Effect of heat treatment on the microstructure and property of cold-sprayed nanostructured FeAl/Al2O3 intermetallic composite coating

It is difficult to deposit dense intermetallic compound coatings by cold spraying directly using compound feedstock powders due to their intrinsic low temperature brittleness. A method to prepare intermetallic compound coatings in-situ employing cold spraying was developed using a metastable alloy powder assisted with post heat treatment. In this study, a nanostructured Fe(Al)/Al₂O₃ composite alloy coating was prepared by cold spraying of ball-milled powder. The cold-sprayed Fe(Al)/Al₂O₃ composite alloy coating was evolved in-situ to FeAl/Al₂O₃ intermetallic composite coating through a post heat treatment. The effect of heat treatment on the phase formation, microstructure and microhardness of cold-sprayed Fe(Al)/Al₂O₃ composite coating was investigated. The results showed that annealing at a temperature of 600 °C results in the complete transformation of the Fe(Al) solid solution to a FeAl intermetallic compound. Annealing temperature significantly influenced the microstructure and microhardness of the cold-sprayed FeAl/Al₂O₃ coating. On raising the temperature to over 950 °C, diffusion occurred not only in the coating but also at the interface between the coating and substrate. The microhardness of the FeAl/Al₂O₃ coating was maintained at about 600HV_0.1 at an annealing temperature below 500 °C, and gradually decreased to 400HV_0.1 at 1100 °C.     

Synthesis and characterization of titanium-45S5 Bioglass nanocomposites

Titanium-45S5 Bioglass nanocomposites were synthesized by the combination of mechanical alloying and powder metallurgy process. The structure, mechanical and corrosion properties of these materials were investigated. Microhardness test showed that the obtained material exhibits Vicker’s microhardness as high as 770 HV_0.2 for Ti-20 wt.% 45S5 Bioglass, which is more than three times higher than that of a conventional microcrystalline titanium (225 HV_0.2). Additionally, titanium-10 wt.% of 45S5 Bioglass nanocomposites (i_c = 1.20 × 10⁻⁷ A/cm², E_c = −0.42 V vs. SCE) were more corrosion resistant than microcrystalline titanium (i_c = 2.27 × 10⁻⁶ A/cm², E_c = −0.36 V vs. SCE). In vitro biocompatibility of these materials was evaluated and compared with a conventional microcrystalline titanium, where normal human osteoblast (NHOst) cells from Cambrex (CC-2538) were cultured on the disks of the materials and cell growth was examined. The morphology of the cell cultures obtained on Ti-10 wt.% 45S5 Bioglass nanocomposite was similar to those obtained on the microcrystalline titanium. Mechanical alloying and powder metallurgy process for the fabrication of titanium-45S5 Bioglass nanocomposites with a unique microstructure, higher hardness, lower Young’s modulus and better corrosion resistance, in comparison to microcrystalline titanium, were developed. On the other hand, Ti-10 wt.% 45S5 Bioglass composites posses higher fracture toughness compared to 45S5 Bioglass. The proper modification of chemical composition and microstructure of Ti-bioceramic nanocomposites can expand the use of titanium in the biomedical fields.     

Cavitation erosion characteristics of a Fe–Cr–Si–B–Mn coating fabricated by high velocity oxy-fuel (HVOF) thermal spray

A Fe–Cr–Si–B–Mn coating was prepared by high velocity oxy-fuel (HVOF) thermal spray on the surface of 1Cr18Ni9Ti stainless steel. Microstructures of the coating were investigated by X-ray diffraction (XRD), optical microscopy (OM) and scanning election microscopy (SEM), and the cavitation erosion resistance of the coating was evaluated using a GB6383-86 standard method in fresh water and compared with hydro-machine material ZG06Cr13Ni5Mo martensite stainless steel. The coating consisted of a Fe–Cr-rich matrix and several kinds of borides, the former comprised both amorphous phase and nanocrystalline grains. The nanocrystalline grains with a size about 10–50 nm further formed into an agglomerate-like structure with an average size of 100–500 nm. The coating had a significantly higher microhardness (HV_0.21008) than the comparing material ZG06Cr13Ni5Mo (HV_0.2260), which resulted in greater weight losses of ZG06Cr13Ni5Mo at the whole cavitation erosion process. It was found that the mass loss began at the edges of the pores or the interface between un-melted or half-melted particles and the matrix in the coating, while the mass loss was initiated at the lath interface of martensite in the ZG06Cr13Ni5Mo. The experimental results indicate that the HVOF thermal spray is a promising method to prepare the cavitation resistance coating.     

Effects of Si addition on mechanical properties and superelasticity of Ti–7.5Nb–4Mo–2Sn shape memory alloy

Effects of 0–2.1 at.% Si additions on microstructure and mechanical properties of a Ni-free biomedical superelastic β-Ti alloy, Ti–7.5 at.%Nb–4 at.%Mo–2 at.% Sn (Ti–7.5Nb–4Mo–2Sn), were investigated. The alloys after annealing at 973 K mainly contain β and α″. As the concentration of Si is higher than 1 at.%, Ti₅Si₃ particles can be found in the alloys, and the number density of the particles increases with the increasing of silicon’s concentration. The addition of Si promotes the strength of the Ti–7.5Nb–4Mo–2Sn due to the Si solid solution strengthening effect and fine Ti₅Si₃ precipitates. However, as the Si concentration reaches 2.1%, the alloy exhibits a brittle fracture. The 0.5–1.6 at.% Si additions improve the superelasticity of the Ti–7.5Nb–4Mo–2Sn alloy by increasing the critical stress for inducing martensite (σ_SIM).     

Synthesis of TiC-TiB2-Ni cermets by thermal explosion under pressure

TiC/TiB₂-based cermets were fabricated in situ by means of the thermal explosion under pressure technique starting from Ti-B₄C powders with the addition of varying contents of Ni metal binder to achieve near-net-shape bulks. The combustion reaction was ignited in a graphite die heated by current. Full conversion of the reactants was obtained by thermal explosion and the process yielded TiC-TiB₂-Ni materials characterised by a fine microstructure. Appreciable differences in terms of microstructure, hardness and fracture toughness by indentation were observed between core and external surface of the products due to fast cooling caused by heat transfer to the die walls. Cermets with a high content of Ni showing high hardness and fracture toughness were obtained, with values of HV₅ = 2182 and K_Ic = 8.8 MPa m^1/2 for 30 wt.% Ni and of HV₅ = 1684 and K_Ic = 12.7 MPa m^1/2 for 47 wt.% Ni.     

Microstructure and tribological property of nanocrystalline Co–W alloy coating produced by dual-pulse electrodeposition

The nanocrystalline Co–W alloy coatings were produced by dual-pulse electrodeposition from aqueous bath with cobalt sulfate and sodium tungstate (Na₂WO₄). Influence of the current density and Na₂WO₄ concentration in bath on the microstructure, morphology and hardness of the Co–W alloy coatings were investigated using an X-ray diffraction, a scanning electronic microscope and a Vickers hardness tester, respectively. In addition, the friction and wear properties of the Co–W alloy coating electrodeposited under different condition were evaluated with a ball-on-disk UMT-3MT tribometer. The correlation between the electrodeposition condition, the microstructure and alloy composition, and the hardness and tribological properties of the deposited Co–W alloy coatings were discussed in detail. The results showed that the microhardness of the deposited Co–W alloy coating was significantly affected by its average grain size, W content and crystal orientation. Smaller grain size, higher W content and strong hcp (1 0 0) orientation favor the improvement of the hardness for Co–W alloy coatings. The deposited Co–W alloy coating could obtain the maximum microhardness over 1000 kgf mm⁻² by careful control of the electrodeposition conditions. The tribological properties of the electrodeposited Co–W alloy coating were greatly affected by its grain size, microhardness, surface morphologies and composition, and could be significantly improved by optimizing the electrodeposition condition.     

Some observations on the hydrogen embrittlement of Fe3Al-Fe3AlC intermetallic compounds

Effects of carbon on the hydrogen embrittlement behaviour of Fe₃Al intermetallic compounds were observed by revealing its microstructure. In low-carbon content (0.05 wt.%) alloy embrittlement was found in the Fe₃Al phase, in moderate level of carbon content (0.14-0.5 wt.%) there was no embrittlement in the alloy, whereas in high level of carbon content (1 wt.%) embrittlement was found in the interdendritic region.     

Effect of Ca additions on microstructure and microhardness of an as-cast Mg-5.0 wt.% Al alloy

The effects of Ca additions (0.5-2.0 wt.%) on the microstructure and the microhardness of an as-cast Mg-5.0 wt.% Al alloy have been investigated. The coarse microstructure of the base alloy can be refined through adding Ca. DSC and TEM results showed that, as Ca additions increased up to 1.5 wt.% Ca, the β-Mg₁₇Al₁₂ phase was completely replaced by a (Al, Mg)₂Ca phase. The Vickers microhardness of the as-cast Mg-Al-Ca alloys increased with increasing Ca content. Tests on the Mg-5.0Al-2.0Ca (wt.%) alloy showed an indentation size effect, which was well described by Meyer's Law.     

Preliminary investigations about effects of Zr, Sc and Ce additions on as-cast microstructure and mechanical properties of Mg-3Sn-1Mn (wt.%) magnesium alloy

In this paper, the effects of Zr, Sc and Ce additions on the as-cast microstructure and mechanical properties of Mg-3Sn-1Mn (wt.%) magnesium alloy were preliminarily investigated and compared. The results indicate that adding 0.36 wt.% Sc and 0.87 wt.% Ce to the Mg-3Sn-1Mn alloy, respectively leads to the formation of the extra phases of Mg-Sn-Sc and Mg₁₂Ce while adding 0.43 wt.% Zr does not cause the formation of any new phases. At the same time, adding 0.43 wt.% Zr or 0.87 wt.% Ce can refine the grains while adding 0.36 wt.% Sc coarsens the grains. Among the Zr- and Ce-containing alloys, the grains of the latter are relatively finer than those of the former. In addition, adding 0.43 wt.% Zr, 0.36 wt.% Sc and 0.87 wt.% Ce to the Mg-3Sn-1Mn alloy can improve the tensile and/or creep properties of the alloy. However, the addition of 0.43 wt.% Zr is not beneficial to the creep properties. Among the Zr-, Sc- and Ce-containing alloys, the alloy with the addition of 0.87 wt.% Ce exhibits the optimal tensile and creep properties.     

Influence of the supersaturated silicon solid solution concentration on the effectiveness of severe plastic deformation processing in Al-7 wt.% Si casting alloy

A comparative study of room temperature severe plastic deformation (SPD) of a hypoeutectic Al-7 wt.% Si casting alloy by high pressure torsion (HPT) and equal channel angular pressing (ECAP) has been performed. Microstructural parameters and microhardness were evaluated in the present work. Three different initial Si solid solution contents have been considered: as cast (C sample, 1.6 wt.% Si), annealed and quenched (Q sample, 1.2 wt.% Si) and annealed and furnace cooled (S sample, 0.7 wt.% Si). The samples processed by ECAP have smaller average Si particle sizes (0.9-1.7 μm), than those for samples processed by HPT (2.4-4.4 μm). The initial supersaturated Si solid solution is the major factor affecting the microstructure and the mechanical properties of the material. Fine deformation-induced Si precipitates from the supersaturated solid solution were responsible of the large grain refinement obtained by both SPD processing methods, which was considerably higher than that reported for pure aluminium. Q samples, processed by both SPD methods, containing an intermediate concentration of Si in solid solution, show the highest hardness due to the finest and most homogeneous microstructure. The finest and homogeneous grain size was ∼0.2 μm for the HPTed and ∼0.4 μm for the ECAPed Q samples.     

Microstructure and properties of laser clad high-entropy alloy coating on aluminium

An AlCrFeNiCuCo high-entropy alloy (HEA) coating was synthesised on an aluminium substrate by laser cladding. Samples were characterised using an optical microscope, X-ray diffraction, scanning electron microscopy with energy-dispersive spectroscopy, a microhardness tester, and an electrochemical workstation. The results showed that the interface between the cladding layer and matrix was sound, while the HEA coating consisted of BCC and FCC solid solutions and an Al-rich phase resulting from substrate dilution. The microstructure of the clad layer comprised both columnar and equiaxed grains. The average microhardness of the coating was 550 HV_0.2, and it exhibited better corrosion resistance than the aluminium matrix in a 1?mol?L^?1 H₂SO₄ solution. The typical corrosion characteristic of the coating was pitting and localised corrosion.     

Microstructure and martensitic transformation in Si-coated TiNi powders prepared by ball milling

Si was coated on the surface of Ti–49Ni (at%) alloy powders by ball milling in order to improve the electrochemical properties of the Si electrodes of secondary Li ion batteries and then the microstructure and martensitic transformation behavior were investigated by means of scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), X-ray diffraction (XRD) and differential scanning calorimetry (DSC). Ti–Ni powders coated with Si were fabricated successfully by ball milling. As-milled powders consisted of highly deformed Ti–Ni powders with the B2 phase and amorphous Si layers. The thickness of the Si layer coated on the surface of the Ti–Ni powders increased from 3–5 μm to 10–15 μm by extending the milling time from 3 h to 48 h. However, severe contamination from the grinding media, ZrO₂ occurred when the ball milling time was as long as 48 h. By heating as-milled powders to various temperatures in the range of 673–873 K, the highly deformed Ti–Ni powders were recovered and Ti₄Ni₄Si₇ was formed. Two-stage B2–R–B19′ transformation occurred when as-milled Si-coated Ti–49Ni alloy powders were heated to temperatures below 873 K, above this temperature one-stage B2–B19′ transformation occurred.     

Design and development of powder processed Fe–P based alloys

The present investigation deals with designing Fe, Fe–P binary and Fe–P–Si ternary alloys produced by an in-house developed powder metallurgical technique based on ‘Hot Powder Preform Forging’. Proper soaking of preforms at high temperature (1050 °C) eliminates iron-phosphide eutectic and brings entire phosphorus into solution in iron. Attempting hot forging thereafter completely eliminates hot as well as cold shortness and thereby helps to form these preforms (alloys) into very thin sheets of 0.5 mm. The use of costly hydrogen atmosphere during sintering has been eliminated by the addition of carbon as a reducing agent to form CO gas within the compact by reacting with oxygen of iron powder particles. The glassy ceramic coating applied over the compact serves as a protective coating to avoid atmospheric oxygen attack over the compact held at high temperature. These alloys so formed were subjected to density examination at various stages. Microstructural study has been carried out to estimate the grain size, volume percentage of porosity in the alloys, and uniform distribution of phosphorus and silicon in an iron matrix. X-ray diffraction studies of these alloys revealed the presence of only ferrite as product phase. Addition of alloying elements such as P and Si has improved the resistivity and magnetic properties of iron. Fe–0.07C–0.2O–0.3P–0.5Si alloy showed a resistivity as high as 31.7 μΩ cm. Coercivity values of the alloys ranged from 0.51 to 1.98 Oe. The total magnetic loss of Fe–0.07C–0.2O–0.3P–0.5Si alloy was the lowest (2.03 W/kg) amongst the alloys developed owing to its high resistivity combined with its low coercivity. These alloys which are drawn to thin sheets could find their possible application in the manufacturing of transformer cores.     

Mechanical and microstructural characteristics of detonation gun sprayed NiCrAlY + 0.4 wt% CeO2 coatings on superalloys

The microstructure and mechanical properties of detonation gun sprayed NiCrAlY + CeO₂ alloy coatings deposited on superalloys were investigated. The morphologies of the coatings were characterized by using the techniques such as optical microscopy, X-ray diffraction and field emission scanning electron microscopy/energy-dispersive analysis. The coating depicts the formation of dendritic structure and the microstructural refinement in the coating was due to ceria. Average porosity on three substrates was less than 0.58% and surface roughness of the coatings was in the range of 6.17–6.94 μm. Average bond strength and microhardness of the coatings were found to be 58 MPa and 697–920 H_V, respectively.     

Low temperature sintering and microwave dielectric properties of SmAlO3 ceramics

The effects of sintering aids on the microstructures and microwave dielectric properties of SmAlO₃ ceramics were investigated. CuO and ZnO were selected as sintering aids to lower the sintering temperature of SmAlO₃ ceramics. With the additions, the sintering temperature of SmAlO₃ can be effectively reduced from 1650 to 1430°C. The crystalline phase exhibited no phase differences at low addition level while Sm₄Al₂O₉ appeared as a second phase as the doping level was over 0.5 wt.%. In spite of the additions, the dielectric constants showed no significant change and ranged 19-21. However, the quality factor Q×f was strongly dependent upon the type and amount of additions. The Q×f values of 51,000 and 41,000 GHz could be obtained at 1430°C with 0.25 wt.% CuO and ZnO additions, respectively. The temperature coefficients depended on the additions and varied from −40 to −65 ppm/°C. Results of X-ray diffractions, EDS analysis and scanning electron microscopy were also presented.     

Effect of Fe and Mn additions on microstructure and mechanical properties of spray-deposited Al–20Si–3Cu–1 Mg alloy

Spray deposition is a novel process which is used to manufacture rapidly solidified bulk and near-net-shape preforms. In this paper, Al–20Si–3Cu–1 Mg alloy was prepared by spray deposition technique. The effect of Fe and Mn additions on microstructure and mechanical properties of spray-deposited Al–20Si–3Cu–1 Mg alloy was investigated. The results show that two kinds of intermetallics, i.e. δ-Al₄FeSi₂ and β-Al₅FeSi, is formed in the microstructure of spray-deposited Al–20Si–5Fe–3Cu–1 Mg alloy. With additions of 5% Fe and 3% Mn to Al–20Si–3Cu–1 Mg alloy, the needle shape of Al–Si–Fe intermetallic phases is substituted by the particle shape of Al₁₅(FeMn)₃Si₂ phases. The presence of the intermetallic phases (δ-Al₄FeSi₂, β-Al₅FeSi and Al₁₅(FeMn)₃Si₂) improves the tensile strengths of the alloy efficiently at both the room and elevated temperatures(300 °C).     

Dependency of microstructure parameters and microhardness on the temperature gradient for directionally solidified Ti–49Al alloy

Intermetallics Ti–49Al (at.%) alloy was directionally solidified with different temperature gradients (G) ranged from 2.8 K mm⁻¹ to 12.5 K mm⁻¹ at a constant growth rate (V = 10 μm s⁻¹) by using a Bridgman-type directional solidification furnace. The microstructure of the directionally solidified specimen is constituted of α₂(Ti₃Al) and γ(TiAl) lamellar structures. The values of the primary dendritic spacing (λ), interlamellar spacing (λ_L) and microhardness (HV) were measured. Dependencies of λ, λ_L and HV on G were determined by using the linear regressing analysis. According to these results, the values of λ and λ_L decrease with the increase of G, and the values of HV increase with the increase of G and with the decrease of λ and λ_L. In addition, these results were compared with the previous similar experimental results of TiAl-based alloys.     

Effect of existing form of alloying elements on the microhardness of Al-Si-Cu-Ni-Mg piston alloy

Effect of alloying elements including Si, Cu, Ni and Mg with different existing forms on the microhardness of Al-12Si-4Cu-2Ni-2.6Mg (in wt.%) piston alloy was investigated. It is found that microhardness of the alloy reaches to 1.88 GPa when all the Cu, Ni, Mg and 3.63 wt.% Si dissolved in the α-Al matrix, and increases to 2.02 GPa while only the solid-solved Si precipitates to form nanoparticles. The precipitated Si has greater contribution to the alloy's microhardness than the solid-solved Si in the same level. Furthermore, the precipitation of intermetallics containing Cu, Ni and Mg that disperses in the Al-matrix can further improve the microhardness to 2.09 GPa. The hardening efficiency of the intermetallics precipitation of Cu, Mg and Ni on microhardness is less than that of the nanoscale Si precipitates under the same mass fraction. For Cu, Mg and Ni alloying elements, whether dissolving in α-Al matrix or precipitating as nanoparticles, there is no evident difference on improving microhardness of the tested alloy.     

The role of alloying additives and aging treatment on the impact behavior of 319 cast alloy

This article investigated the effects of alloying additives on the impact toughness of as-cast and heat-treated 319 alloys. The results revealed that the impact energy decreases with increasing the level of Fe, Mn, and Mg additions. The aged alloys at 180 °C had a slightly increase in the impact energy compared to the as-cast alloys. The aged alloys containing combined additions of Fe–Mn and Fe–Mg displayed a similar variation in the impact energy at different aging temperatures and times. The fracture surface of the alloys was strongly controlled by the morphology of eutectic Si and Cu- and Fe-rich phases.