Eutectic solidification of aluminum-silicon alloys

A mechanism that describes nucleation and growth as well as morphology modification by chemical additives of the eutectic phases in aluminum-silicon hypoeutectic alloys is presented. The mechanism is supported with results of nonequilibrium thermal analyses, scanning electron microscopy (SEM) and transmission electron microscopy (TEM), selected area electron diffraction, and elemental X-ray mapping, as well as results of high-temperature rheological measurements that are performed on alloy samples of precisely controlled chemistry.     

Melting and solidification in microgravity of sintered aluminum powder alloys

Results of melting and solidification experiments in μ-g of sintered aluminum powder alloys (with 4 pct and 7 pct of A1₂O₃) are presented. Thin oxide films have been used as tight containers which remain adherent during melting and solidification. Convective motion in melted metals in μ-g are indicated from observations of the oxide particle distribution after melting and solidification. Effects of Marangoni convection are always observed in relatively large cylindrical samples, 5 mm diameters, melted and solidified in μ-g. Thin disc-shaped samples do not present evidence of convective motions in μ-g. Even in the absence of convective motion in the thin samples, some particle aggregation occurs, depending on the interactions with the solidification front and conditioned by diffusion controlled critical radii for capture in the solid. This paper is based on a presentation made in the symposium “Experimental Methods for Microgravity Materials Science Research” presented at the 1988 TMS-AIME Annual Meeting in Phoenix, Arizona, January 25–29, 1988, under the auspices of the ASM/MSD Thermodynamic Data Committee and the Material Processing Committee.     

Nonequilibrium solidification of undercooled melt of Ag-Cu alloy entrained in the primary phase

The solidification structure of undercooled melt of Ag-Cu alloy, entrained in its primary Cu-rich phase, has been investigated. The undercooling procedure consisted of equilibration of a Cu-13 pct Ag alloy in the two-phase liquid-solid region, followed by repeated thermal cycling of the liquid. Slow cooling of the sample in the present work established the ability to undercool the melt up to 70 K below the eutectic temperature of this alloy. The microstructure of the undercooled alloy indicated a complete absence of eutectic reaction on subsequent quenching of the melt directly from the equilibration temperature. The compositional analysis of the constituent phases by electron probe microanalysis (EPMA) technique provided evidence for the massive diffusionless solidification of the undercooled liquid. The X-ray diffraction study and electron microscopic examination indicated evidence for the spinodal transformation of the metastable solid solution phase. The composition of the phases formed on decomposition matched well with the calculated coherent spinodal boundaries in this system. The evolution of the metastable microstructure in the mushy-state quenching process of this alloy is discussed.     

The influence of microgravity on the solidification of Zn-Bi immiscible alloys

Four experiments with alloys from the immiscible Zn-Bi system have been performed under microgravity conditions. Two alloys with a composition slightly within the miscibility gap (8 pct Bi) were cooled through the miscibility gap with two different cooling rates. It was found that Bi droplets were rather homogenously distributed in the samples, but the sizes of the droplets were somewhat larger than what would be expected from diffusion controlled growth. In samples with higher Bi contents (24 pct and 38 pct) larger areas of Bi-rich phase appeared in the center of the samples and as a layer around the samples. Calculations of the droplet size have been performed and compared with the experimental found droplet size. The calculated size was smaller and the difference was shown to depend on a collision coalescence. The layer around the samples was explained by a flotation of Bi-droplets to the surface.     

A melting and solidification study of alloy 625

The melting and solidification behavior of Alloy 625 has been investigated with differential thermal analysis (DTA) and electron microscopy. A two-level full-factorial set of chemistries involving the elements Nb, C, and Si was studied. DTA results revealed that all alloying additions decreased the liquidus and solidus temperatures and also increased the melting temperature range. Terminal solidification reactions were observed in the Nb-bearing alloys. Solidification microstructures in gastungsten-arc welds were characterized with transmission electron microscopy (TEM) techniques. All alloys solidified to an austenitic (γ) matrix. The Nb-bearing alloys terminated solidification by forming various combinations of γ/MC(NbC), γ/Laves, and γ/M₆C eutectic-like constituents. Carbon additions (0.035 wt pct) promoted the formation of the γ/MC(NbC) constituent at the expense of the γ/Laves constituent. Silicon (0.4 wt pct) increased the formation of the yJLaves constituent and promoted formation of the γ/M₆C carbide constituent at low levels (<0.01 wt pct) of carbon. When both Si (0.4 wt pct) and C (0.035 wt pct) were present, the γ/MC(NbC) and γ/Laves constituents were observed. Regression analysis was used to develop equations for the liquidus and solidus temperatures as functions of alloy composition. Partial derivatives of these equations taken with respect to the alloying variables (Nb, C, Si) yielded the liquidus and solidus slopes t(m _L , m _S ) for these elements in the multicomponent system. Ratios of these liquidus to solidus slopes gave estimates of the distribution coefficients (k) for these same elements in Alloy 625.     

Rapid melting and solidification of a surface layer

A one-dimensional computer heat flow model is used to investigate the effect of high intensity heat fluxes,e.g. those achieved via continuous CO2 laser radiation, on the important surface layer melting and subsequent solidification variables of three substrate materials: aluminum, iron, and nickel. Temperature profilesvs time, melting, and solidification interface velocities, heating, and cooling rates in the surface layers of the three metals are calculated. Results are presented in a general form to permit determination of these variables for large ranges of absorbed heat fluxes and times. General trends established show that temperature gradients in the liquid and solid phases and interface velocities are directly proportional to the absorbed heat flux, whereas melt depth is inversely proportional to the absorbed heat flux. Average cooling rates comparable to splat cooling can be achieved by increasing the heat flux and reducing the dwell time of the incident radiation. An order of magnitude increase in the absorbed heat flux results in a corresponding two orders of magnitude increase in average cooling rates in the liquid during solidification of crystalline and noncrystalline structures. Formerly Research Associate, Formerly Research Associate, Formerly Research Associate,     

Rapid melting and solidification of a surface layer

Metallurgical and Materials Transactions B - A one-dimensional computer heat flow model is used to investigate the effect of high intensity heat fluxes,e.g. those achieved via continuous CO2 laser...     

The unidirectional solidification of Al-4 wt pct Cu ingots in microgravity

Three Al-4 wt pct Cu alloy ingots, 10 mm in diameter and 25-mm long, were unidirectionally solidified in microgravity during the flight of a sounding rocket, with solidification rates of about 1.6×10⁻⁴ m/s and temperature gradients of about 2600 K/m. The apparatus was comprised of three muffle furnaces, which melted the ingots prior to the launch of the rocket. Unidirectional solidification of the ingots was accomplished by chill plates attached to the furnaces, which were withdrawn from the ingots during the microgravity portion of the flight, bringing the chill plates into contact with the bases of the capsules containing the ingots. Solidification was complete in less than 4 minutes. For comparison, several ground-based ingots were solidified in unit gravity under similar conditions. Metallographic analysis of the solidified ingots showed that the macrostructures of the unit-gravity and microgravity ingots were similar, all exhibiting columnar grains. However, the microstructures were significantly different, with the microgravity ingots exhibiting primary dendrite spacings about 40 pct larger than the unit-gravity ingots and secondary dendrite arm spacings about 85 pct larger. The larger dendrite spacings for the ingots solidified in microgravity are explained by lower dendrite growth velocities. The absence of convective mixing in the microgravity ingots slightly increased temperature gradients in the liquid portion of the alloy during solidification, which resulted in decreased growth velocities. K.N. TANDON, formerly Associate Professor, Materials Engineering Laboratory, Department of Mechanical and Industrial Engineering, University of Manitoba     

The unidirectional solidification of Al-4 Wt pct Cu ingots in microgravity

Three Al-4 wt pct Cu alloy ingots, 10 mm in diameter and 25-mm long, were unidirectionally solidified in microgravity during the flight of a sounding rocket, with solidification rates of about 1.6 × 10⁻⁴ m/s and temperature gradients of about 2600 K/m. The apparatus was comprised of three muffle furnaces, which melted the ingots prior to the launch of the rocket. Unidirectional solidification of the ingots was accomplished by chill plates attached to the furnaces, which were withdrawn from the ingots during the microgravity portion of the flight, bringing the chill plates into contact with the bases of the capsules containing the ingots. Solidification was complete in less than 4 minutes. For comparison, several ground-based ingots were solidified in unit gravity under similar conditions. Metallographic analysis of the solidified ingots showed that the macrostructures of the unit-gravity and microgravity ingots were similar, all exhibiting columnar grains. However, the microstructures were significantly different, with the microgravity ingots exhibiting primary dendrite spacings about 40 pct larger than the unit-gravity ingots and secondary dendrite arm spacings about 85 pct larger. The larger dendrite spacings for the ingots solidified in microgravity are explained by lower dendrite growth velocities. The absence of convective mixing in the microgravity ingots slightly increased temperature gradients in the liquid portion of the alloy during solidification, which resulted in decreased growth velocities.     

Synchrotron microradiography of temperature gradient zone melting in directional solidification

Using synchrotron microradiography, temperature gradient zone melting (TGZM) was observed in Sn-13 wt pct Bi alloy in real time during directional solidification. A significant amount of remelting was measured on the cold sides of the dendrite arms, whereas added solidification on the hot sides of the dendrite arms was observed during dendrite growth. Kinetics of TGZM was measured based on the real-time observations. TGZM had a significant effect on dendrite morphology during continuous cooling and holding within the solidification range. The presence of tertiary dendrite arms enhanced the rate of TGZM. Remelting also led to the disintegration of some secondary dendrite arms.     

Synchrotron microradiography of temperature gradient zone melting in directional solidification

Using synchrotron microradiography, temperature gradient zone melting (TGZM) was observed in Sn-13 wt pct Bi alloy in real time during directional solidification. A significant amount of remelting was measured on the cold sides of the dendrite arms, whereas added solidification on the hot sides of the dendrite arms was observed during dendrite growth. Kinetics of TGZM was measured based on the real-time observations. TGZM had a significant effect on dendrite morphology during continuous cooling and holding within the solidification range. The presence of tertiary dendrite arms enhanced the rate of TGZM. Remelting also led to the disintegration of some secondary dendrite arms.     

Synchrotron microradiography of temperature gradient zone melting in directional solidification

Using synchrontron microradiography, temperature gradient zone melting (TGZM) was observed in Sn-13 wt pct Bi alloy in real time during directional solidification. A significant amount of remelting was measured on the cold sides of the dendrite arms, whereas added solidification on the hot sides of the dendrite arms was observed during dendrite growth. Kinetics of TGZM was measured based on the real-time observations. TGZM had a significant effect on dendrite morphology during continuous cooling and holding within the solidification range. The presence of tertiary dendrite arms enhanced the rate of TGZM. Remelting also led to the disintegration of some secondary dendrite arms.     

The role of transient convection in the melting and solidification in arc weldpools

A mathematical formulation has been developed to describe the transient growth and collapse of axisymmetric weldpools in spot welding operations. In the statement of the problem allowance is made for both conductive and convective heat transfer. In describing convection, the driving forces included buoyancy, electromagnetic forces, and surface tension forces. In most cases it was found that convection played a major role in affecting the weldpool shape, and that this convection was often dominated by surface tension forces. The model also allowed us to represent the transient collapse of weldpools upon the cessation of the heat and current supply. It was found that the melt velocity was reduced as the weldpool shrank. Most of the solidification took place from a circulating weldpool. By calculating both the growth rate and the relevant temperature gradients, it was possible to estimate the dendrite arm spacing which was found to be of the order of tens of microns. Formerly Research Associate in the Department of Materials Science and Engineering at Massachusetts Institute of Technology     

Heat flow model for surface melting and solidification of an alloy

The heat flow model previously developed for a pure metal is extended to the solidification of an alloy over a range of temperatures. The eq11Ations are then applied to rapid surface melting and solidification of an alloy substrate. The substrate is subjected to a pulse of stationary high intensity heat flux over a circular region on its bounding surface. The finite difference form of the heat transfer eq11Ation is written in terM_s of dimensionless nodal temperature and enthalpy in an oblate spheroidal coordinate system. A numerical solution technique is developed for an alloy which precipitates a eutectic at the end of solidification. Generalized solutions are presented for an Al-4.5 wt pct Cu alloy subjected to a uniform heat flux distribution over the circular region. Dimensionless temperature distributions, size and location of the “mushy” zone, and average cooling rate during solidification are calculated as a function of the product of absorbed heat flux,q, the radius of the circular region,a, and time. General trends established show that for a given product ofqa all isotherM_s are located at the same dimensionless distance for identical Fourier numbers. The results show that loss of superheat and shallower temperature gradients during solidification result in significantly larger “mushy” zone sizes than during melting. Furthermore, for a given set of process parameters, the average cooling rate increases with distance solidified from the bottom to the top of the melt pool.     

Rapid melting and solidification of surface due to stationary heat flux

A general two-dimensional computer heat flow model is developed in an oblate spheroidal coordinate system for rapid melting and subsequent solidification of the surface of a semiinfinite solid subjected to a high intensity heat flux over a circular region on its bounding surface. Generalized numerical solutions are presented for an aluminum substrate subjected to both uniform and Gaussian heat flux distributions. Temperature distributions, melt depth and geometry, and melting and solidification interface velocities are calculated as a function of applied heat flux, radius of the circular region, and time. It is shown that the important melting and solidification parameters are a function of the product of the absorbed heat flux, q, and the radius of the circular region, a. General trends established show that melt depth perpendicular to the surface is inversely proportional to the absorbed heat flux for a given temperature at the center of the circular region. Dimensionless temperature distributions and the ratio of liquid-solid interface velocity to absorbed heat flux,R/q, as a function of dimensionless melt depth remain the same if the productqa is kept constant, whileq anda are varied. For a given total power absorbed melting and solidification parameters are compared for uniform and Gaussian heat flux distributions. For a given temperature at the center of the circular region both melt depth and width are smaller for the Gaussian distribution while temperature gradients and interface velocities are larger. Formerly Graduate Research Assistant, Department of Mechanical and Industrial Engineering, University of Illinois. Formerly Research Associate, Department of Metallurgy and Mining Engineering,University of Illinois. Formerly Professor at the University of Illinois, Urban, IL.     

Prediction of grain structures in various solidification processes

Grain structure formation during solidification can be simulatedvia the use of stochastic models providing the physical mechanisms of nucleation and dendrite growth are accounted for. With this goal in mind, a physically based cellular automaton (CA) model has been coupled with finite element (FE) heat flow computations and implemented into the code3- MOS. The CA enmeshment of the solidifying domain with small square cells is first generated automatically from the FE mesh. Within each time-step, the variation of enthalpy at each node of the FE mesh is calculated using an implicit scheme and a Newton-type linearization method. After interpolation of the explicit temperature and of the enthalpy variation at the cell location, the nucleation and growth of grains are simulated using the CA algorithm. This algorithm accounts for the heterogeneous nucleation in the bulk and at the surface of the ingot, for the growth and preferential growth directions of the dendrites, and for microsegregation. The variations of volume fraction of solid at the cell location are then summed up at the FE nodes in order to find the new temperatures. This CAFE model, which allows the prediction and the visualization of grain structures during and after solidification, is applied to various solidification processes: the investment casting of turbine blades, the continuous casting of rods, and the laser remelting or welding of plates. Because the CAFE model is yet two-dimensional (2-D), the simulation results are compared in a qualitative way with experimental findings.     

High-rate solidification and melting of concentrated solutions and the Hillert parallel construction

A phase-field model is proposed for the solidification and melting of a binary concentrated solution (melt). The method of extended irreversible thermodynamics is used to derive thermodynamically consistent equations and to take into account low and high phase transformation rates. The Hillert parallel construction is applied to determine the driving forces of the solidification or melting of a binary system. When thermodynamic equilibrium states are described, the Gibbs potentials are assumed to be known. They are specified from the existing thermodynamic information databases or from experimental data. The results of a numerical investigation of the proposed model are presented.