The contribution of the nucleation process to grain formation in calculating solidification microstructure by CA-DFD

To predict solidification macrostructures, the direct finite difference (DFD) method for heat transfer calculation was coupled with cellular automaton (CA). In the CA-DFD, the nucleation process as the initial condition of calculations was determined according to Gaussian distribution or being instantaneous. In the case of Gaussian distribution, there are six nucleation-related parameters. In this work, the inspection of relationships of preset nuclei to grain, preset nuclei to born nuclei, and born nuclei to grain was carried out by comparison of each ratio. However, these relationships are only valid under the same solidification environments. In contrast to the preset method, the successive nuclei setting method (SNS) was carried out. This method manages the nucleus settings by every time step. The microstructures by SNS were compared with those by preset.     

Effect of silicon content on microstructure and electrochemical behavior of hypoeutectic Al-Si alloys

The correlation of mechanical properties and corrosion behavior with microstructure parameters can be very useful for planning solidification conditions in order to achieve a desired level of final properties. The present study aims to investigate the influence of silicon content on the microstructural pattern, i.e., dendrite spacings and distribution of interdendritic phases on the corrosion behavior of Al-Si alloys castings. The corrosion resistance was analyzed by both the electrochemical impedance spectroscopy (EIS) technique and Tafel's plots carried out in a 0.5 M NaCl test solution at 25 °C. The increase on silicon content has provided a dendritic refinement and a more extensive redistribution of the eutectic mixture which has provoked a decrease on the corrosion resistance.     

Non-equilibrium effects on solid transition of solidification microstructure of deeply undercooled alloys

Integrated effects of undercooling and solute drag on recrystallisation mechanism of rapid solidification microstructure were investigated in highly undercooled Ni-Cu alloys. The equiaxed grained microstructures were prepared by fluxing method and subsequent quenching. Annealing the microstructures of the as-quenched alloys, substantial recrystallisation growth was observed. Applying solute trapping model of undercooled melt and solute drag model of solid-state transformation, it can be inferred that the microstructural evolution was dominated by nucleation and growth of recrystallisation process which is strongly dependent on the initial undercooling of the alloy melt and the solute drag force of the solid-state transition process.     

Reducing porosity and optimizing performance for Al-Cu-based alloys with large solidification intervals by coupling travelling magnetic fields with sequential solidification

Porosity is a major casting defect in alloys with large solidification intervals due to the disordered microstructure and broad mushy zones,which decreases badly the mechanical performance.Hence,finding ways to effectively reduce the porosity,further to optimize microstructure and mechanical per-formance is of great significance.In this regard,the Al-Cu-based alloys with large solidification intervals are continuously processed by coupling the travelling magnetic fields (TMF) with sequential solidifica-tion.Additionally,experiments combined with simulations are utilized to comprehensively analyze the mechanism of TMF on the reduction in porosity,including shrinkage porosity and gas porosity,from dif-ferent perspectives.Current findings determine that downward TMF can effectually optimize together the porosity,microstructure and performance,by inducing the strong long-range directional melt flows,stabilizing the mushy zones,and optimizing the feeding channels and exhaust paths,as well as increas-ing the driving force of degassing process.Eventually,downward TMF can increase the ultimate tensile strength,yield strength,elongation and hardness from 175.2 MPa,87.5 MPa,13.3 ％ and 80.2 kg mm-2 without TMF to 218.6 MPa,109.3 MPa,15.6 ％ and 95.5 kg mm-2,while reduce the total porosity from 0.95 ％ to 0.18 ％.However,Up-TMF exerts negative effects on the optimization of porosity,microstruc-ture and performance due to the opposite strong directional magnetic force and melt flows.Overall,our study provides an effective way to optimize together the porosity,microstructure and mechanical performance,and reveals their relationship,as well as details the relevant mechanisms of TMF on the porosity reduction from different perspectives.     

Thermodynamic–kinetic model for the simulation of solidification in binary copper alloys and calculation of thermophysical properties

An earlier developed thermodynamic–kinetic solidification model for binary copper alloys is extended to take into account the formation of the bcc phase via the peritectic transformation and the formation of binary compounds from the fcc phase. Also the eutectic and eutectoid transformations are simulated but only approximately, by modeling the movement of the fcc/eutectic and fcc/eutectoid interfaces due to the diffusion kinetics of the fcc phase only. The new model can handle binary copper alloys containing solutes Ag, Al, Cr, Fe, Mg, Mn, Ni, P, Si, Sn, Te, Ti, Zn and Zr. Depending on the alloy composition, cooling rate and dendrite arm spacing, the model determines the fractions and compositions of the phases (liquid, fcc, bcc, compounds) and calculates thermophysical material properties (enthalpy, specific heat, thermal conductivity, density and liquid viscosity), needed in heat transfer models, from the liquid state down to room temperature. The model is applied to Cu–Sn and Cu–Zn alloys but also to some other binary alloys to show the effect of cooling on the phases formed. Depending on the alloy system, the solidification structures obtained after real cooling processes are shown to be quite different from those estimated from phase diagrams.     

Prediction of solidification behaviour and microstructure of Ni based alloys obtained by casting and direct additive laser growth

Numerical tools are now used widely in the prediction of material properties necessary in order to gain a better understanding of the relationship between material properties and performance, to improve the reliability of processes and the quality of the final product, and to reduce costs, waste and energy use. In this paper, the solidification properties and the microstructure of some commercial Ni based alloys were analysed and predicted numerically using the ProCAST software. The microstructure of a sample obtained by the direct additive laser growth, a new additive manufacturing technique based on the selective laser melting, is presented and discussed. Numerical approaches and software packages that can be used to model additive manufacturing processes are discussed and critically analysed.     

Effect of addition of Al-Si eutectic alloy on microstructure and mechanical properties of Mg-12wt%Li alloy

Mg-12Li, Mg-12Li-3(Al-Si), Mg-12Li-7(Al-Si) and Mg-12Li-9(Al-Si) alloys (all in wt%) were fabricated by high frequency vacuum induction melting in a water cooled copper crucible. After subsequently hot-rolling and annealing, their microstructure and mechanical properties were investigated. Experimental results show that mechanical properties of Mg-12Li alloy were significantly improved by the addition of Al-Si eutectic alloy. Mg-12Li-7(Al-Si) alloy shows the highest strength of 196 MPa of the investigated alloys, which is about 1.8 times of the strength of Mg-12Li alloy, and maintains high elongation of 27%. The improved mechanical property with addition of Al and Si in the eutectic proportion into Mg-12Li alloy was attributed to the solution strengthening effect of Al and precipitation hardening effect from AlLi and Mg₂Si precipitates.     

Effect of melt treatment on microstructure and impact properties of Al-7Si and Al-7Si-2.5Cu cast alloys

The microstructures and impact toughness of Al-7Si and Al-7Si-2.5Cu cast alloys were studied after various melt treatments like grain refinement and modification. The results indicate that combined grain refined and modified Al-7Si-2.5Cu alloys have microstructures consisting of uniformly distributed α-Al grains, interdendritic network of fine eutectic silicon and fine CuAl₂ particles in the interdendritic region. These alloys exhibited improved impact toughness in as cast condition when compared to those treated by individual addition of grain refiner or modifier. The improved impact toughness of Al-7Si-2.5Cu alloys are related to breakage of the large aluminum grains and uniform distribution of eutectic silicon and fine CuAl₂ particles in the interdendritic region resulting from combined refinement and modification. This paper attempts to investigate the influence of microstructural changes in the Al-7Si and Al-7Si-2.5Cu cast alloys by grain refinement, modification and combined action of both on the impact toughness.     

Modelling of convection during solidification of metal and alloys

The role of convection during solidification is studied with the help of a mathematical model. The effect of various mush models on convection and consequent macrosegregation is examined with the help of numerical simulations. The predicted macrosegregation profiles are compared with published experimental data. Subsequently, the importance of proper auxiliary relationship for thermo-solutal coupling in the mushy region is highlighted through some careful numerical simulations. Finally, the role of material parameters on double-diffusive convection is illustrated through comparative study of solidification of aqueous ammonium chloride, iron-carbon and lead-tin binary systems. Important results of these studies are presented and discussed.     

Internal stress and solid solubility effects on the thermal expansivity of Al-Si eutectic alloys

Thermal expansion measurements are reported for a number of as-cast Al-Si eutectic alloys including a Sr-modified alloy which gives nearly spherical Si particles. The measurements were obtained by heating and cooling over repeated temperature cycles between room temperature and 500°C. In general, lower expansivity values were measured on the cooling cycle as compared with the heating cycle, resulting in a net positive permanent deformation at room temperature. Analytical solutions are described for the thermal expansivity of a concentric-spheres model for a Si particle contained within an Al matrix. The effect of plastic flow in the Al is included. Overall, the predictions show reasonable agreement with the measured expansivities. The observed differences between heating and cooling are of the same order as that which is predicted. At high temperatures, the measured increase in expansivities is smaller than calculated. The latter effect is explained by the decrease in expansivity which results from an increasing solid solubility of silicon in aluminum with increasing temperature.Paper presented at the Ninth International Thermal Expansion Symposium, December 8–10, 1986, Pittsburgh, Pennsylvania, U.S.A.     

Thermal analysis and solidification pathways of Mg–Al–Ca system alloys

Mg–Al–Ca alloys are creep resistant magnesium alloys with high application potentials. The solidification pathways and microstructure formation in this alloy system are still under discussion. In this paper, the solidification behavior of AZ91 and AM50 with Ca addition (AZC91x and AMC50x alloys) was investigated by a computer-aided cooling curve analysis (CA-CCA) system. Microstructure and phase identification were carried out by SEM and EDX analysis. The results show that the Ca-containing phase formation mainly depends on Ca content and Ca/Al ratio. With increasing the Ca/Al ratio these phases transform from Al₂Ca to (Mg, Al)₂Ca and Mg₂Ca. Moreover, Ca addition decreases the liquidus temperature of Mg–Al alloys, but influences the solidus temperature in a more complex way. Increasing the Ca content also decreases the solid fraction at which dendrite coherency occurs. The relationship between solidification interval, dendrite coherency point, formation of Ca-containing phases and hot tearing is also discussed.     

First-principles study on the mechanical,thermal properties and hydrogen behavior of ternary V-Ni-M alloys

Studying hydrogen behavior in alloys and the mechanical properties of alloys are essential to various practical uses,such as separation membranes,as well as hydrogen embrittlement protection.In order to further develop the non-Pd-alloy membranes used in hydrogen separation,the mechanical,thermal properties of V14NiM(M= Al,Fe,Si,Ti,Zn)and hydrogen solubility and diffusion behaviors of V-based ternary alloys were studied by first principles calculation.The results indicated that the hydrogen solution energies of V-Ni-M are greater than pure vanadium.And the mono-vacancy in pure vanadium can capture 6 H atoms while the V-Ni-M alloys can only capture 5 H atoms.Therefore,the V-Ni-M alloys exhibit lower solubility of hydrogen and higher brittleness resistance to embrittlement compared with pure vanadium.And the diffusion coefficients of V-Ni-M alloys are smaller than that of pure vanadium thanks to smaller hydrogen solubility.The hydrogen solubility and hydrogen permeability can maintain relatively balanced.The study of mechanical properties suggests that the V-Ni-Ti has the best resistance to deformation and pure vanadium has the best ductility.Moreover,V-Ni-Si alloy has the smallest thermal expansion coefficient in the temperature range of 473-723 K,which is the temperature of hydrogen separation,indicating that V-Ni-Si is the best for hydrogen separation according to thermal properties.     

Effect of carbon content on solidification behaviors and morphological characteristics of the constituent phases in Cr-Fe-C alloys

A combination of transmission electron microscopy, electron backscatter diffraction and wavelength dispersive spectrum has been used to identify crystal structure, grain boundary characteristic and chemical composition of the constituent phases in Cr-Fe-C alloys with three different carbon concentrations. Depending on the three different carbon concentrations, the solidification structures are found to consist of primary α-phase and [α + (Cr,Fe)₂₃ C₆] eutectic in Cr-18.4Fe-2.3 C alloy; primary (Cr,Fe)₂₃ C₆ and [α + (Cr,Fe)₂₃ C₆] eutectic in Cr-24.5Fe-3.8 C alloy and primary (Cr,Fe)₇ C₃ and [α + (Cr,Fe)₇ C₃] eutectic in Cr-21.1Fe-5.9 C alloy, respectively. The grain boundary analysis is useful to understand growth mechanism of the primary phase. The morphologies of primary (Cr,Fe)₂₃ C₆ and (Cr,Fe)₇ C₃ carbides are faceted structures with polygonal shapes, different from primary α-phase with dendritic shape. The primary (Cr,Fe)₂₃ C₆ and (Cr,Fe)₇ C₃ carbides with strong texture exist a single crystal structure and contain a slight low angle boundary, resulting in the polygonal growth mechanism. Nevertheless, the primary α-phase with relative random orientation exhibits a polycrystalline structure and comprises a massive high-angle boundary, caused by the dendritic growth mechanism.     

旋转磁场对Pb-Sn-Sb合金组织及性能的影响

为了改善Pb-Sn-Sb三元轴承合金液态成型过程中的比重偏析,用旋转磁场控制Pb-Sn-Sb合金液态成型过程.采用光学显微镜、扫描电镜能谱分析研究了旋转磁场对Pb-Sn-Sb合金显微组织及成分分布的影响.用布氏硬度计、摩擦磨损试验机测试Pb-Sn-Sb合金的硬度及摩擦磨损性能.实验结果表明:旋转磁场能有效改善Pb-Sn-Sb合金的比重偏析,且能细化晶粒.激磁电压为45V时,SbSn块状化合物在试样上下截面分布最均匀,块度变小,比重偏析改善效果最好;试样上下截面Pb、Sn、Sb三元素含量基本趋于一致.随着激磁电压增加,试样上下截面的硬度及耐磨性有一定程度提高,并明显趋于一致.     

Effect of in situ reaction conditions on the microstructure changes of Cu-TiB2 alloys by combining in situ reaction and rapid solidification

A new short flow technique combining in situ reaction and rapid solidification has been developed and used to prepare Cu-TiB₂ (0.45, 1.6 and 2.5 wt% TiB₂) alloys. The effects of in situ reaction conditions, cooling rate and solute concentration on the microstructure change of Cu-TiB₂ alloys were systematically investigated and analyzed by modeling. It is shown that the size and distribution of TiB₂ particles are strongly dependent on the choice of reactor shape, in situ reaction conditions and solute concentration, specifically, the size and aggregation level of TiB₂ particles tend to increase as increasing normal volume percent of TiB₂ particles when the same in situ reaction condition is used. Some different in situ reaction mechanisms, based on the microstructure change and TiB₂ particle distribution under different conditions, were also established and analyzed, which can be used to quantitatively predict the size of melt micelles needed for synthesizing uniformly distributed TiB₂ particles with different sizes in the copper matrix.     

Coefficients for equilibrium partition of a third element between solid and liquid in iron-carbon base ternary alloys and their relation to graphitization during iron-carbon eutectic solidification

During iron-carbon eutectic solidification, the coefficients for partition of a third element between the eutectic liquid and its solid were evaluated thermodynamically. The coefficientk _M ^A/L for the equilibrium partition of the third element (M) between austenite and liquid iron largely depended on the interaction between carbon and the third element and a simplified method for the evaluation ofk _M ^A/L was introduced. The coefficients,K ^S andK ^M, for the partition of the element between the eutectic liquid and its solid in the stable and metastable eutectic solidification, respectively, were also calculated fromk _M ^A/L and the coefficientk _M ^C/A for the equilibrium partition of the element between cementite and austenite. It was indicated by the thermodynamics of the free energy for the co-existing phases that the effect of a third element on graphitization occurring during eutectic solidification was related quantitatively to the value of K which was represented byK ^S-K ^M. The effect of a third element on the difference between the stable and metastable eutectic temperatures and on the carbon activity of liquid iron was closely related to K or the equilibrium partition coefficient,k _M ^C/A .     

定向凝固钛铝合金熔体与铸型界面反应研究展望

钛铝合金是性能优异的高温合金,在航空航天领域有广泛的应用前景,但由于其熔体具有较高的活性,制备时熔体与所有已知的铸型材料会发生不同程度的反应,限制了钛铝合金铸件的发展.定向凝固技术作为制备高精度钛铝合金的新工艺,使铸件组织定向排列,可以进一步提高钛铝合金的使用性能,因此如何调控凝固过程中钛铝合金熔体与铸型材料间的界面反应成为目前有关定向凝固钛铝合金研究的一个热点.从目前国内外关于钛铝合金熔体与铸型材料间界面反应的研究出发,综述了定向凝固过程中铸型材料、涂层成分、工艺参数及合金元素等对界面反应的影响,介绍了界面反应的理论水平,系统收集了界面反应的各项研究结果.     

Influences of solute content, melt superheat and growth direction on the transient metal/mold interfacial heat transfer coefficient during solidification of Sn–Pb alloys

Several factors such as alloy composition, melt superheat, mold material, roughness of inner mold surface, mold coating layer, etc., can affect the transient metal/mold heat transfer coefficient, h_i. An accurate casting solidification model should be able to unequivocally consider these effects on h_i determination. After this previous knowledge on interfacial heat transfer, such models might be used to control the process based on thermal and operational parameters and to predict microstructure which affects casting final properties. In the present work, three different directional solidification systems were designed in such a way that thermal data could be monitored no matter what configuration was tested with respect to the gravity vector: vertical upward and downward or horizontal. Experiments were carried-out with Sn–Pb hypoeutectic alloys (5 wt.% Pb, 10 wt.% Pb, 15 wt.% Pb and 30 wt.% Pb) for investigating the influence of solute content, growth direction and melt superheat on h_i values. The experimentally obtained temperatures were used by a numerical technique in order to determine time-varying h_i values. It was found that h_i rises with decreasing lead content of the alloy, and that h_i profiles can be affected by the initial melt temperature distribution.     

Optimizing microstructure,shrinkage defects and mechanical performance of ZL205A alloys via coupling travelling magnetic fields with unidirectional solidification

ZL205A alloys tend to form disordered and defective microstructure due to the large solidification intervals and multi-phase.Accordingly,finding ways to effectively optimize the microstructure and mechanical performance is of great significance.In this regard,the coupling of travelling magnetic fields (TMF) with unidirectional solidification was used to continuously regulate the mushy zones of ZL205A alloys.Additionally,experiments are combined with simulations to systematically reveal the mechanisms on the optimizations at each stage of solidification process.Current findings demonstrate that different directional strong melt flows generated by TMF are responsible for these optimizations.Additionally,the effects of TMF on microstructure are different at each stage of solidification process.Specifically,downward TMF coupled with unidirectional solidification can refine and uniform the microstructure,decrease the formation of precipitation,promote the growth consistency of matrix phase α-Al growing along the <001 > crystal orientation,reduce the secondary dendrites and overlaps between dendrites,eliminate the shrinkage defects,and increase the ultimate tensile strength,yield strength,elongation and hardness from 198.3 MPa,102.2 MPa,7.5 ％ and 82.3 kg mm-2 without TMF to 225.5 MPa,116.1 MPa,13.6 ％ and 105.2 kg mm-2.Contrastively,although upward TMF can reduce Al3Ti and refine α-Al,it increases the formation of Al6Mn,Al2Cu,secondary dendrites,overlaps between dendrites,and shrinkage defects;then it deflects and disorders the growth of α-Al,further to decrease the overall performance of alloys.