Fabrication of Al-3.7?Pct Si-0.18?Pct Mg Foam Strengthened by AlN Particle Dispersion and its Compressive Properties

Al-3.7 pct Si-0.18 pct Mg foams strengthened by AlN particle dispersion were prepared by a melt foaming method, and the effect of foaming temperature on the foaming behavior was investigated. Al-3.7 pct Si-0.18 pct Mg alloy containing AlN particles was prepared by noncompressive infiltration of Al powder compacts with molten Al alloy in nitrogen atmosphere, and it was foamed at different foaming temperatures ranging from 1023 to 1173 K. The porosity of prepared foam decreases and the pore structure becomes homogeneous with increasing foaming temperature. When the foaming temperature is higher than 1123 K, homogeneous pores are formed in the prepared ingot without using oxide particles and metallic calcium granules, which are usually used for stabilizing a foaming process. This stabilization of the foaming at high temperatures is possibly caused by Al₃Ti intermetallic compounds formed at high temperature and AlN particles. Compression tests for the prepared foams revealed that the absorbed energy per unit mass of prepared Al-3.7 pct Si-0.18 pct Mg foam is higher than those of aluminum foams strengthened by alloying or dispersion of reinforcements. It is remarkable that the oscillation in stress, which usually appears in strengthened aluminum foams, does not appear in the plateau stress region of the present Al-3.7 pct Si-0.18 pct Mg foam. The homogeneity in cell walls and pore morphology due to the stabilization of pore formation and growth by AlN and Al₃Ti particles is a possible cause of this smooth plateau stress region.     

The nucleation of aluminum grains in alloys of aluminum with titanium and boron

The microstructure of a ternary alloy, Al-5 wt pct Ti, 1 wt pct B, has been examined by optical and electron transmission microscopy, by selected area diffraction, and electron probe microscopy, by selected area diffraction, and electron probe microanalysis. Particles of Al₃Ti are found at the center of grains and there exist preferred epitaxial orientations between this compound and the surrounding aluminum. Particles containing titanium and boron occur at aluminum grain boundaries and have no preferred configurations with respect to the aluminum or to one another. It is concluded that the active heterogeneous nuclei are therefore Al₃Ti and that particles of TiB₂, AlB₂, or a ternary compound are not active in this alloy. Grain size measurements in binary Al-Ti alloys suggest that particles of a nucleating phase must be present at concentrations as low as 0.01 wt pct Ti, and it is suggested that these could be Al₃Ti if the existing binary phase diagram Al-Ti is in error.     

The impact of cooling rates on the microstructure of Al-U alloys

The impact of cooling rates on the microstructure of Al-U alloys was studied by optical, scanning electron, and transmission electron microscopy. A variety of solidification techniques were employed to obtain cooling rates ranging between 3 × 10⁻² and 10⁶ K/s. High-purity uranium (99.9 pct) and high-purity aluminum (99.99 pct), or “commercially pure” type Al-1050 aluminum alloys were used to prepare Al-U alloys with U concentration ranging between 3 and 22 wt pct. The U concentration at which a coupled eutectic growth was observed depends on the cooling rates imposed during solidification and ranged from 13.8 wt pct for the slower cooling rates to more than 22 wt pct for the fastest cooling rates. The eutectic morphology and its distribution depends on the type of aluminum used in preparing the alloys and on the cooling rates during solidification. The eutectic in alloys prepared from pure aluminum was evenly distributed, while for those prepared from Al-1050, the eutectic was unevenly distributed, with eutectic colonies of up to 3 mm in diameter. Two lamellar eutectic structures were observed in alloys prepared from pure aluminum containing more than 18 wt pct U, which solidified by cooling rates of about 10 K/s. One structure consisted of the stable eutectic between UAl₄ and Al lamella. The other structure consisted of a metastable eutectic between UAl₃ and Al lamella. At least three different eutectic morphologies were observed in alloys prepared from Al-1050.     

The effect of molybdenum on γ′ coarsening and on elevated-temperature hardness in some experimental nickel-base superalloys

The coarsening of γ′ and the elevated-temperature hardness have been studied as a function of molybdenum content, time, and temperature in experimental wrought nickel-base superalloys. The alloys were selected from a systematic series containing 3, 4 1/2, and 6 wt pct Al and 1 wt pct Al plus 3 1/2 wt pct Ti. Each of the aluminum (plus titanium) series consisted of four alloys containing 0, 2, 5, and 8 wt pct Mo. The alloys were solution-treated plus aged up to 112 h at 1700°F (925°C) and up to 1000 h at 1400°F (760°C). Molybdenum retards the coarsening of γ′ on aging; this retarding effect is most pronounced in alloys containing 6 wt pct Al. The coarsening of γ′ particles follows Ostwald ripening kinetics. Hardness testingin vacuo at temperatures up to 1750°F (955°C) shows that molybdenum also increases the elevated-temperature hardness significantly. The relation of elevated-temperature hardness to the volume fraction of γ′ is considered, and the influence of aluminum and titanium contents is discussed.     

Silicide precipitation in the Ti−Zr−Al−Si system

Silicide precipitation has been studied in a number of martensitic Ti−Si alloys and ternary and more complex alloys containing zirconium and aluminum. The precipitation has been shown to be strongly influenced by composition. Heterogeneous nucleation of Ti₅Si₃ occurs at, and above, 500°C in binary Ti−Si alloys containing up to 2.4 pct Si and little conventional precipitation hardening can be achieved. Zirconium additions are incorporated into the silicide and produces finer, more stable particle dispersions accompanied by an improved aging response. If critical concentrations of zirconium (approximately 5 pct) and silicon (approximately 1 pct) are present, matrix nucleation of G.P. zones occurs at, and below 550°C. This is accompanied by a significant aging response. Additions of aluminum reduce the rate of precipitate growth while having little effect on the nature of the precipitates produced. It has been shown that typical commercial heat treatments of “near α” silicon-bearing alloys (0.5 pct Si max) do not produce silicide dispersions. This paper is based upon a thesis submitted by H. M. FLOWER in partial fulfillment of the requirements of the degree of Doctor of Philosophy at the University of London.     

Evaluation of Al-Ti-C Master Alloys as Grain Refiner for Aluminum and Its Alloys

Al-Ti-C master alloys have a great potential as efficient grain refiners for aluminum and its alloys. In the present work, the Al-Ti-C master alloys are synthesized via a relatively novel technique through the reaction of a compacted mixture of K₂TiF₆ and graphite with molten aluminum. The obtained alloys are examined using scanning electron microscopy (SEM), energy-dispersive spectroscopy, and X-ray diffraction (XRD) methods. The results indicate that the produced Al-Ti-C master alloys contain TiC and TiAl₃ particles within the aluminum matrix. Also, these alloys were evaluated using the KBI test mold. The results indicate that the produced Al-Ti-C master alloy is an efficient grain refiner for pure aluminum and its alloys compared with the Al-Ti-B one. The factors affecting the grain refinement of aluminum and its alloys are studied. The proper conditions for evaluating the efficiency of the produced Al-Ti-C master alloy to obtain a minimum grain size are as follows: temperature, 993 K (720 °C); holding time, 2 minutes; and (Ti/Al) weight ratio, 0.01 pct.     

Foamability of MgAl2O4 (Spinel)-Reinforced Aluminum Alloy Composites

A novel foamable aluminum alloy has been developed. It contains sub-micron-sized MgAl₂O₄ (spinel) particles that are generated in situ by a reaction of SiO₂ with a molten Al-Mg alloy. The study involves an optimization of parameters such as Mg concentration, SiO₂ particles size, and reaction time and shows that a composite containing MgAl₂O₄ particles as chief reinforcement in the matrix leads to effective foaming. Composites containing large sized transition phases and particle agglomerates in the matrix yield poor foam structure. The best foamable composite obtained contained 3.4 vol. pct of ultrafine (80 nm to 1 μm) MgAl₂O₄ particles uniformly distributed in an Al-Si alloy matrix. The corresponding metal foam contained 75 pct porosity and exhibited a uniform distribution of cells.     

Thermal equilibria and mechanical stability of Ti3 Al phase in Ti-Mo-Al alloys

The phase diagram of the isopleth section of the Ti-7 at. pct Mo-Al system has been improved and expanded to include alloys up to 25 at. pct aluminum. The mechanical and thermal stability of alloys aged in the two-phase region, β +Ti₃Al, was correlated to the microstructure. X-ray rocking-curve studies of the polycrystalline specimens showed that after 2 pct deformation of a Ti-7 Mo-16 Al alloy theβ matrix became preferentially plastically deformed, while the Ti₃Al particles functioned as hard particles undergoing little lattice distortions. Formerly a Graduate Student. This paper is based on a thesis submitted by T. Hamajima in partial fulfillment of the requirements for a Ph.D. degree from Rutgers University.     

Effect of Co content on the stress-corrosion cracking behavior of 7091-type aluminum powder alloys

An investigation of the stress-corrosion cracking (SCC) behavior of three aluminum powder alloys, containing 0.0, 0.4, and 0.8 wt pct Co, using double cantilever beam specimens has shown a significant increase in SCC resistance with increasing Co content. This resistance to cracking takes the form of both a decrease in plateau crack velocity and an increase in the threshold stress intensity factor for cracking (K _ISCC ) as the Co content increases. The SCC fracture is intergranular and the crack path is tortuous because of the oxides and Co₂Al₉ intermetallic particles contained within the powder metallurgy alloys. We propose that the improvements in SCC resistance result from the Co₂Al₉ particles, which catalyze the recombination and evolution of hydrogen, thereby reducing hydrogen absorption and embrittlement. Formerly with Martin Marietta Laboratories     

A fundamental study on the preparation of niobium aluminide powders by calciothermic reduction

Fine niobium aluminide powders such as NbAl₃ were produced directly from mixtures of Nb₂O₅ and aluminum powder by calciothermic reduction. Prior to the reduction experiment, phase equilibria between Nb-Al and Ca-Al alloys were studied. Isothermal annealing of the specimens in the Nb-Al-Ca system at 1273 K showed that NbAl₃ is in equilibrium with CaAl₂ and Al-rich Ca-Al liquid alloys and that Nb₃Al and Nb₂Al equilibrate with Ca-Al alloys containing around 9 to 18 and 18 to 36 mol pct Al, respectively. Based on these experimental phase equilibria and on reported thermodynamic data of the Al-Ca system, the activities of Al in Nb-Al alloys were evaluated. This information is necessary in determining suitable compositions and conditions for the coreduction and ultimate production of single-phase niobium aluminide. The procedure for preparation of niobium aluminide powders by calciothermic reduction of Nb₂O₅ consists of three steps: (1) blending of starting materials (Nb₂O₅ + Al); (2) high-temperature reaction with calcium; and (3) acid leaching. After the reduction of Nb₂O₅ with calcium and aluminum to produce niobium aluminide powders, by-products of Ca-Al alloy, CaAl₂, and CaO were formed. These were removed by leaching in aqueous acid solution. The NbAl₃ particles obtained were a few micrometers in size and contained about 0.15 wt pct oxygen.     

Development of Al-Ti-C grain refiners containing TiC

Cast Al-Ti-C grain refiners were synthesized by reacting up to 2 pct graphite particles of 20 micron average size with stirred Al-(5 to 10) pct Ti alloy melts, which generated submicron-sized TiC particles within the melts, and their solidified structures showed preferential segregation of the carbide phase in the grain or cell boundary regions and occasional presence of free carbon whose amount exceeded equilibrium values. At the usual melt temperatures of below 1273 K, though, TiC formed first, but was subsequently found to react with the melt forming a sheathing of A1₄C₃ and Ti₃AlC which resulted into poisoning of the TiC particles. However, it was possible to reverse these reactions in order to regain the virgin TiC particles by superheating the melts in the temperature region where TiC particles are thermodynamically stable. Grain refining tests using the TiC master alloys produced fine equiaxed grains of cast aluminum whose sizes were comparable to that obtainable with the standard TiB₂ commercial grain refiner. TiC particles introducedvia the master alloys were found to occur in the grain centers, thereby confirming that they nucleated aluminum crystals. On leave from Regional Research Laboratory (CSIR), Bhopal, is Research Associate.     

The effect of Mg on the microstructure and mechanical behavior of Al-Si-Mg casting alloys

The microstructure and tensile behavior of two Al-7 pct Si-Mg casting alloys, with magnesium contents of 0.4 and 0.7 pct, have been studied. Different microstructures were produced by varying the solidification rate and by modification with strontium. An extraction technique was used to determine the maximum size of the eutectic silicon flakes and particles. The eutectic Si particles in the unmodified alloys and, to a lesser extent, in the Sr-modified alloys are larger in the alloys with higher Mg content. Large Fe-rich π-phase (Al₉FeMg₃Si₅) particles are formed in the 0.7 pct Mg alloys together with some smaller β-phase (Al₅FeSi) plates; in contrast, only β-phase plates are observed in the 0.4 pct Mg alloys. The yield stress increases with the Mg content, although, at 0.7 pct Mg, it is less than expected, possibly because some of the Mg is lost to π-phase intermetallics. The tensile ductility is less in the higher Mg alloys, especially in the Sr-modified alloys, compared with the lower Mg alloys. The loss of ductility of the unmodified alloy seems to be caused by the larger Si particles, while the presence of large π-phase intermetallic particles accounts for the loss in ductility of the Sr-modified alloy.     

Microstructure-property relationships of two AI-3Li-2Cu-0.2Zr-XCd alloys

The microstructure and tensile properties of two A1-3 wt pct Li-2 wt pct Cu-0.2 wt pct Zr alloys, one Cd-free and one containing 0.2 wt pct Cd, have been investigated. The Cd-free alloy remained unrecrystallized for all solutionizing treatments studied, whereas a special treatment had to be developed to prevent recrystallization during solutionizing of the 0.2 wt pct Cd alloy. In combination with cadmium, zirconium either enters into, or nucleates on, the course Al₇Cu₂Fe and T₂ phases during high temperature annealing. This reduces the volume fraction of small coherent Al₃Zr particles in the matrix which normally inhibits recrystallization. Consequently, a low temperature anneal to precipitate Al₃Zr is necessary prior to high temperature solutionizing in order to prevent recrystallization in the Cd-containing alloy. Unlike its effect in lower lithium, higher copper content aluminum alloys, cadmium does not significantly affect the nucleation of the strengthening precipitates. If anything, cadmium has a detrimental effect on the age hardening response of this alloy, since it increases the formation of coarse Al-Cu-Li equilibrium phases at grain and subgrain boundaries and thus removes some of the copper and lithium from participating in the formation of the strengthening precipitates T₁ and δ′. Subgrain boundary fracture occurred during tensile tests of both alloys in the unrecrystallized condition; however, transgranular fracture occurred in tests of the partially recrystallized 0.2 wt pct Cd alloy. Both types of fractures are believed due to a form of strain localization associated with precipitate free zones and shearable precipitates. Formerly with the Fracture and Fatigue Research Laboratory, Georgia Institute of Technology, Atlanta, GA     

Effects of be and fe content on plane strain fracture toughness in A357 alloys

The effect of Be and Fe content on the plane strain fracture toughnessK _IC of aluminum-based A357 alloys is investigated. The fracture behavior of A357 alloys has been evaluated as a function of both the magnitude and morphology of iron-bearing compounds and silicon particles. Addition of Be is beneficial for tensile properties and fracture toughness in the case of alloys containing intermediate (0.07 pct) and higher (0.15 pct) Fe levels. On the other hand, Be added to alloys containing the lower Fe (0.01 pct) level appears detrimental to tensile strength, but the quality index, notch-yield ratio (NYR), and plane strain fracture toughness were improved. Fractographic analysis reveals that crack extension of A357 alloys occurs mainly in an intergranular fracture mode. The fracture processes are initiated by void nucleation at iron-bearing compounds or irregularly shaped eutectic silicon particles as a result of their cracking and decohesion from the matrix. Then, void growth and coalescence result in growth of the main crack by shear-linkage-induced breakdown of submicronstrengthening particles. The effect of Be on increasingK _IC is more apparent in the higher Fe alloys than in the lower Fe alloys. Superior toughness obtained by microstructural control has also been achieved in the intermediate and higher Fe levels of Be-containing alloys, with values equal to those obtained in alloys of lower Fe content.     

Effects of silicon addition on the first stage of

The influence of silicon on the precipitation kinetics of Al-Cu-Mg alloys is not yet understood, although its effect on the improvement of mechanical properties is well established. In this study, the kinetics of the first stage of precipitation in Al-1.52 pct Cu-0.75 pct Mg alloy con-taining 0.49, 0.76, and 1.03 pct Si were investigated by differential scanning calorimetry. From the calorimetric data, the extent of reactionY and the reaction rate(dY/dt) were evaluated as functions of the reaction temperature. The rates are expressible by the relation(dY/dt) = (1 —Y)k₀ exp(— Q*/RT), whereK ₀ is the frequency factor andQ* is the activation energy. For the alloys containing 0.49, 0.76, and 1.03 pct Si, the activation energies are 76.7, 70.1, and 64.6 kJ/mole, respectively, andk ₀ changes systematically with silicon content. Critical analysis of these results and those available in the literature on the silicon-free and 0.23 pct Si containing alloys shows that GP zones precipitate in the 0.49, 0.76, and 1.03 pct Si alloys, while only GPB zones precipitate in the silicon-free and 0.23 pct Si containing alloys. The sudden change in the precipitation behavior occurs due to the preferential removal of magnesium from the matrix by the insoluble particles which are present in 0.49, 0.76, and 1.03 pct Si alloys. The alteration of the matrix composition is also responsible for systematic decrease in the activation energy.     

Retardation of intermetallic phase formation in experimental superferritic stainless steels

While superferritic stainless steels containing 29 pct chromium possess excellent resistance to corrosion, they may, under certain conditions, be embrittled by the precipitation of intermetallic phases. The extent to which the precipitation reactions can be retarded by alloying additions of aluminum and copper has been evaluated. It was found that additions of aluminum to an Fe-29 pct Cr-4 pct Mo-1.5 pct Ni base alloy suppress the precipitation of the undesirable sigma and chi intermetallic phases, but additions of up to 3 pct aluminum promote 475 ‡C embrittlement. Additions of copper slightly reduce the precipitation of sigma and chi phases under most conditions but enhance 475 ‡C embrittlement. The resistance to corrosion in 10 pct H₂SO₄ and 10 pct FeCl₃ was assessed. All the aluminum-containing alloys performed significantly better in H₂SO₄ than the base alloy; however, large additions of aluminum had a deleterious effect on the pitting resistance in FeCl₃. Additions of copper improved the resistance to FeCl₃ and lowered the rate of corrosion in the H₂SO₄ solution used.     

Damage by eutectic particle cracking in aluminum casting alloys A356/357

The strain dependence of particle cracking in aluminum alloys A356/357 in the T6 temper has been studied in a range of microstructures produced by varying solidification rate and Mg content, and by chemical (Sr) modification of the eutectic silicon. The damage accumulates linearly with the applied strain for all microstructures, but the rate depends on the secondary dendrite arm spacing and modification state. Large and elongated eutectic silicon particles in the unmodified alloys and large π-phase (Al₉FeMg₃Si₅) particles in alloy A357 show the greatest tendency to cracking. In alloy A356, cracking of eutectic silicon particles dominates the accumulation of damage while cracking of Fe-rich particles is relatively unimportant. However, in alloy A357, especially with Sr modification, cracking of the large π-phase intermetallics accounts for the majority of damage at low and intermediate strains but becomes comparable with silicon particle cracking at large strains. Fracture occurs when the volume fraction of cracked particles (eutectic silicon and Fe-rich intermetallics combined) approximates 45 pct of the total particle volume fraction or when the number fraction of cracked particles is about 20 pct. The results are discussed in terms of Weibull statistics and existing models for dispersion hardening.     

Microstructure of Cu-Co alloys solidified at various supercoolings

The effects of supercooling on the microstructure of Cu-Co alloys containing 10 to 65 wt pct Co were investigated. Supercooling of the alloys below a characteristic temperature,t _SEP, resulted in a metastable phase separation into two liquids: one Co rich (L1) and the other Cu rich (L2). The microstructure of the phase-separated alloys consisted of spherulites of one phase embedded in a matrix of the other. The spherulites in alloys containing less than 40 wt pct Co were solidified from the L1 melt and from L2 in alloys containing more than 55 wt pct Co. Supercooling of copper alloys containing around 50 wt pct Co resulted in a duplex structure of fine and coarse dendrites. Microstructural evidence was presented for the formation of aε-Cu metastable phase in alloys containing less than 30 wt pct Co.     

Removal of Vanadium from Molten Aluminum—Part III. Analysis of Industrial Boron Treatment Practice

Transition metal impurities (V, Ti, Zr, and Cr) reduce the electrical conductivity of smelter grade aluminum. These impurities are removed in the form of their borides by reacting with added Al-B master alloys i.e., boron treatment. Although, boron treatment is widely used for the production of high purity aluminum alloys in casthouse the fundamental understanding is lacking and published industrial data are limited. In the current study, industrial trials on the removal of impurities were conducted at one of the high purity aluminum alloys producers in Australasia. Kinetics analysis revealed that the rate of reaction is controlled by the mass transfer of impurities in the bulk melt. The measured mass transfer coefficient (k _m) of V and Ti were 1.1 × 10^?4 and 2.6 × 10^?4 m/s respectively, in the naturally stirred molten aluminum. The rate of V and Ti removal was faster compared to Zr and Cr during the boron treatment of smelter grade aluminum. Mass balance analysis revealed that 70 wt pct of V and Ti combined as borides in the first hour of the total 12 hours of boron treatment process. The calculated amount of un-reacted B was approximately 25.5 wt pct of initial amount added that remained in the final alloy. There was no evidence of boride rings formation, although partially dissolved AlB₁₂ particles were observed under scanning electron microscope. Finally, implications for industrial practice are discussed for the improvement of current boron treatment process that include changing the source of boron, multiple stage addition of boron and better stirring of the molten aluminum.