Recent development and prospect of electromagnetic processing of materials

Application of electromagnetic force to materials processing, so called Electromagnetic Processing of Materials (EPM) has been recognized as a cutting edge technology, especially in the fields of advanced materials processing. The background to promote EPM is described. The present state of EPM is given through a brief introduction of several examples of the applications of a high frequency magnetic field, a DC magnetic field, DC magnetic and electric fields, and a traveling magnetic field. Furthermore, a high static magnetic field has been applied to generate compression waves in molten metals. As other examples of the application of a high static field, the crystal orientations in thin films in vapordeposition and electrodeposition processes and those in carbon fibers in a graphitization process are described. Finally the future view of EPM is revealed.     

静磁场在材料生产过程中的应用研究评述

在材料电磁过程研究中，静磁场尤其是强磁场材料科学是当今世界的研究热点。本文从静磁场作用下生成的洛仑兹力和磁化力两个角度系统地归纳总结了静磁场技术在材料生产领域的应用原理和实践。对静磁场下的洛仑兹力，主要介绍了流体流动、波动和对流控制、电磁振动及电磁超声波等方面的研究现状；对强磁场下的磁化力，主要介绍了其在相变、结晶配向、磁悬浮、磁对流等方面的研究进展。最后对强磁场材料科学的研究趋势和发展前景做了展望。     

Direct Generation of Internse Compression Waves in Molten Metals by Using a High Static Magnetic Field and Their Application

Compression waves propagating through molten metals are contributed to degassing accelerating reaction rate,removing exclusions from molten metals and refining solidifcation structures during metallurgical processing of materials,In the present study ,two electromagnetic methods are proposed to generate intense compression waves directly in liquid metals.One is the simultaneous imposition of a high frequency electrical current filed and a static magnetic field ;the other is that of a high frequency magnetic field and a static magnetic field ,A mathematical model based on compressible fluid dynamics and electromagnetic fileds theory has been developed to derive pressure distri-butions of the generated waves in a metal.It shows that the intensity of compression waves is proportional to that of the high frequency electromagnetic force,And the frequency is the same as that of the imposed electromagnetic force,On the basis of theoretical analyses ,pressure change in liquid gallium was examined by a pressure transducer under various conditions.The observed results approximately agreed with the predictions derived from the theoretical analyses and calculations.Moreover,the effect of the generated waves on improvement of solidification structures was also examined .It shows that the generated compression waves can refine solidification structures when they were applied to solidification process of Sn-Pb alloy ,This study indicates a new method to generate compression waves by imposing high frequency electromagnetic force locally on molten metals and this kind of compression waves can probably overcome the difficulties when waves are excited by mechanical vibration in high temperature environments.     

Crystal orientation of non-magnetic materials by imposition of a high magnetic field

From the view point of learning from the nature, the controlling of crystal orientation is accounted to be a major subject for materials processing. This paper reviews the researches on the crystal orientation by use of a high magnetic fieldand belongs to the category of researches for mimicking structures, namely the crystal orientation, which nature or livingbodies are forming. Regarding to the crystal orientation, several methods such as unidirectional solidification and epitaxial growth and so on have been developed hitherto. On the other hand the magnetization force that is familiar with the force to attract iron to a magnet, has been recognized to be effective even in non-magnetic materials when those are placed under a high magnetic field, which has become rather conveniently available by developing superconducting technologies in these days. In this paper, main results obtained when the imposition of a high magnetic field was accompanied to several materials processing such as electrodeposition, vaperdeposition, solidification, baking, slip-casting and precipitation, arereviewed from the view point of crystal orientation of non-magnetic materials.     

高频电磁力作用下金属液内电磁超声波的生成

为解决由机械振动产生的超声波无法在高温环境中成功应用的难题，提出了利用静磁场和交流电流、静磁场和交流磁场的相互作用分别在金属液内直接生成高强度电磁超声波的方法，运用超声波压力传感器对用这两种方法在金属液内生成的电磁超声波的强度进行了测量。研究表明：电磁超声波的强度与所施加的高频电磁力的强度成正比，频率与电磁力的频率相同；实验结果和理论解析结果基本一致；利用高频电磁力的局部作用在金属液全场范围内生成的电磁超声波可以在金属精炼及凝固过程中获得广泛应用。     

Direct Generation of Intense Compression Waves in Molten Metals by Using a High Static Magnetic Field and Their Application

Compression waves propagating through molten metals are contributed to degassing, accelerating reaction rate,removing exclusions from molten metals and refining solidification structures during metallurgical processing of materials. In the present study, two electromagnetic methods are proposed to generate intense compression wavesdirectly in liquid metals. One is the simultaneous imposition of a high frequency electrical current field and a staticmagnetic field; the other is that of a high frequency magnetic field and a static magnetic field. A mathematical modelbased on compressible fluid dynamics and electromagnetic fields theory has been developed to derive pressure distributions of the generated waves in a metal. It shows that the intensity of compression waves is proportional to thatof the high frequency electromagnetic force. And the frequency is the same as that of the imposed electromagneticforce. On the basis of theoretical analyses, pressure change in liquid gallium was examined by a pressure     

Processing of non-ferromagnetic materials in strong static magnetic field

Static magnetic field processing of non-ferromagnetic materials has been of broad interest and been applied in such fields as drug delivery, colloid chemistry and engineering of materials containing particles. A ‘strong’ magnetic field refers to a ‘strong’ response from the manipulated material and can vary in definitions. The response is corresponding to a local interaction between the material and the local magnetic field, being influenced by the magnetic susceptibilities of the material and the surrounding/coated medium. By carefully designing the medium, a significantly ‘strong’ response from a weakly magnetic material can even be generated by a traditional magnet, i.e. magnetic flux density ∼0.01 T. Therefore, the ability to manipulate materials by using a magnetic field depends critically on the understanding of the principles of the magnetic properties of materials and their magnetic responses. This paper provides a critical discussion on the principles including magnetic field effect thermodynamics, magnetic energy, magnetic anisotropy and different magnetic forces during ’strong’ magnetic field processing of weakly magnetic materials (focusing on metallic materials). A series of case studies and the related magnetic field effect are subsequently integrated and discussed. Overall this review aims to provide a better understanding and efficient overview on the phenomenon principles in the field of magnetic field processing.     

Nanostructured electronic and magnetic materials

Research and development in nanostructured materials is one of the most intensely studied areas in science. As a result of concerted R & D efforts, nanostructured electronic and magnetic materials have achieved commercial success. Specific examples of novel industrially important nanostructured electronic and magnetic materials are provided. Advantages of nanocrystalline magnetic materials in the context of both materials and devices are discussed. Several high technology examples of the use of nanostructured magnetic materials are presented. Methods of processing nanostructured materials are described and the examples of sol gel, rapid solidification and powder injection moulding as potential processing methods for making nanostructured materials are outlined. Some opportunities and challenges are discussed.     

In situ observation of magnetic orientation process of feeble magnetic materials under high magnetic fields

Abstract

An in situ microscopic observation of the magnetic orientation process of feeble magnetic fibers was carried out under high magnetic fields of up to 10 T using a scanning laser microscope. In the experiment, carbon fibers and needle-like titania fibers with a length of 1 to 20 μm were used. The fibers were observed to gradually orient their axes parallel to the direction of the magnetic field. The orientation behavior of the sample fibers was evaluated on the basis of the measured duration required for a certain angular variation. As predicted from the theoretical consideration, it was confirmed that the duration required for a certain angular variation normalized by the viscosity of the fluid is described as a function of the fiber length. The results obtained here appear useful for the consideration of the magnetic orientation of materials suspended in a static fluid.     

磁场作用下铝合金凝固过程的电阻变化

为了确定磁场对铝合金凝固过程的影响,利用双电桥测试了Al-21%Cu、Al-22Si合金分别在无磁场、直流磁场和交流磁场作用下从液态到固态的电阻变化.分析了Al-Cu合金与Al-Si合金电阻-温度曲线的差别,研究了磁场对合金凝固过程中液、固相线温度及微观结构的影响.结果表明,Al-21%Cu合金的电阻-温度曲线呈单调下降趋势,且有两个明显的转折点,而Al-22%Si合金的电阻-温度曲线不再是单调下降,两个转折点也很不明显,在直流磁场作用下,Al-21%Cu、Al-22%Si合金的液相线、固相线温度均有所降低,在交流磁场作用下,两种铝合金的液、固相线温度均有所升高.在Al-Si合金凝固过程中施加外磁场时,抑制了初生β-Si的生成.     

Effect of the simultaneous application of a high static magnetic field and a low alternating current on grain structure and grain boundary of pure aluminum

Effect of the simultaneous application of a high static magnetic field and a low alternating electric current on the solidification structure of pure aluminum has been investigated. Results show that the refinement of the solidification structure is enhanced by the electric current under a certain magnetic field. However, when the magnetic field intensity exceeds a certain value, the refinement is impaired under a certain electric current. The observation by electron backscattered diffraction (EBSD) shows the complex fields have led to the increase of the low angle boundaries with the refinement. Moreover, the application of the static gradient magnetic field is capable of modifying the distribution of the refined grains. The above results may be attributed to the formation of the cavities during the electromagnetic vibration process and the high magnetic field.     

Effects of a high-gradient magnetic field on the migratory behavior of primary crystal silicon in hypereutectic Al–Si alloy

Abstract

The migration of primary Si grains during the solidification of Al–18 wt%Si alloy under a high-gradient magnetic field has been investigated experimentally. It was found that under a gradient magnetic field, the primary Si grains migrated toward one end of the specimen, forming a Si-rich layer, and the thickness of the Si-rich layer increased with increasing magnetic flux density. No movement of Si grains was apparent under a magnetic field below 2.3 T. For magnetic fields above 6.6 T, however, the thickness of the Si-rich layer was almost constant. It was shown that the static field also played a role in impeding the movement of the grains. The primary Si grains were refined in the Si layer, even though the primary silicon grains were very dense. The effect of the magnetic flux density on the migratory behavior is discussed.     

Energy coupled to matter for magnetic alignment of rare earth–doped alumina

Energy coupled to matter (ECM) concepts such as magnetic field–assisted processing were used to align rare earth–doped alumina ceramics in the presence of applied fields. The addition of gadolinium and ytterbium dopants to alumina increased the magnetic susceptibility anisotropies, and induced magnetic torques that led to significant alignment of ceramic particles under the application of magnetic fields as low as 1.8?T. In comparison, undoped alumina materials showed minimal alignment under applied field strengths as high as 9?T. Density function theory modeling indicated that the specific dopant type dictated changes in the magnetic properties of different rare earth–doped alumina systems by directly affecting the magnetic moment localization and magnetocrystalline anisotropy.     

材料电磁加工的现状与未来展望

综述了材料电磁加工的研究现状和未来的发展动向。由于在熔化、精炼、铸造、轧制等连续铸造过程中应用了电磁场,连铸坯的表面质量和凝固组织得到改善。在电镀、金属腐蚀、金属凝固等过程中施加强磁场,改变了溶质的质量传输,提高了产品质量。     

The Effect of Dy Doping on the Magnetic Behavior of YBCO Superconductors

The effect of dysprosium (Dy) doping on yttrium barium copper oxide (YBCO) prepared by conventional solid-state reaction method has been investigated by means of XRD, AC susceptibility, and DC magnetization measurements. AC susceptibility measurements for sintered YBCO pellets have been performed as a function of temperatures at constant frequency and AC field amplitude in the absence of a DC bias field. DC magnetization measurements were done at 5, 20, and 77 K upon zero field cooling (ZFC) process. The magnetization measurements showed a paramagnetic behavior existing at high magnetic fields. The magnetic field dependence of critical current density of the samples has been estimated from DC magnetization data. The partial Dy substitution for Y on YBCO superconductors improves the bulk critical current density at high magnetic fields and at high-temperature regions (higher than 20 K).     

Unidirectionally oriented hydroxyapatite/collagen composite fabricated by using a high magnetic field

A unidirectionally oriented hydroxyapatite (HAp)/collagen composite was prepared by using a high magnetic field. In the present study, a calcium-containing collagen solution was mixed with a phosphate-containing solution and kept at a temperature of 37 °C. During this process, the heat-induced self-assembling of collagen molecules and precipitation of HAp crystals took place simultaneously. Both collagen fibrils and HAp crystals have magnetic susceptibility anisotropy, which makes it possible for them to be oriented by using a high magnetic field. In order to prepare a unidirectionally oriented structure, samples were rotated when the high magnetic field was imposed perpendicularly to the rotation axis. The results indicated that collagen fibrils have been unidirectionally oriented with weakly crystallized HAp nanocrystals closely attached along the surfaces of the collagen fibrils. A biocomposite with similar structural and composition to natural bones has been prepared.     

Magnetically Enhanced Thin-Film Coarsening by a Magnetic XPFC Model Allowing to Decouple Magnetic Anisotropy and Magnetostriction

External magnetic fields provide a macroscopic control mechanism to influence the microstructure of polycrystalline materials. Herein, the influence of strong magnetic fields on grain growth in thin films is modeled with a magnetic extended phase field crystal model. The magneto–structural effects are incorporated into the correlation function in reciprocal space. With this approach, magnetic anisotropy, magnetostriction, and mobility of grain boundary can be controlled and a variety of geometrical and topological properties consistent with experimental results can be determined.     

静磁场对定向凝固镍基高温合金组织影响的研究进展

综述了国内外静磁场对镍基高温合金组织影响的研究现状,重点分析了施加不同方式、强度的静磁场对定向凝固镍基高温合金枝晶组织、元素偏析、凝固缺陷及高温力学性能的影响规律,并从变截面处杂晶的控制、晶体取向偏离的控制以及对凝固特性的影响机制等方面提出了静磁场在定向凝固镍基高温合金研究中潜在的发展方向。     

Texturing by cooling a metallic melt in a magnetic field

Abstract

Processing in a magnetic field leads to the texturing of materials along an easy-magnetization axis when a minimum anisotropy energy exists at the processing temperature; the magnetic field can be applied to a particle assembly embedded into a liquid, or to a solid at a high diffusion temperature close to the melting temperature or between the liquidus and the solidus temperatures in a region of partial melting. It has been shown in many experiments that texturing is easy to achieve in congruent and noncongruent compounds by applying the field above the melting temperature T_m or above the liquidus temperature of alloys. Texturing from a melt is successful when the overheating temperature is just a few degrees above T_m and fails when the processing time above T_m is too long or when the overheating temperature is too high; these observations indicate the presence of unmelted crystals above T_m with a size depending on these two variables that act as growth nuclei. A recent model that predicts the existence of unmelted crystals above the melting temperature is used to calculate their radius in a bismuth melt.