金时，主切削力和切削温度随进给量的增加同步增长，在切削时应尽量选取较小的进给量避免切削区温度过高。在较高切削速度时．存在一段使切削力最小的范围，切削时切削速度应尽量选在这段范围内，改善切削效果。切削温度在所选切削范围内随切削速度的增加而持续增加。     

过滤铸造对高硅铝合金中初晶硅尺寸的控制

初晶硅颗粒的细化是过共晶高硅铝合金制备过程中的一个主要问题。本研究提出了一种通过过滤的方式来获得含有细化初晶硅颗粒的高硅铝合金的方法。在过滤铸造的过程中,过共晶硅铝合金熔体保持在Al-Si二元相图共晶线偏上一点的温度。大颗粒初晶硅被筛网阻拦下来,细小的初晶硅颗粒连同共晶熔体穿过筛网进入下部坩埚冷却结晶。在本研究中通过以上方法所制备的高硅铝合金中硅的质量分数约为27%,初晶硅颗粒的平均直径在45 μm以下,圆度为1.43,布氏硬度为70 HB。通过该方法有望制备出初晶硅颗粒球形度更高、硅含量更高的高硅铝合金产品。     

Cu-P合金变质过共晶铝硅合金时熔体搅拌工艺对变质效果的影响

针对过共晶铝硅合金经过P变质后初生硅仍然粗人大的问题,采用Cu-9%P合金变质处理Al-15%Si、Al-18%Si、Al-20%Si合金,变质处理后对熔体进行搅拌,研究了搅拌工艺对变质处理效果的影响,分析了熔体搅拌提高变质效果机理。结果表明,Cu-P合金变质过共晶铝硅合金时,对熔体进行搅拌可显著提高变质效果,初生硅最高可细化85%;在最佳搅拌时间内,搅拌强度越大、硅含量越高,变质效果越好;搅拌熔体迫使富P区域内AIP停止生长,熔体流动速度越快,对富PP区域内AlP的冲刷越强烈,越容易得到细小的AlP;搅拌熔体能够增加组织中初生α相的数量,搅拌工艺合适时,典型的共晶组织基本消失,可获得连续的α基体上均匀分布细小初生硅的凝固组织。     

Analysis of thermodynamics and kinetics of titanium between top slag and liquid steel

Titanium is an impurity element in some special steel grades.The existence of titanium decreases the grain size and lowers the yield strength,resulting in low quality of these steels with regard to various properties.Thus,the titanium content should be reduced to the minimum.Based on the industrial production of ultra-low carbon Al-Si killed steel,this paper investigated the physical-chemical behaviors of titanium with and without desulfurization during RH refining.The influences of Ti content in hot metal,ladle slag composition,and ladle slag quantity,etc.,on the Ti content in refined liquid steel were discussed.The results show that the partition ratio of titanium between ladle slag and liquid steel is inversely proportional to the Al content to the power of 4/3,and the empirical formula regressed from practical experience can be expressed as w(TiO2)/w[Ti]=48/w[Al]4/3.Maximum partition ratio of titanium between top slag and liquid steel can be ensured by an optimum slag composition including components of FeOx and Al2O3 and an appropriate slag basicity.The contents of FetO and Al2O3 should be controlled above 6% and below 20% respectively and the slag basicity should be kept within 1.5 to 3.0.Moreover,desulfurization refining in the RH vacuum will decrease the partition ratio of titanium between ladle slag and liquid steel significantly.To keep the Ti content stably below 15×10-4% in a 300 ton ladle,the Ti content in hot metal must be lower than 500×10-4% and the thickness of ladle slag carried over from BOF slag must be less than 50 mm.     

Modeling of gas porosity and microstructure formation during dendritic and eutectic solidification of ternary Al-Si-Mg alloys

A two-dimensional(2-D)multi-component and multi-phase cellular automaton(CA)model coupled with the Calphad method and finite difference method(FDM)is proposed to simulate the gas pore for-mation and microstructures in solidification process of hypoeutectic Al-Si-Mg alloys.In this model,the pore growth,and dendritic and eutectic solidification are simulated using a CA technique.To achieve the equilibrium among multiple phases during ternary Al-based alloy solidification,the phase transition thermodynamics and kinetics are evaluated by adopting the Calphad method.The diffusion equations of hydrogen and two solutes are solved by FDM.The developed CA-FDM coupled model can be used for sim-ulating the evolution of gas microporosity and microstructures,involving dendrites and irregular binary and ternary eutectics,of ternary hypoeutectic Al-Si-Mg alloys.It has the capability of reproducing the interactions between the hydrogen microporosity formation and the growth of dendrites and eutectics,the competitive growth among the growing gas pores of different sizes,together with the time-evolving concentration fields of hydrogen and solutes.The simulated morphology of gas pore and microstructure has a good agreement with the experimental observation.The influences of the initial hydrogen concen-tration and cooling rate on the microporosity formation are investigated.It is found that the main portion of porosity formation occurs in the eutectic solidification stage through analyzing the profiles of porosity percentage and solid fraction varying with solidification time.The varying features of simulated porosity percentage,the maximum and average pores radii indicate that increasing initial hydrogen concentration promotes the formation of higher final porosity percentage and larger pores,while the size of gas pores will significantly reduce with increasing cooling rate,leading to a lower final porosity percentage.     

Understanding grain refining and anti Si-poisoning effect in Al-10Si/Al-5Nb-B system

Grain refinement is critical for fabricating high-quality Al-Si casting components in the application of automobile and aerospace industries,while the well-known Si-poisoning effect makes it difficult.Nbbased refiners offer an effective method to refine Al-Si casting alloys,but their anti Si-poisoning capability is far from being understood.In this work,the grain refining mechanism and the anti Si-poisoning effect in the Al-10 Si/Al-5 Nb-B system were systematically investigated by combining transmission electron microscope,first-principles calculations,and thermodynamic calculations.It is revealed that NbB₂provides the main nucleation site in the Al-10 Si ingot inoculated by 0.1 wt.%Nb Al-5 Nb-B refiner.The exposed Nb atoms on the(0001)NbB₂and(1-100)NbB₂surface can be substituted by Al to form(Al,Nb)B₂intermedia layers.In addition,a layer of NbAl₃-like compound(NbAl₃')can cover the surface of NbB₂with the orientation relation of(1-100)[11-20]NbB_2//(110)[110]NbAl₃'.Both of the(Al,Nb)B₂and NbAl₃'intermedia layers contribute to enhancing the nucleation potency of NbB₂particles.These discoveries provide fundamental insight to the grain refining mechanism of the Nb-B based refiners for Al-Si casting alloys and are expected to guide the future development of stronger refiners for Al-Si casting alloys.     

Mechanism of mechanical–chemical synergistic activation for preparation of mullite ceramics from high-alumina coal fly ash

High-alumina coal fly ash (HAFA) is a special solid waste due to the existence of more than 45% alumina and 35% silica, which can be applied to prepare Al-Si series ceramics if the impurities can be removed and the Al/Si mass ratio can exceed 2.55 (Mullite: 3Al₂O₃.2SiO₂). In this work, a new mechanical–chemical synergistic activation–desilication process is proposed, and the contents of different impurities can be lowered up to less than 1%, and the Al/Si mass ratio can be elevated from 1.26 to 2.71. Especially, the mechanism of this process is investigated in detail. The analysis of the mechanism shows that the decrease of Q⁴(3Al) and the increase of Q⁴(0Al), Q⁴(1Al), and Q⁴(2Al) improve amorphous silicate reactivity through synergistic activation, and the exposed amorphous Si-O-/Si-O-Si can be removed by OH- during the desilication process (desilicated ratio>55%), which help the fine mullite to exhibit excellent properties (bulk density > 2.85 g/cm³, apparent porosity < 0.5%) during the sintering process. Finally, this process not only decreases the pollution but also alleviates the shortage of Al/Si resources and promotes the clean development of coal-fired power generation.