Hydrogen porosity in directionally solidified aluminium–copper alloys: a mathematical model

A combined continuum and stochastic model of diffusion-controlled growth was developed to simulate the formation of porosity during the solidification of aluminium alloys. The whole population of pores was tracked, rather than just the average values. A finite difference solution of the diffusion equations was used, combined with a stochastic model of nucleation. The growth of each individual pore was simulated, assuming the shape to be spherical until it impinged on the developing dendrites, at which point the growth was modelled as a hemispherically capped segmented cone, with the growth radius limited by the liquid space between the dendrites. A previously published model by one of the authors was used to predict the dendritic spacing as a function of the thermal conditions.The model was compared with in situ observations of the formation of porosity during the solidification of aluminium–copper alloys, where the size, distribution and morphological evolution of pores were measured as a function of temperature/time. The predicted development of the porosity, including the distribution in size and morphology, compared well with that observed experimentally. The qualitative agreement between the model predictions and experimental results supports the hypothesis that the effect of hydrogen and its diffusion must be incorporated into any accurate model of pore formation in aluminium alloys.     

Phase and microstructure selection in directionally solidified peritectic alloys with convection

A boundary layer model was used to investigate the convection effects on phase and microstructure selection in directionally solidified peritectic alloy. Due to the convection effects, the steady-state compositions of one phase at interface corresponding to an initial composition reduce, which causes its steady-state point moves upward along its solidus line and the compositional range is not consistent with the band cycle in banding. A criterion of critical interface temperature was put forward to determine whether a phase entered steady-state growth or not. Furtherly by equivalent transformation, the equivalent solidus lines and subsequent equivalent phase diagram were derived for peritectic solidification with convection. Using this equivalent phase diagram, a phase and microstructure selection map is built for a peritectic alloy with convection effect, which shows that the compositional range for banding reduces, and moves to the hyperperitectic region, and also the coupled growth region of both solids comparing with purely-diffusive limit. The predicted map for directionally solidified Pb-Bi alloy agrees well with its experimental observations.     

Intermetallic phase formation in directionally solidified Al−Si−Fe alloy

The present study has been undertaken to better understand the solidification behavior of Al−Si−Fe alloys containing 7wt.% Si and 0.9wt.% Fe, with particular regard to the formation of phase during controlled solidification and influence of growth rates on intermetallic phase selection. The alloys studied were Al-7Si-0.9Fe alloys, which were produced by a modified Bridgman solidification arrangement. These alloys were solidified unidirectionally with different growth rates (1–30mm/min). The solidified microstructure of these alloys consists of the growth of primary aluminum and multiple second phase reactions.     

Model for calculation of microstructural development in rapidly directionally solidified immiscible alloys

A model has been developed for the calculation of the microstructural evolution in a rapidly directionally solidified immiscible alloy.Numerical solutions have been performed for Al-Pb immiscible alloys.The results demonstrate that at a higher solidfication velocity a constituteional supercooling region appears in front of the solid/liquid interface and the liquid-liquid decomposition takes place in this region.A higher solidification velocity leads to a higher nucleation rate and ,therefore,a higher number density of the minority phase droplets.A s a result,the average radius of droplets in the melt at the solid/liquid interface decreases with the solidification velcity.     

Tensile creep of directionally solidified NiAl–9Mo in situ composites

Well-aligned Mo fiber-reinforced NiAl in situ composites were produced by specially controlled directional solidification. The creep behavior parallel to the growth direction was studied in static tensile tests at temperatures between 900 °C and 1200 °C. A steady-state creep rate of 10^?6 s^?1 was measured at 1100 °C under an initial applied tensile stress of 150 MPa. Compared to binary NiAl and previously investigated NiAl–Mo eutectics with irregularly oriented Mo fibers, this value demonstrates a remarkably improved creep resistance in NiAl–Mo with well-aligned unidirectional Mo fibers. A high-resolution transmission electron microscope investigation of the NiAl/Mo interface revealed a clean semi-coherent boundary between NiAl and Mo, which enabled an effective load transfer from the NiAl matrix to the Mo fibers, and thus leads to the remarkably increased creep strength. The stress exponent, n, was found to be between 3.5 and 5, dependent on temperature. The activation energy for creep, Q_c, was measured to be 291 ± 19 kJ mol^–1, which is close to the value for self-diffusion in binary NiAl. Transmission electron microscopy observations substantiated that creep occurred by dislocation climb in the NiAl matrix. The Mo fiber was found to behave in a quasi-rigid manner during creep. A creep model for fiber-reinforced metal matrix composites was applied for an in-depth understanding of the mechanical behavior of the individual components and their contribution to the creep strength of the composite.     

Macrosegregation and thermosolutal convection-related freckle formation in directionally solidified Sn–Ni peritectic alloy in crucibles with different diameters

Different from other alloys, the observation in this work on the dendritic mushy zone shows that the freckles are formed in two different regions before and after peritectic reaction in directional solidification of Sn–Ni peritectic alloys. In addition, the experimental results demonstrate that the dendritic morphology is influenced by the temperature gradient zone melting and Gibbs–Thomson effects. A new Rayleigh number (Ra_P) is proposed in consideration of both effects and peritectic reaction. The prediction of Ra_P confirms the freckle formation in two regions during peritectic solidification. Besides, heavier thermosolutal convection in samples with larger diameter is also demonstrated.     

Influence of hexagonal to orthorhombic phase transformation on diffusion-controlled dendrite evolution in directionally solidified Sn–Ni peritectic alloy

The hexagonal to orthorhombic (HO) transformation from β-Ni₃Sn₂ (hexagonal) phase to α’-Ni₃Sn₂ (orthorhombic) phase was confirmed in directionally solidified Sn–Ni peritectic alloys. It is shown that the remelting/resolidification process which is caused by both the temperature gradient zone melting (TGZM) and Gibbs?Thomson (G?T) effects can take place on secondary dendrites. Besides, the intersection angle between the primary dendrite stem and secondary branch (θ) is found to increase from π/3 to π/2 as the solidification proceeds. This is the morphological feature of the HO transformation, which can change the diffusion distance of the remelting/ resolidification process. Thus, a diffusion-based analytical model is established to describe this process through the specific surface area (S_V) of dendrites. The theoretical prediction demonstrates that the remelting/resolidification process is restricted when the HO transformation occurs during peritectic solidification. In addition, the slope of the prediction curves is changed, indicating the variation of the local remelting/resolidification rates.     

Tool wear estimation in micro-machining.: Part I: tool usage–cutting force relationship

The relationship between the cutting force characteristics and tool usage (wear) in a micro-end-milling operation was studied for two different metals. Neural-network-based usage estimation methods are proposed that use force-variation- and segmental-averaging-based encoding techniques.     

Effects of boron on the microstructure and thermal stability of directionally solidified NiAl–Mo eutectic

Microalloying with 0.01 at.% B decreases the range of growth speeds over which a well-aligned fibrous eutectic microstructure can be obtained in directionally solidified NiAl–Mo. Compared to the undoped alloy, the size/spacing of the Mo fibers is larger, and the fiber density smaller, in the B-doped alloy. Annealing at 1400 °C coarsens the fibers by a mechanism involving fault migration and annihilation driven by diffusion along the fiber–matrix interface. The coarsening kinetics, given by the decrease in Mo fiber density with time, is exponential, and microalloying with B decreases the coarsening rate.     

Structure simulation in unidirectionally solidified turbine blade by dendrite envelope tracking model(I):numerical modeling

1 Introduction Unidirectional solidification technology is used to get special properties of casting, for example, to get the turbine blades with columnar or single crystal structures. Several modelling approaches have been carried out for the structure d…     

IFHTSE Global 21: heat treatment and surface engineering in the twenty-first century Part 19 – Type I quenchants for quenching of aluminium: a review

Abstract

Some aluminium forgings and castings are cold water quenched in order to achieve the desired design minimum physical properties. When unacceptable distortion or cracking is encountered, hot water has traditionally been specified as an alternative quenchant. However, hot water quenching typically results in a significant loss of mechanical properties and a significant increase in the potential for intergranular corrosion. Approximately 30 years ago, SAE designated Type I poly(alkyleneglycol) copolymer quenchants were introduced as an alternative to hot water. These quenchants offered significant, often dramatic, advantages in residual stress and distortion reduction while still achieving the Mil-Handbook 5 design minimum properties. However, even though these quenchants have been available for such a long time, there is still wide spread misunderstanding regarding how they work, when they should be used and how they should be monitored. The objective of this paper is to address these issues.     

Growth rate and composition of directionally solidified intermetallic TiAl–Nb alloys with different solidification conditions

Intermetallic Ti-xAl-8Nb(x = 41,43,45,47,49;at%) alloys were solidified unidirectionally upwards with a constant temperature gradient of G=3.8 K·mm~(-1)at wide range of growth rates of v=10-400 μm·s~(-1)using a Bridgman directional solidification(DS) furnace.Microstructural parameters including the primary dendrite arm spacing(λ_1),secondary dendrite arm spacing(λ_2),dendrite tip radius(R) and mushy zone depth(d) were measured statistically.The values of λ_1,λ_2,R and d decrease as the growth rate increases for a given composition(x).The values of λ_1,λ_2,R and v increase with the increase in x value,while the value of d firstly increases and then decreases with the increase in x value for a given v.The relationships between λ_1,λ_2 and R were analyzed by the linear regression.The average growth rate exponent of λ_1 is 0.29,which is in accordance with the previous experimental observations,and that of λ_2 is close to the previous experimental results,while those of R and d are lower than the results in other alloy systems.In addition,theoretical models for λ_1,λ_2 and R were compared with the experimental observations,and a comparison of the present experimental results with the theoretical models and previous experimental results was also made.     

Effects of processing parameters on the surface quality of directionally solidified tita-nium alloy slab with cold crucible

Titanium and TiAl-based alloys are promising structurematerials for aero/space-crafts of next generations due totheir excellent properties, such as high specific strength,high specific rigidity, high oxidization resistance and highcreep resistance at high temperature[1-3]. However, the Tialloys are highly active, especially in molten state they canreact with almost all other materials. This makes thespontaneous nucleation difficult during solidification andresults in coarse structures. These …     

Error compensation in machine tools — a review: Part I: geometric,cutting-force induced and fixture-dependent errors

Accuracy of machined components is one of the most critical considerations for any manufacturer. Many key factors like cutting tools and machining conditions, resolution of the machine tool, the type of workpiece etc., play an important role. However, once these are decided upon, the consistent performance of the machine tool depends upon its ability to accurately position the tool tip vis-à-vis the required workpiece dimension. This task is greatly constrained by errors either built into the machine or occurring on a periodic basis on account of temperature changes or variation in cutting forces. The three major types of error are geometric, thermal and cutting-force induced errors. Geometric errors make up the major part of the inaccuracy of a machine tool, the error caused by cutting forces depending on the type of tool and workpiece and the cutting conditions adopted. This part of the paper attempts to review the work done in analysing the various sources of geometric errors that are usually encountered on machine tools and the methods of elimination or compensation employed in these machines. A brief study of cutting-force induced errors and other errors is also made towards the end of this paper.     

Effects of coherency stress and vacancy sources/sinks on interdiffusion across coherent multilayer interfaces – Part I: Theory

A phase field model corresponding to vacancy-mediated interdiffusion in coherent multilayers with completely miscible constituents is developed to explore the effects of several factors on interdiffusion across coherent multilayer interfaces, such as: (1) the dependence of diffusion potentials and mobilities on coherency stress; (2) the dependence of diffusion potentials and mobilities on composition; (3) the elastic constant inhomogeneity resulting from a inhomogeneous composition distribution; and (4) the properties of vacancy sources/sinks. The Gibbs free energy of the system consists of chemical and elastic energies. The gradient energy is neglected as the multilayers under consideration can be chemically well approximated by an ideal substitutional solution model. Elastic energy is a function of the stress-free strain and inhomogeneous elastic moduli distributions, while the stress is solved by anisotropic phase field microelasticity theory. The diffusion potentials are obtained straightforwardly as functional derivatives of the free energy with respect to composition and are in keeping with previous derivations that involved many mathematical manipulations or quite advanced theories. The diffusion mobilities are affected by the stress through modification of the vacancy formation and migration energies. Two limiting cases of vacancy sources/sinks are taken into account: ideal vacancy sources/sinks are uniformly and densely distributed, or not present at all, so the vacancy concentration is in equilibrium all the times, as determined by the local stress and composition in the former case, but deviates from the equilibrium concentration in the latter. The model can be conveniently extended to consider the non-ideal activity of vacancy sources/sinks by introducing a general kinetic relation for the vacancy creation rate.     

Modelling of electromagnetic processes in system 'welding arc – evaporating anode' Part 1 – Model of anode region

Abstract

A mathmatical model of electromagnetic processes occurring in the 'arc column – anode region – evaporating anode' system is presented. The anode region of electric arc with an evaporating metallic anode is described by a model, under which the non-equilibrium near anode plasma containing atoms and ions of the evaporated metal, along with atoms and ions of the ambient (inert) gas, is subdivided into a space charge layer immediately adjoining the anode surface and ionisation region adjacent to the arc column. This model allows determining the potential drop between welding arc column plasma and anode surface depending on the current density and plasma temperature near the anode, as well as upon the temperature of its surface.     

Effect of abruptly changing withdrawal rate on solidification microstructure in directionally solidified Al-4.5wt%Cu alloy简

Al-4.5wt.%Cu alloy has been directionally solidified at constant and abruptly changing withdrawal rates, respectively. The effects of the withdrawal rate on solidification microstructure, primary dendrite arm spacing(PDAS) and liquid solute distribution in front of the solid-liquid interface were investigated. The experimental results for the PDAS at a constant withdrawal rate agree well with the values calculated by the Hunt, Trivedi and Hunt-Lu models. At an abrupt change in the withdrawal rate, the maximum to minimum ratio of the PDAS at a given solidification parameter, i.e. λ1max/λ1min, is more than 2, and the PDAS values are remarkably history-dependent. Further, the liquid-solute distribution curve based on theoretical calculation shows that the larger the initial withdrawal rate is, the smaller the minimum of liquid solute concentration in front of the solid-liquid interface is after the abrupt change in withdrawal rate.     

CRSS of γ/γ′ phases from in situ neutron diffraction of a directionally solidified superalloy tension tested at 900 °C

Neutron diffraction was used to monitor elastic strains during in situ tension testing of a directionally solidified (DS) superalloy at 900 °C. Changes in misfit and thermal expansion coefficients of individual phases were obtained. In the γ phase, it is demonstrated that elastic strains saturate at 350 MPa, which is well below the yield strength of the alloy. This is interpreted as the onset of dislocation glide through less stressed vertical channels. The critical resolved shear stress (CRSS) of γ is found to be 143 ± 11 MPa, in agreement with a calculated CRSS that is dominated by Orowan bowing of dislocations through nanoscale-wide γ channels. This provides confirmation of Orowan bowing in plasticity/creep of the γ phase. Implications of CRSS and misfit in a “threshold stress” for creep and rafting are discussed. The CRSS of γ′ is found to be consistent with pairwise penetration of dislocations into γ′.     

Microcracking in multipass weld metal of alloy 690 Part 2 – Microcracking mechanism in reheated weld metal

Abstract

To elucidate the microcracking (ductility dip cracking) mechanism in the multipass weld metal of alloy 690, the hot ductility of the reheated weld metal was evaluated using three different filler metals with varying contents of impurity elements such as P and S. Hot ductility of the weld metal decreased at temperatures over 1400 K, and the weld metal containing a low quantity of impurity elements showed much higher ductility than that containing a high quantity of impurity elements. Local deformability at high temperature of the alloy 690 reheated weld metal was compared with that of Invar alloy. Grain boundary sliding in alloy 690 occurred not in the intermediate temperature range (800–1000 K), where grain boundary sliding was activated in Invar alloy, but at high temperatures just below the melting temperature of alloy 690. The computer simulation of microsegregation suggested that the deterioration of hot ductility is caused by the grain boundary segregation of impurity elements during the multiple thermal cycling. The ductility dip cracking in the reheated weld metal resulted predominantly from the embrittlement of grain boundaries due to the imbalance between intergranular strength and intragranular strength at high temperature.