Effect of heat treatment on the microstructure,tensile properties,and fracture behavior of permanent mold Al-10 wt pct Si-0.6 wt pct Mg/SiC/10p composite castings

The present study was undertaken to investigate the effect of solution treatment (in the temperature range 520 °C to 550 °C) and artificial aging (in the temperature range 140 °C to 180 °C) on the variation in the microstructure, tensile properties, and fracture mechanisms of Al-10 wt pct Si-0.6 wt pct Mg/SiC/10_p composite castings. In the as-cast condition, the SiC particles are observed to act as nucleation sites for the eutectic Si particles. Increasing the solution temperature results in faster homogenization of the microstructure. Effect of solution temperature on tensile properties is evident only during the first 4 hours, after which hardly any difference is observed on increasing the solution temperature from 520 °C to 550 °C. The tensile properties vary significantly with aging time and temperature, with typical yield strength (YS), ultimate tensile strength (UTS), and percent elongation (EL) values of ∼300 MPa, ∼330 MPa, and ∼1.4 pct in the underaged condition, ∼330 MPa, ∼360 MPa, and ∼0.65 pct in the peakaged condition, and ∼323 MPa, ∼330 MPa, and ∼0.8 pct in the overaged condition. Prolonged solution treatment at 550 °C for 24 hours results in a slight improvement in the ductility of the aged test bars. The fracture surfaces exhibit a dimple morphology and cleavage of the SiC particles, the extent of SiC cracking increasing with increasing tensile strength and reaching a maximum in the overaged condition. Microvoids act as nucleation sites for the formation of secondary cracks that promote severe cracking of the SiC particles. A detailed discussion of the fracture mechanism is given.     

The effect of quench rate on the microstructure,mechanical properties,and corrosion behavior of U-6 wt pct Nb

The effect of cooling rate on the microstructure, mechanical behavior, corrosion resistance, and subsequent age hardenability of U-6 wt pct Nb is described and discussed. Cooling rates in excess of 20 Ks^-1 cause the parent γ-phase to transform martensitically to a niobium supersaturated variant of the α-phase. This martensitic phase exhibits low hardness and strength, high ductility, good corrosion resistance, and substantial age hardenability. As cooling rate decreases from 10 Ks^-1 to 0.2 Ks^-1, fine scale microstructural changes (consistent with spinodal decomposition) occur to an increasing extent. These changes produce large increases in hardness and strength and large decreases in ductility, slight decreases in corrosion resistance, and slight changes in age hardenability. At cooling rates less than 0.2 Ks^-1 the parent phase undergoes cellular decomposition to a coarse two-phase lamellar microstructure. This lamellar microstructure exhibits intermediate strength and ductility, substantially reduced corrosion resistance, and no age hardenability. An analysis of the cooling rates at the centers of water quenched plates indicates that fully martensitic microstructures can be obtained in plates as thick as 50 mm.     

Microstructure and corrosion behavior of as-cast and heat-treated Al-4.5 Wt pct Cu-2.0 wt pct Mn alloys

The microstructure and corrosion behavior of as-cast and heat-treated Al-4.5 pct Cu-2.0 pct Mn alloy specimens solidified at various cooling rates were investigated. The equilibrium phases Al₆Mn and θ-Al₂Cu, which are observed in the conventionally solidified alloy in the as-cast condition, were not detected in rapidly solidified (melt-spun) material. Instead, the ternary compound Al₂₀Cu₂Mn₃ was present in addition to the α phase, which was present in all cases. The morphological and kinetic nature of corrosion was investigated metallographically and through potentiostatic techniques in 3.5 wt pct NaCl aqueous solution. Corrosion of the as-cast material was described by two anodic reactions: corrosion of the intermetallic phases and pitting of the α-Al solid solution. The corrosion rate increased with cooling rate from that for the furnace-cooled alloy to that for the copper mold-cast alloy and, subsequently, decreased in the rapidly solidified alloy. In the heat-treated material, corrosion could be described by two anodic reactions: corrosion of Al₂₀Cu₂Mn₃ precipitate particles and pitting of the α-Al matrix. S.M. Skolianos, formerly Graduate Student, Department of Metallurgy, University of Connecticut     

The effect of enhanced gravity levels on microstructural development in Pb-50 wt pct Sn alloys during controlled directional solidification

The Pb-50 wt pct Sn alloys were directionally solidified at 21.1 μm s⁻¹ through a temperature gradient of ∼3.5 K mm⁻¹. With the aid of a centrifuge, the solidifying dendritic interfaces were subjected to constant gravity levels, opposite to the growth direction, up to 15.3 times that of Earth’s. Microstructural examination revealed no significant change in the secondary dendrite arm spacing, the interdendritic eutectic spacing, or the primary dendrite trunk diameter as a function of increasing gravity level; the primary dendrite arm spacing, however, decreased significantly. The primary spacing decrease is argued to result from suppressing convection in the bulk liquid or by modification of the rejected solute layer as a result of enhanced buoyancy.     

Mechanical properties and fracture behavior of an ultrafine-grained Al-20 wt pct Si alloy

The effect of powder particle size on the microstructure, mechanical properties, and fracture behavior of Al-20 wt pct Si alloy powders was studied in both the gas-atomized and extruded conditions. The microstructure of the as-atomized powders consisted of fine Si particles and that of the extruded bars showed a homogeneous distribution of fine eutectic Si and primary Si particles embedded in the Al matrix. The grain size of fcc-Al varied from 150 to 600 nm and the size of the eutectic Si and primary Si was about 100 to 200 nm in the extruded bars. The room-temperature tensile strength of the alloy with a powder size <26 μm was 322 MPa, while for the coarser powder (45 to 106 μm), it was 230 MPa. The tensile strength of the extruded bar from the fine powder (<26 μm) was also higher than that of the Al-20 wt pct Si-3 wt pet Fe (powder size: 60 to 120 μm) alloys. With decreasing powder size from 45 to 106 μm to <26 μm, the specific wear of all the alloys decreased significantly at all sliding speeds due to the higher strength achieved by ultrafine-grained constituent phases. The thickness of the deformed layer of the alloy from the coarse powder (10 μm at 3.5 m/s) was larger on the worm surface in comparison to the bars from the fine powders (5 μm at 3.5 m/s), attributed to the lower strength of the bars with coarse powders.     

Mechanical properties and fracture behavior of an ultrafine-grained Al-20 wt pct Si alloy

The effect of powder particle size on the microstructure, mechanical properties, and fracture behavior of Al-20 wt pct Si alloy powders was studied in both the gas-atomized and extruded conditions. The microstructure of the as-atomized powders consisted of fine Si particles and that of the extruded bars showed a homogeneous distribution of fine eutectic Si and primary Si particles embedded in the Al matrix. The grain size of fcc-Al varied from 150 to 600 nm and the size of the eutectic Si and primary Si was about 100 to 200 nm in the extruded bars. The room-temperature tensile strength of the alloy with a powder size <26 μm was 322 MPa, while for the coarser powder (45 to 106 μm), it was 230 MPa. The tensile strength of the extruded bar from the fine powder (<26 μm) was also higher than that of the Al-20 wt pct Si-3 wt pct Fe (powder size: 60 to 120 μm) alloys. With decreasing powder size from 45 to 106 μm to <26 μm, the specific wear of all the alloys decreased significantly at all sliding speeds due to the higher strength achieved by ultrafine-grained constituent phases. The thickness of the deformed layer of the alloy from the coarse powder (10 μm at 3.5 m/s) was larger on the worn surface in comparison to the bars from the fine powders (5 μm at 3.5 m/s), attributed to the lower strength of the bars with coarse powders.     

Effect of fiber volume fraction on the fracture behavior of Nb-1 wt pct Zr/218W composites at elevated temperatures

Nb-1 wt pct Zr/218W long-fiber composite monotapes, nominally containing 0 to 70 vol pct of 218 tungsten fibers, were fabricated by arc spraying the Nb-1 pct Zr matrix onto the tungsten fibers. The monotapes were consolidated by hot pressing and hot isostatic pressing techniques. Tensile tests conducted between 1400 and 1600 K, under engineering strain rates varying between 1.5×10⁻⁵ and 1.5×10⁻³ s⁻¹, demonstrated that composites containing 70 vol pct of fibers had the highest strength-to-density ratio. Microstructural observations of specimens tested at 1400 K revealed that composites containing less than 50 vol pct of fibers showed extensive matrix cavitation, fiber-matrix debonding, and necking of the fibers. Above 50 vol pct, the composite matrix was less prone to cavitation, with an increasing tendency toward shear deformation of the fibers as the fiber volume fraction increased. No fiber damage was observed at 1400 K away from the fractured end, but significant fiber damage was observed at higher temperatures. A phenomenological model is presented to rationalize these observations. L.J. GHOSN, formerly Researcher with Case Western Reserve University, Cleveland, OH 44115 This article is based on a presentation made in the Symposium “Mechanisms and Mechanics of Composites Fracture” held October 11–15, 1998, at the TMS Fall Meeting in Rosemont, Illinois, under the auspices of the TMS-SMD/ASM-MSCTS Composite Materials Committee.     

The Structure and Kinetics of the Nanoscale Precipitation Processes in Al-1.0 wt pct Mg2Si-0.4 wt pct Mg-0.5 wt pct Ag Alloy

The influence of addition of 0.4 wt pct Mg on the precipitation sequence in the balanced Al-1.0 wt pct Mg₂Si bearing 0.5 wt pct Ag has been investigated during the continuous heating of the quenched alloy from the solid solution state. Differential scanning calorimetry (DSC) and high-resolution transmission electron microscopy techniques have been used. The DSC experiments showed that all processes occurred are thermally activated. The activation energies of the precipitation processes have been determined and hence the kinetics of these precipitates have been determined. The obtained results have shown that the existence of excess Mg inhibits the formation of the early stage clusters of solute-vacancy clusters. These clusters can be assisted by the binding energies between solute Si, Mg, and Ag atoms and the excess vacancies. On the other hand, excess Mg accelerates the precipitation of random, β′-phase and β-phase precipitates.     

The effect of dispersed oxides on the oxidation behavior of Al-and Ti-Containing Ni-20 pct Cr alloys

The effect of dispersed Y₂O₃ and La₂O₃ on the isothermal and cyclic oxidation behavior of Al- and Ti-containing Ni-20Cr alloys has been investigated. It has been found that the dispersolids improve the oxidation resistance of these alloys, but this improvement is less than that observed in aluminum- and titanium-free Ni-20Cr alloys. The oxidation resistance imparted by the presence of the dispersoids was found to increase as the aluminum and titanium contents were decreased. It is proposed that these changes in oxidation resistance arise from differences in the extent of subscale attack, oxidation induced alloy porosity and internal oxidation.     

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.     

Strain rate sensitivity and ductile-brittle behavior of polycrystalline Fe-Si alloys with 2.5, 3.5, and 4.5 wt pct Si

The strain rate sensitivity of the tensile properties of polycrystalline Fe-Si alloys with 2.5, 3.5, or 4.5 wt pct Si and a C+N content of 0.005 to 0.010 wt pct has been determined at room temperature. From these and previous results the influence of silicon on the athermal and thermal components of the yield (proof) stress of ferrite has been deduced. Both components increase with silicon content, but at the highest strain rates (and lowest temperatures) the thermal component varies little with silicon content and is smaller than that reported for pure iron. Transmission electron microscopy of ductile alloys has shown that the density and arrangements of dislocations are not greatly influenced by silicon content or strain-rate within the range investigated. At room temperature the dislocation velocity exponent,m*, increases with silicon content, being 4.5, 7.4, and 10.6 (±1.0) in the three alloys. For the grain size studied (5 to 7 ASTM) it appears that the stress for yielding by glide must not exceed about 700 MN/m² (100 ksi) if brittle behavior is to be avoided. The combinations of temperature and strain rate at which the ductile-brittle transition occurs are indicated for different silicon contents and different grain sizes. Formerly with the same Institute     

The effect of aging on the fracture behavior of Cu-AI-Ni jo phase alloys

The beneficial effect of aging on the intergranular embrittlement of the shape memory Cu-AI-Ni β phase alloys is described. The fracture progressively changes from completely intergranular to transgranular when quenched samples are aged. The change in fracture behavior appears to be associated with the precipitation of a ductile phase (a) in the grain boundary region. This hypothesis is supported by the results of electron microprobe analysis and Auger electron spectroscopy. Aging does not have any significant effect on the microhardness of samples. Some transmission electron microscopic observations of the changes occurring on aging are also presented. Formerly with The University of Connecticut, Storrs, CT 06268.     

Tensile flow and fracture behavior of DO3 Fe-25 at. pct Al and Fe-31 at. pct al alloys

The tensile properties, fracture modes, and deformation mechanisms of two DO₃ alloys, Fe-25 and Fe-31 at. pct Al, have been investigated as a function of temperature up to 600°C. The first alloy was produced by powder metallurgy and hot-extrusion, the second by casting and hot-extrusion. At room temperature extensive plastic deformation occurs in these intermetallics, exhibiting an elongation to fracture of 8 pct and 5.6 pct, respectively. In the Fe-25Al alloy the deformation process consisted of motion and extensive cross-slip of ordinary dislocations and associated formation of antiphase-boundary (APB) bands, while in the Fe-31 Al alloy, plasticity occurred by the motion of superlattice dislocations which eventually dissociated to form APB bands. At room temperature both alloys exhibited transgranular cleavage fracture modes. The variation of tensile properties and fracture modes with temperature is presented. H. A. LIPSITT, formerly with the Materials Laboratory of the Air Force Wright Aeronautical Laboratories, Wright-Patterson Air Force Base, OH 45433-6533     

Case reviews on the effect of microstructure on the corrosion behavior of austenitic alloys for processing and storage of nuclear waste

This article describes the corrosion behavior of special austenitic alloys for waste management applications. The special stainless steels have controlled levels of alloying and impurity elements and inclusion levels. It is shown that “active” inclusions and segregation of chromium along flow lines accelerated IGC of nonsensitized stainless steels. Concentration of Cr⁺⁶ ions in the grooves of dissolved inclusions increased the potential to the transpassive region of the material, leading to accelerated attack. It is shown that a combination of cold working and controlled solution annealing resulted in a microstructure that resisted corrosion even after a sensitization heat treatment. This imparted extra resistance to corrosion by increasing the fraction of “random” grain boundaries above a threshold value. Randomization of grain boundaries made the stainless steels resistant to sensitization, IGC, and intergranular stress corrosion cracking (IGSCC) in even hot chloride environments. The increased corrosion resistance has been attributed to connectivity of random grain boundaries. The reaction mechanism between the molten glass and the material for process pot, alloy 690, during the vitrification process has been shown to result in depletion of chromium from the reacting surfaces. A comparison is drawn between the electrochemical behavior of alloys 33 and 22 in 1 M HCl at 65 °C. It is shown that a secondary phase formed during welding of alloy 33 impaired corrosion properties in the HCl environment. This article is based on a presentation made in the symposium “Effect of Processing on Materials Properties for Nuclear Waste Disposition,” November 10–11, 2003, at the TMS Fall meeting in Chicago, Illinois, under the joint auspices of the TMS Corrosion and Environmental Effects and Nuclear Materials Committees.     

The electrical conductivity of cast Al−Si alloys in the range 2 to 12.6 wt pct silicon

The changes in electrical conductivity of cast Al−Si alloys, in the range of 2 to 12.6 wt pct silicon due to strontium additions (0.03 wt pct) have been investigated and explained in terms of variations in microstructure. The strontium-containing alloys exhibited a higher conductivity than alloys with no strontium, and this conductivity difference increased as the silicon and magnesium contents were increased and the solidification rate was decreased. It has been demonstrated that this difference is due to changes in microstructural features of the eutectic silicon upon modification.     

Creep behavior of an Al-2. 0 wt pct Li alloy in the temperature range 300 °C to 500 °C

The elevated temperature deformation behavior of an Al-2. 0 wt pct Li alloy in the temperature range 300 °C to 500 °C was studied using constant extension-rate tension testing and constant true-stress creep testing under both isothermal and temperature cycling conditions. Optical microscopy and transmission electron microscopy (TEM) were employed to assess the effect of deformation on microstructure. The data showed that the stress exponent,n, has a value of about 5. 0 at temperatures above theα +δAlLi solvus (approximately 380 °C) and that subgrains form during plastic deformation. Models for dislocation-climb and dislocation-glide control of creep were analyzed for alloys deformed in the temperature range of stability of the terminal AlLi solid solution. A climb model was shown to describe closely the behavior of this material. Anomalous temperature dependence of the activation energy was observed in this same temperature range. This anomalous behavior was ascribed to unusual temperature dependence of either the Young’s modulus or the stacking fault energy, which may be associated, in turn, with a disorder-order transformation on cooling of the alloy. Formerly with the Materials Engineering Section. Department of Mechanical Engineering, Naval Postgraduate School.     

The effect of temperature and carbon content on the cavitation behavior of a 1.5 pct Cr-0.5 pct V steel

Constant strain rate tests at 10^-6 s^-1 have been carried out at 823 K and 923 K on a vacuum melted 1 1/2 pct Cr 1/2 pct V ferritic steel containing 3 different carbon contents. After straining to various elongation values specimens were unloaded, cooled and fractured at 77 K. This gave fracture surfaces consisting almost entirely of intergranular facets, enabling a quantitative study to be made of the different stages of cavity nucleation and growth. It was found that cavity growth rates were independent of carbon content but were higher at 923 K than at 823 K. Subsequent grain boundary sliding measurements, using a surface offset technique showed that sliding increased with increasing carbon content and that cavity nucleation occurred selectively at large grain boundary carbides. Formerly of the Department of Metallurgy, University of Manchester.