Comparison of microstructural evolution in laser-deposited and arc-melted <Emphasis Type="Italic">In-Situ</Emphasis> Ti-TiB composites

In-situ Ti-TiB composites have been processed via two different routes: arc by melting elemental Ti and B and by direct laser deposition of a blend of elemental Ti and B powders using the laser-engineered net-shaping (LENS^™) process. The conventionally cast composite exhibits a significantly coarser-scale microstructure as compared with the LENS^™-deposited composite and consists of primary proeutectic TiB precipitates dispersed in an eutectic matrix. The microstructure of the LENS^™-deposited Ti-TiB composite consists of a fine-scale homogeneous dispersion of primary TiB precipitates in an α-Ti matrix. In addition, a nanometer-scale dispersion of secondary TiB precipitates is formed in the α matrix. The hardness and modulus of these composites have been measured using nanoindentation techniques. The ability to produce such a fine dispersion of TiB precipitates in near-net-shape, near-full-density Ti-TiB composites processed using LENS^™ could potentially be highly beneficial from the viewpoint of applicability of these metal-matrix composites.     

Phase evolution during laser <Emphasis Type="Italic">In-Situ</Emphasis> carbide coating

With the help of laser surface engineering, in-situ carbide composite coating on the surface of plain carbon steel was achieved. Energy dispersive spectroscopy (EDS) in supplement with X-ray diffractometry indicated the evolution of TiC, Fe−Cr, and M₇C₃ as major phases in the coating. A variation in the evolution of M₇C₃ phase was observed with respect to the laser power over the range of 900 to 2100 W (3 mm×600 μm rectangular beam spot) during processing. Computational techniques were employed with the aim of studying possible reasons for phase evolution, stability of phases, solidification path, and optimization of parameters to stabilize the M₇C₃ phase and hence tailor properties.     

Microstructure and sliding-wear behavior of tungsten-reinforced W-Ni-Si metal-silicide <Emphasis Type="Italic">in-situ</Emphasis> composites

W-Ni-Si metal-silicide-matrix in-situ composites reinforced by tungsten primary grains were fabricated using a water-cooled copper-mold laser-melting furnace by the LASMELT process. Main constitutional phases of the W/W-Ni-Si in-situ composites are the tungsten primary phase, peritectic W₂Ni₃Si, and the remaining W₂Ni₃Si/Ni₃₁Si₁₂ eutectics, depending on the alloy compositions. The sliding-wear resistance of the W/W-Ni-Si intermetallic composites was evaluated at room temperature and 600 °C. Wear mechanisms of the W/W₂Ni₃Si in-situ composites were discussed based on morphology observations of the worn surface and wear debris. Results show that the W/W-Ni-Si composites have excellent wear resistance under both room- and high-temperature sliding-wear-test conditions, because of the high yield strength and toughness of the tungsten-reinforcing phase and the high hardness and the covalent-dominated intermetallic atomic bonds of the W₂Ni₃Si and Ni₃₁Si₁₂ metal silicides. Tungsten-reinforcing grains played the dominant role in resisting abrasive-wear attacks of microcutting, plowing, and brittle spalling during the sliding-wear process, while the W₂Ni₃Si and Ni₃₁Si₁₂ metal silicides are responsible for the excellent adhesive wear resistance.     

Magnetic contribution to the interdiffusion coefficients in bcc (<Emphasis Type="Italic">α</Emphasis>) and fcc (<Emphasis Type="Italic">γ</Emphasis>) Fe-Ni alloys

The interdiffusion coefficients in bcc (α) and fcc (γ) Fe-Ni alloys below their Curie temperatures have been calculated based on the magnetic contribution to the free energy for interdiffusion. The free energy for interdiffusion due to magnetic ordering in bcc Fe-Ni alloys is positive. The calculated interdiffusion coefficients in bcc Fe-Ni alloys fit the experimental data quite well. In fcc Fe-Ni alloys, the magnetic contribution to interdiffusion depends on both temperature and composition and is abnormal for Ni compositions in the Invar region. The free energy of vacancy formation is positive and the free energy of vacancy migration is negative, due to the effect of magnetic ordering. The interdiffusion coefficient in the ferromagnetic phase is lower than that extrapolated from the paramagnetic phase for Ni compositions of 50 at. pct and greater and is higher than that extrapolated from the paramagnetic phase for Ni compositions of 40 at. pct and lower.     

<Emphasis Type="Italic">In-situ</Emphasis> reactive processing of nickel aluminides by laser-engineered net shaping

Nickel aluminide intermetallics (e.g., Ni₃Al and NiAl) are considered to be attractive materials for high-temperature structural applications. Laser-engineered net shaping (LENS) is a rapid prototyping process, which involves laser processing fine metal powders into three-dimensional shapes directly from a computer-aided design (CAD) model. In this work, an attempt has been made to fabricate aluminide intermetallic compounds via reactive in-situ alloying from elemental powders using the LENS process. In-situ reactive alloying was achieved by delivering elemental Ni and Al powders from two different powder feeders, eliminating segregation observed in the samples deposited by using the premixed elemental powders. Nickel aluminides of various compositions were obtained easily by regulating the ratio of their feed rates. The aluminide deposits exhibited a high solidification and subsolidus cracking susceptibility and porosity formation. The observed porosity resulted from a water-atomized Ni powder and can be minimized or eliminated by the use of a N₂-gas-atomized Ni powder of improved quality. Cracking was due to the combined effect of the high thermal stresses generated from the LENS processing and the brittleness of the intermetallics. Crack-free deposits were fabricated by preheating the substrate to a temperature of 450 °C to 500 °C during LENS processing. Compositionally graded Ni-Al deposits with a gradient microstructure were also produced by the in-situ reactive processing.     

Creep behavior of copper-chromium <Emphasis Type="Italic">in-situ</Emphasis> composite

Creep deformation and fracture behaviors were investigated on a deformation-processed Cu-Cr in-situ composite over a temperature range of 200 °C to 650 °C. It was found that the creep resistance increases significantly with the introduction of Cr fibers into Cu. The stress exponent and the activation energy for creep of the composite at high temperatures (≥400 °C) were observed to be 5.5 and 180 to 216 kJ/mol, respectively. The observation that the stress exponent and the activation energy for creep of the composite at high temperatures (≥400 °C) are close to those of pure Cu suggests that the creep deformation of the composite is dominated by the deformation of the Cu matrix. The high stress exponent at low temperatures (200 °C and 300 °C) is thought be associated with the as-swaged microstructure, which contains elongated dislocation cells and subgrains that are stable and act as strong athermal obstacles at low temperatures. The mechanism of damage was found to be similar for all the creep tests performed, but the distribution and extent of damage were found to be very sensitive to the test temperature.     

Interdiffusion behavior of Pt-modified <Emphasis Type="Italic">γ</Emphasis>-Ni + <Emphasis Type="Italic">γ</Emphasis>′-Ni<Subscript>3</Subscript>Al alloys coupled to Ni-Al-based alloys

The effect of platinum addition on the interdiffusion behavior of γ-Ni + γ′-Ni₃Al alloys was studied by using diffusion couples comprised of a Ni-Al-Pt alloy mated to a Ni-Al, Ni-Al-Cr, or Ni-based commercial alloy. The commercial alloys studied were CMSX-4 and CMSX-10. Diffusion annealing was at 1150 °C for up to 100 hours. An Al-enriched γ′-layer often formed in the interdiffusion zone of a given couple during diffusion annealing due to the uphill diffusion of Al. This uphill diffusion was ascribed to Pt addition decreasing the chemical activity of aluminum in the γ + γ′ alloys. For a given diffusion couple end member, the thickening kinetics of the γ′ layer that formed increased with increasing Pt content in the Ni-Al-Pt γ + γ′ alloy. The γ′-layer thickening kinetics in diffusion couples with Cr showed less of a dependence on Pt concentration. Inference of a negative effect of Pt and positive effect of Cr on the Al diffusion in this system enabled explanation of the observed interdiffusion behaviors. There was no or minimal formation of detrimental topologically close-packed (TCP) phases in the interdiffusion zone of the couples with CMSX-4 or CMSX-10. An overlay Pt-modified γ + γ′ coating on CMSX-4 showed excellent oxidation resistance when exposed to air for 1000 hours at 1150 °C. Moreover, the Al content in the coating was maintained at a relatively high level due to Al replenishment from the CMSX-4 substrate.     

<Emphasis Type="Italic">In-situ</Emphasis> formation of SiC-reinforced Al-Si alloy composites using methane gas mixtures

Theoretical and experimental studies on the in-situ formation of an Al-Si alloy composite using a methane gas mixture were carried out. An Al-Si alloy composite with in-situ formed SiC as a reinforced phase was produced by bubbling methane gas at temperatures from 1223 to 1423 K. An optical microscope, scanning electron microscope (SEM), and electron microprobe were used for the product characterization. Primary and eutectic silicon were observed in the samples taken from the top part of the crucible, and only eutectic silicon was observed in the samples taken from the bottom of crucible. The SiC formation rate increased with the decrease in the bubble size. A silicon concentration gradient existed at different vertical positions of the liquid alloy. The silicon concentration close to the top of the liquid alloy was higher than that at the bottom. The SiC concentration was very low in the bulk alloy. The bubbling of the gas mixture in the melt resulted in the formation of a layer of foam on top of the crucible. Formed SiC particles were enriched in the foam and carried out of the crucible by the overflow foam to a composite collector located under the crucible. The foam in the composite collector was broken, and composites in the foam contained up to 30 wt pct SiC. The particle size of the SiC is in the range of 1 to 10 μm. The bubbling process resulted in the unevenness of the silicon concentration and the different crystallizing processes. The SiC formation rate was found to be about 12.5 mg/(L·s). A kinetic model was developed. The model-predicted results are in very good agreement with the experimental results.     

Effect of strain rate on the strain-induced <Emphasis Type="Italic">γ</Emphasis> → <Emphasis Type="Italic">α</Emphasis>′-martensite transformation and mechanical properties of austenitic stainless steels

The effect of strain rate on strain-induced γ → α′-martensite transformation and mechanical behavior of austenitic stainless steel grades EN 1.4318 (AISI 301LN) and EN 1.4301 (AISI 304) was studied at strain rates ranging between 3×10⁻⁴ and 200 s⁻¹. The most important effect of the strain rate was found to be the adiabatic heating that suppresses the strain-induced γ → α′ transformation. A correlation between the work-hardening rate and the rate of γ → α′ transformation was found. Therefore, the changes in the extent of the α′-martensite formation strongly affected the work-hardening rate and the ultimate tensile strength of the materials. Changes in the martensite formation and work-hardening rate affected also the ductility of the studied steels. Furthermore, it was shown that the square root of the α′-martensite fraction is a linear function of flow stress. This indicates that the formation of α′-martensite affects the stress by influencing the dislocation density of the austenite phase. Olson-Cohen analysis of the martensite measurement results did not indicate any effect of strain rate on shear band formation, which was contrary to the transmission electron microscopy (TEM) examinations. The β parameter decreased with increasing strain rate, which indicates a decrease in the chemical driving force of the α → α′ transformation.     

Effect of alloying and aging on morphological changes from lamellar to equiaxed microstructure of <Emphasis Type="Italic">α</Emphasis><Subscript>2</Subscript>+<Emphasis Type="Italic">γ</Emphasis> titanium aluminides

The stability of a lamellar structure consisting of α ₂ and γ phases in alloys Ti-48Al, Ti-48Al-2Mo, Ti-48Al-4Nb, and Ti-48Al-1Mo-4Nb has been studied as a function of aging time and temperature. The alloys were solution treated (1400 °C, 30 min, and air-cooled (AC)) and aged at 1000 °C and 1100 °C for 1, 4, and 16 hours, respectively. The results indicate that the kinetics of lamellae to equiaxed transformation depends on alloy chemistry, aging time, and temperature. The Nb decreases and Mo increases the kinetics of transformation. The combined effect of Nb and Mo results in the highest volume fraction of equiaxed microstructure at a given aging time and temperature. The results have been discussed in relation to microstructural features and have been compared with those reported in other α ₂+γ alloys.     

Phase evolution during laser <Emphasis Type="Italic">in-situ</Emphasis> carbide coating

With the help of laser surface engineering, in-situ carbide composite coating on the surface of plain carbon steel was achieved. Energy dispersive spectroscopy (EDS) in supplement with X-ray diffractometry indicated the evolution of TiC, Fe-Cr, and M₇C₃ as major phases in the coating. A variation in the evolution of M₇C₃ phase was observed with respect to the laser power over the range of 900 to 2100 W (3 mm ×600 μm rectangular beam spot) during processing. Computational techniques were employed with the aim of studying possible reasons for phase evolution, stability of phases, solidification path, and optimization of parameters to stabilize the M₇C₃ phase and hence tailor properties.     

Optimization of the johnson-mehl-avarami equation parameters for <Emphasis Type="Italic">α</Emphasis>-ferrite to <Emphasis Type="Italic">γ</Emphasis>-austenite transformation in steel welds using a genetic algorithm

A nonisothermal Johnson-Mehl-Avarami (JMA) equation with optimized JMA parameters is proposed to represent the kinetics of transformation of α-ferrite to γ-austenite during heating of 1005 steel. The procedure used to estimate the JMA parameters involved a combination of numerical heat-transfer and fluid-flow calculations, the JMA equation for nucleation and growth for nonisothermal systems, and a genetic algorithm (GA) based optimization tool that used a limited volume of experimental kinetic data. The experimental data used in the calculations consisted of phase fraction of γ-austenite measured at several different monitoring locations in the heat-affected zone (HAZ) of a gas tungsten arc (GTA) weld in 1005 steel. These data were obtained by an in-situ spatially resolved X-ray diffraction (SRXRD) technique using synchrotron radiation during welding. The thermal cycles necessary for the calculations were determined for each monitoring location from a well-tested three-dimensional heat-transfer and fluid-flow model. A parent centric recombination (PCX) based generalized generation gap (G3) GA was used to obtain the optimized values of the JMA parameters, i.e., the activation energy, pre-exponential factor, and exponent in the nonisothermal JMA equation. The GA based determination of all three JMA equation parameters resulted in better agreement between the calculated and the experimentally determined austenite phase fractions than was previously achieved.     

Probabilistic micromechanical modeling of fatigue-life variability in an <Emphasis Type="Italic">α+β</Emphasis> Ti alloy

The fatigue-life variability in an α+β Ti alloy (Ti-6Al-4V) has been examined through a probabilistic micromechanical model that treats the crack-initiation and growth processes at the grain-size level. First, a physics-based crack-initiation model is described. This is followed by a summary of a physics-based fatigue-crack-growth model. The combined model is applied to predict the variability of crack initiation and growth lives due to microstructural variations in Ti-6Al-4V. Finally, possible fatigue mechanisms or scenarios that can lead to the worst-case fatigue life are elucidated via probabilistic modeling of the fatigue-crack-initiation process, the driving force of the grain-sized cracks, as well as the intrinsic (closure-free) threshold and the closure-affected threshold of the small cracks. In the absence of preexisting cracks, the worst-case total fatigue life is obtained when two conditions are met: (1) the crack size at initiation is on the order of 1 to 2 times the grain size, and (2) the driving force (applied ΔK) exceeds the intrinsic threshold of the small cracks. The probabilistic results are also used to elucidate the conditions for the occurrence of dual fatigue limits in high-cycle fatigue (HCF) or giga-cycle fatigue.     

Some studies on the thermal-expansion behavior of C-fiber,SiC<Subscript><Emphasis Type="Italic">p</Emphasis></Subscript>, and <Emphasis Type="Italic">In-situ</Emphasis> Mg<Subscript>2</Subscript>Si-reinforced AZ31 Mg alloy-based hybrid composites

Magnesium alloy-based hybrid composites with carbon-fiber, SiC _p , and in-situ Mg₂Si reinforcements have been prepared by the squeeze-infiltration technique. The results of the studies done on the measurement of the coefficient of thermal expansion after thermal cycling of these composites show that the thermal cycling initially leads to rapid linear expansion of the composite. However, the expansion becomes stabilized after a few cycles, pointing toward formation of the stable interfaces due to the formation of stable precipitates. The model for the growth kinetics of these precipitates at the interface shows a rapid initial growth of the precipitates with the number of thermal cycles, which becomes staturated after a few thermal cycles. The thermal treatment of the composite lowers the coefficient of linear thermal expansion, which can be explained on the basis of further stabilization of the interfaces after the thermal treatment.     

Numerical modeling of the damping capacity of Al/SiC(<Emphasis Type="Italic">p</Emphasis>)

In the present article, the damping behaviors of Al/SiC particulate-reinforced metal-matrix composites (PMMCs) at room temperature are investigated by the numerical modeling method. Through the cell method (CM) and finite-element method (FEM), the influences of particulate shape and distribution on the damping capacity of Al/SiC(p) composite are studied. Also, the case of multiparticulate with random distribution and random size is investigated as a comparison with the single-particulate case. At last, the simulation results are compared with the experimental results, which show that they are consistent with each other in quality.