Bulk amorphous Al85Fe15 alloy and Al85Fe15-B composites with amorphous or nanocrystalline-matrix produced by consolidation of mechanically alloyed powders

An Al80Fe14B6 powder mixture was subjected to mechanical alloying. Presence of an amorphous structure in the milling product was revealed by XRD investigations. The calorimetric study showed that the amorphous phase crystallised above 370 °C. The milled Al₈₀Fe₁₄B₆ powder was consolidated under a pressure of 7.7 GPa in different conditions: at 350 °C and at 1000 °C. Besides, the mechanically alloyed amorphous Al₈₅Fe₁₅ powder was consolidated at 360 °C. The amorphous structure was retained after consolidation applied at 350 °C and 360 °C. Compaction at 1000 °C caused crystallisation of the amorphous phase and appearance of metastable nanocrystalline phases. Structural investigations revealed that both bulk Al₈₀Fe₁₄B₆ samples are composites with boron particles embedded in amorphous or nanocrystalline matrix. The hardness of the nanocrystalline-matrix composite and of the amorphous-matrix one is equal to 707 HV1 and 641 HV1 respectively, whereas that of bulk amorphous Al₈₅Fe₁₅ alloy is 504 HV1. The specific yield strength of amorphous-matrix and nanocrystalline-matrix composites, estimated using the Tabor relationship, is 625 and 650 kNm/kg respectively, while that of amorphous Al₈₅Fe₁₅ alloy is 492 kNm/kg. We also suppose that application of high pressure affected crystallisation of amorphous phase, influencing the phase composition of the products of this process.     

The microstructures and mechanical properties of cast Mg–Zn–Al–RE alloys

The microstructures and mechanical properties of cast Mg–Zn–Al–RE alloys with 4 wt.% RE and variable Zn and Al contents were investigated. The results show that the alloys mainly consist of α-Mg, Al₂REZn₂, Al₄RE and τ-Mg₃₂(Al,Zn)₄₉ phases, and a little amount of the β-Mg₁₇Al₁₂ phase will also be formed with certain Zn and Al contents. When increasing the Zn or Al content, the distribution of the Al₂REZn₂ and Al₄RE phases will be changed from cluster to dispersed, and the content of τ-Mg₃₂(Al,Zn)₄₉ phase increased gradually. The distribution of the Al₂REZn₂ and Al₄RE phases, and the content of β- or τ-phase are critical to the mechanical properties of Mg–Zn–Al–RE alloys. The Mg–6Zn–5Al–4RE alloy with cluster Al₂REZn₂ phase and low content of β-phase, exhibits the optimal mechanical properties, and the ultimate tensile strength, yield strength and elongation are 242 MPa, 140 MPa and 6.4% at room temperature, respectively.     

Formation and thermal stability of new Zr–Cu-based bulk glassy alloys with unusual glass-forming ability

The simultaneous addition of Al and Ag to Zr–Cu binary alloys increased in the stabilization of supercooled liquid, the reduced glass transition temperature and γ value, leading to greatly enhance the glass-forming ability (GFA). The Zr–Cu–Ag–Al glassy alloy samples with diameters above 15 mm were obtained in the wide composition range of 42–50 at% Zr, 32–42 at% Cu, 5–10 at% Ag, and 5–12 at% Al. The best GFA was obtained for Zr₄₈Cu₃₆Ag₈Al₈ alloy, and the glassy samples with diameters up to 25 mm were fabricated by an injection copper mold casting. The Zr₄₈Cu₃₆Ag₈Al₈ glassy alloy exhibited high tensile and compressive fracture strength of over 1800 MPa.     

Thermal stability and primary phase of Al–Ni(Cu)–La amorphous alloys

Thermal stability and primary phase of Al_85+xNi_9−xLa₆ (x = 0–6) and Al₈₅Ni_9−xCu_xLa₆ (x = 0–9) amorphous alloys were investigated by X-ray diffraction and differential scanning calorimeter. It is revealed that replacing Ni in the Al₈₅Ni₉La₆ alloy by Cu decreases the thermal stability and makes the primary phase change from intermetallic compounds to single fcc-Al as the Cu content reaches and exceeds 4 at.%. When the Ni and La contents are fixed, replacing Al by Cu increases the thermal stability but also promotes the precipitation of single fcc-Al as the primary phase.     

The effects of lanthanum on microstructure and electrochemical properties of Al–Zn–In based sacrificial anode alloys

In order to improve the non-uniform corrosion of Al–0.5Zn–0.03In–1Mg–0.05Ti alloys, Al–5Zn–0.03In–1Mg–0.05Ti–xLa (x = 0.3, 0.5 and 0.7 wt.%) alloys were developed. Microstructures and electrochemical properties of the alloys were investigated. The results show that the optimal microstructures and electrochemical properties are obtained in Al–5Zn–0.03In–1Mg–0.05Ti–0.5La alloy. The main precipitate phase is Al₂LaZn₂ particles. The excellent electrochemical properties of Al–5Zn–0.03In–1Mg–0.05Ti–0.5La alloy is mainly attributed to fine grains and grain boundaries containing fine Al₂LaZn₂ precipitates. At the same time the fine grains can improve the non-uniform corrosion of Al–0.5Zn–0.03In–1Mg–0.05Ti alloy.     

The corrosion behavior of Cu–Al and Cu–Al–Be shape-memory alloys in 0.5 M H2SO4 solution

The corrosion behavior of Cu–Al and Cu–Al–Be (0.55–1.0 wt%) shape-memory alloys in 0.5 M H₂SO₄ solution at 25 °C was studied by means of anodic polarization, cyclic voltammetry, and alternative current impedance measurements. The results of anodic polarization test show that anodic dissolution rates of alloys decreased slightly with increasing the concentrations of aluminum or beryllium. Severe intergranular corrosion of Cu–Al alloy was observed after alternative current impedance measurement performed at the anodic potential of 0.6 V. However, the addition of a small amount of beryllium was effective to prevent the intergranular corrosion. The effect of beryllium addition on the prevention of intergranular corrosion is possibly attributed to the diffusion of beryllium atoms into grain boundaries, which in turn deactivates the grain boundaries.     

Pulsed electric current sintered Fe3Al bonded WC composites

WC based composites with 5, 10 and 20 vol.% Fe₃Al binder were consolidated via pulsed electric current sintering (PECS) in the solid state for 4 min at 1200 °C under a pressure of 90 MPa. Microstructural analysis revealed a homogeneous Fe₃Al binder distribution, ultrafine WC grains and dispersed Al₂O₃ particle clusters. The WC-5 vol.% Fe₃Al composite combines an excellent Vickers hardness of 25.6 GPa with very high Young’s modulus of 693 GPa, a fracture toughness of 7.6 MPa m^1/2 and flexural strength of 1000 MPa. With increasing Fe₃Al binder content, the hardness and stiffness decreased linearly to 19.9 and 539 GPa, respectively with increasing binder content up to 20 vol.%, while the fracture toughness and flexural strength were hardly influenced by the binder content. Compared to WC–Co cemented carbides processed under exactly the same conditions, the WC–Fe₃Al composites exhibit a substantially higher hardness and Young’s modulus.     

Characterization of phases in complex metallic alloys Al73Mn27−xFex (x = 2, 4 and 6)

The characterization of phases in Al₇₃Mn_27−xFe_x (x = 2, 4 and 6) alloys was performed using X-ray diffraction, differential thermal analysis, and scanning electron microscopy enabling energy dispersive X-ray spectroscopy. Both the annealed and the thermally cycled states were studied. In the annealed states the occurrence of T-phase was expected, however it was confirmed for alloys Al₇₃Mn₂₅Fe₂ and Al₇₃Mn₂₃Fe₄ only. The annealing of the Al₇₃Mn₂₁Fe₆ alloy probably led to the formation of decagonal quasicrystal (D). The T- and D-phases were found to be unstable at low temperatures. In the states after DTA the low temperature Al₁₁(Mn,Fe)₄ and γ₂ phases were observed in the Al₇₃Mn₂₅Fe₂ and Al₇₃Mn₂₁Fe₆ alloys, while only the former phase was observed in the Al₇₃Mn₂₃Fe₄ alloy.     

Crystallization studies of Al<Subscript>85</Subscript>Y<Subscript>10</Subscript>Fe<Subscript>5−x</Subscript>Ni<Subscript>x</Subscript> (x = 0, 2.5, 5) alloys

The crystallization behavior of melt-spun A₈₅Y₁₀Fe_5−xN_x (x=0, 2.5, 5) amorphous alloys has been investigated by a combination of differential scanning calorimetry (DSC) and x-ray diffractometry (XRD). XRD traces of these alloys consisted of a single broad peak corresponding to fully amorphous structure. Continuous DSC results showed that, the first crystallization peak temperature of Al₈₅Y₁₀Fe₅ amorphous alloy was about 60 K higher than that of Al₈₅Y₁₀Ni₅. The activation energies for the first crystallization peak increased from 210 kJ/mol for Al₈₅Y₁₀Ni₅ to 280 for Al₈₅Y₁₀Fe₅. These results indicate that 5 at.% substitutions Ni by Fe increases the stability of the amorphous phase.     

A novel Al–Ti–B alloy for grain refining Al–Si foundry alloys

Al–Ti–B refiners with excess-Ti (Ti:B > 2.2) perform adequately for wrought aluminium alloys but they are not as efficient in the case of foundry alloys. Silicon, which is abundant in the latter, forms silicides with Ti and severely impairs the potency of TiB₂ and Al₃Ti particles. Hence, Al–Ti–B alloys with excess-B (Ti:B < 2.2) and binary Al–B alloys are favored to grain refine hypoeutectic Al–Si alloys. These grain refiners rely on the insoluble (Al,Ti)B₂ or AlB₂ particles for grain refinement, and thus do not enjoy the growth restriction provided by solute Ti. It would be very attractive to produce excess-B Al–Ti–B alloys which additionally contain Al₃Ti particles to maximize their grain refining efficiency for aluminium foundry alloys. A powder metallurgy process was employed to produce an experimental Al–3Ti–3B grain refiner which contains both the insoluble AlB₂ and the soluble Al₃Ti particles. Inoculation of a hypoeutectic Al–Si foundry alloy with this grain refiner has produced a fine equiaxed grain structure across the entire section of the test sample which was more or less retained for holding times up to 15 min.     

Electrochemical behavior and localized corrosion associated with Al7Cu2Fe particles in aluminum alloy 7075-T651

Initiation of localized corrosion upon high strength aluminum alloys is often associated with cathodic intermetallic particles within the alloy. Electrochemical measurements and metallurgical characterization have been made to clarify and quantify the physical properties of Al₇Cu₂Fe particles in AA7075-T651. Prior studies regarding either the stereology or electrochemical properties of Al₇Cu₂Fe are scarce. Quantitative microscopy revealed a significant population of Al₇Cu₂Fe in the alloy; comprising up to 65% of the constituent particle population and typically at a size of 1.7 ± 1.0 μm. It was determined that Al₇Cu₂Fe may serve as a local cathode in the evolution of localized corrosion of AA7075-T651 and is capable of sustaining oxygen reduction reactions at rates of several hundreds of μA/cm² over a range of potentials typical of the open circuit potential (OCP) of AA7075-T651 in NaCl solution of various concentrations and pH. The presence of Al₇Cu₂Fe leads to the development of pitting at the particle–matrix interface.     

In situ XRD studies on Al–Ni and Al–Ni–Sr alloys prepared by rapid solidification

In this paper the structure and stability of Al–17 wt.%Ni(Al–17Ni) and Al–17 wt.%Ni–2 wt.%Sr alloys prepared by rapid solidification was investigated by means of XRD techniques. Our work demonstrates that both alloys are crystalline and composed of fcc (Al–Ni) solid solution and orthorhombic Al₃Ni phases. The ternary alloy shows in addition the presence of small amount of tetragonal Al₄Sr phase. In situ XRD experiment demonstrates the stability of the solute solution up to 650 °C, Al₃Ni above 750 °C while Al₄Sr overcomes melting of the major phases at 800 °C. High-temperature structure analysis proved strong bindings between Al and Ni atoms in Al₃Ni phase, corroborating its covalent nature, linear and faster increase of the fcc volume with annealing temperature. The linear correlation between constituting atoms decreases with increase of the temperature.The work also documents the applicability of pair distribution function (PDF) analysis to the study of multiphase crystalline systems.     

Pitting and alkaline dissolution of an amorphous-nanocrystalline alloy with solute-lean nanocrystals

The corrosion resistance of partially devitrified metallic glasses is a critical concern for the viability of the glasses in many technological applications. Although partial devitrification is detrimental to the corrosion resistance of some metallic glasses, both the pitting and alkaline corrosion behavior of partially nanocrystalline Al₉₀Fe₅Gd₅ is similar to that of its amorphous precursor. This is in spite of the fact that the microstructure of the amorphous-nanocrystalline alloy is effectively a composite consisting of f.c.c. Al crystals embedded in an amorphous matrix. Here the pitting corrosion and alkaline dissolution of the amorphous-nanocrystalline alloy is compared to that of its fully amorphous precursor, pure polycrystalline Al, and to a micrometer scale composite consisting of electrically connected pure Al wires and amorphous ribbons.     

Amorphous and nanocrystalline sputtered Mg–Cu thin films

Binary Mg–Cu amorphous alloys were first fabricated in 1980s via liquid quenching. In this study, the Mg_1−xCu_x (x varying from 38 at.% to 82 at.%) partially amorphous thin films are prepared via co-sputtering. Upon thermal annealing, the Mg₂Cu or MgCu₂ nanocrystalline phases are induced in the Mg-rich or Cu-rich thin films, respectively. Due to the presence of fine nanocrystalline Mg₂Cu or MgCu₂ particles in the Mg–Cu amorphous matrix, the as-sputtered thin films show satisfactory Young's modulus 100 GPa and hardness 4 GPa.     

Structure and magnetic characterization of amorphous and crystalline Nd–Fe–Al alloys

Glass formation has been studied in Nd₆₀Fe₃₀Al₁₀ alloy produced by melt-spinning, water quenching and copper mold chill casting. Partially amorphous alloys were obtained by melt-spinning at low wheel speeds of 5 to 15 m/s and by water quenching of a 1-mm diameter rod, while fully amorphous alloys were obtained by melt-spinning at higher wheel speeds of 20 and 30 m/s and chill casting of a 1-mm diameter rod. A high coercivity was observed in the partially amorphous ribbon melt-spun at 5 m/s and water quenched rod, and in the fully amorphous chill cast rod, while low values of coercivity were obtained in fully amorphous ribbons melt-spun at high speeds of 20 and 30 m/s. Crystallization of water quenched and chill cast samples after heat treatment at high temperature resulted in a substantial reduction of the high coercivity. Results of X-ray diffraction indicate that formation of Nd and a ternary Fe–Nd–Al phase with an unknown crystal structure were present after crystallization. TEM results and a magnetic study of the heat treated samples indicate that as long as there is an amorphous phase produced by low cooling rate, the high coercivity remains. The high coercivity of bulk amorphous samples is discussed. The unknown ternary Fe–Nd–Al phase is antiferromagnetic with a Neel temperature at about 260 K.     

Effect of manganese on the microstructure of Mg–3Al alloy

The effect of manganese on the microstructure of Mg–3Al alloy, especially the nucleation efficiency of Al–Mn particles on primary Mg, has been investigated in this paper. Mg–0.72Mn was used to fabricate Mg–3Al–xMn (x = 0, 0.1, 0.2, 0.3, 0.4 and 0.5) alloys, and the grain sizes of these alloys fluctuate at 390 μm indicating addition of manganese does not evidently influence the grain size of Mg–3Al alloy. Through XRD, FESEM and TEM detection, it is found that Al_0.89Mn_1.11 compound is the dominant Al–Mn phase in Mg–3Al–0.3Mn, Mg–3Al–0.4Mn and Mg–3Al–0.5Mn, and distributes in primary Mg matrix and interdendritic regions with an angular blocky morphology. The number of Al_0.89Mn_1.11 increases gradually with increasing manganese content while the grain sizes of primary Mg are nearly the same in Mg–3Al, Mg–3Al–0.3Mn, Mg–3Al–0.4Mn and Mg–3Al–0.5Mn, indicating Al_0.89Mn_1.11 has low nucleation efficiency on primary Mg.     

Nanocrystalline Al3Ni2 alloy with high hardness produced by mechanical alloying and high-pressure hot-pressing consolidation

An elemental powder mixture corresponding to Al₃Ni₂ phase stoichiometry was subjected to mechanical alloying. A metastable nanocrystalline AlNi intermetallic phase with the mean crystallite size of 12 nm was formed upon milling. Heating of the synthesised powder in a calorimeter up to 720 °C caused phase transformation into an equilibrium Al₃Ni₂ intermetallic phase with the mean crystallite size of 41 nm. The product of mechanical alloying was consolidated at 1000 °C under the pressure of 5 GPa and 7.7 GPa. During consolidation, a phase transformation analogous with the one observed in the course of heating in the calorimeter took place. Both bulk materials have nanocrystalline structure with mean crystallite size of 67 nm and 58 nm, the smaller one in the sample consolidated under the higher pressure. The hardness of the produced Al₃Ni₂ intermetallic is 8.81 GPa (898 HV1) and 8.72 GPa (887 HV1), while the specific yield strength, estimated using the Tabor relation, is 624 kNm/kg and 617 kNm/kg for the sample hot-pressed under 5 GPa and 7.7 GPa respectively. On the basis of the obtained results, we can assume that the quality of consolidation with preserving a nanocrystalline structure is satisfactory and the hardness as well as the estimated specific yield strength of the produced materials are relatively high.     

Solid-state reactions upon mechanical alloying of an Fe32Al68 binary mixture

The sequence of solid-state reactions that occur upon mechanical alloying of powder mixtures of Al and Fe taken in an atomic ratio of 68: 32 has been studied by the methods of X-ray diffraction analysis, M?ssbauer spectrometry, and Auger spectrometry. Upon the formation of a nanocrystalline state (<10 nm), there takes place a mutual penetration of Al atoms into Fe and Fe atoms into Al particles. The rate of consumption of the fcc Al is substantially higher than that of the bcc Fe. The process of the mechanical alloying (MA) was found to be two-stage. At the first stage, up to 2 at % Fe is dissolved in the fcc Al, and an amorphous Fe₂₅Al₇₅ phase is formed in the interfaces, whose amount reaches 70 at % at the finish of the initial stage. In the interfaces of the ??-Fe phase, a disordered bcc phase of composition Fe₆₆Al₃₄ is formed, which contains up to 12 at % Al segregates. At the second stage, the amorphous phase crystallizes into an orthorhombic intermetallic compound Fe₂Al₅. The residual ??-Fe, bcc Fe₆₆Al₃₄, and segregated Al form a bcc phase of composition Fe₃₅Al₆₅.     

The phase equilibria of the Al–Ce–Ni system at 500 °C

The phase equilibria at 500 °C in the Al–Ce–Ni system in the composition region of 0–33.3 at.% Ce are investigated using XRD and SEM/EDX techniques applied to equilibrated alloys. The previously reported ternary phases and the variation of the lattice parameters versus the composition for different solid solution phases are investigated. It is confirmed that τ₂(Al₂CeNi) exists at 500 °C, while τ₃(Al₅Ce₂Ni₅) does not exist at 500 °C. A new compound τ₉ with composition of about Al₃₅Ce_16.5Ni_48.5 is found. The solubility of Ni in Al₁₁Ce₃ and αAl₃Ce is generally about 1 at.%, while the solubility of Ni in Al₂Ce is measured to be 2.7 at.%. The solubility of Ce in Al₃Ni, Al₃Ni₂, AlNi and AlNi₃ is all less than 1 at.%. The solubility of Al in CeNi₅, Ce₂Ni₇ and CeNi₃ is measured to be 30.4, 4.8 and 9.2 at.%, respectively, while there is no detectable solubility for Al in CeNi₂. A revised isothermal section at 500 °C in the Al–Ce–Ni system has been presented.     

Microstructure and mechanical properties of bulk nanocrystalline Al88Mm5Ni5Fe2 alloy consolidated at high pressure

Bulk nanocrystalline Al₈₈Mm₅Ni₅Fe₂ alloys have been produced by consolidation of pulverised melt-spun ribbons at high pressure. Different production procedures were explored to improve the quality of compaction of the resulting bulk samples. Quality of compaction of samples pressed at room temperature is clearly improved by increasing applied pressure from 2 to 7.7 GPa. All hot compacted samples had good quality of compaction. Onset of crystallisation shifts to higher temperatures as the applied pressure increases. Nanocrystalline powder fails to be compacted at room temperature even at 7.7 GPa. Mechanical properties were studied in terms of Vickers' microhardness. Relationship between microhardness and microstructure of the bulk samples was studied in the frame of two different theoretical models.