锻造对喷射成形Al-8.5Fe-1.3V-1.7Si合金组织和性能的影响

采用喷射成形和锻造工艺制备了Al-8.5Fe-1.3V-1.7Si合金．通过金相、扫描电镜和力学性能测试等实验，对锻件组织和性能进行了分析。结果表明：“闷车＋包套锻造”工艺对喷射成形Al-8.5Fe-1.3V-1.7Si合金坯件的致密化效果好于用自由锻造和包套锻造致密化的合金，采用该工艺可以制备出组织和性能优良的耐热铝合金材料。“闷车＋包套锻造”锻件在室温下的抗拉强度（σb）达到407MPa，屈服强度（σ0.2）达到344MPa，延伸率（δ5）为7．6％；在315℃，锻件的σb，σ0.2，σ5分别为222，216MPa，7．2％。     

Microstructures and mechanical properties of dispersion-strengthened high-temperature Al-8.5Fe-1.2V-1.7Si alloys produced by atomized melt deposition process

Dispersion-strengthened high-temperature Al-8.5 pct Fe-pct Si-pct V alloys were produced by atomized melt deposition (AMD) process. The effects of process parameters on the evolution of microstructures were determined using optical metallography and scanning and transmission electron microscopy. The extent of undercooling and the rate of droplet solidification were correlated with process parameters, such as melt superheat, metal/gas flow rates, and melt stream diameter. The size distribution and morphology of silicide dispersoids were used to estimate the degree of undercooling and the cooling rate as functions of process parameters. The tensile properties at 25 °C to 425 °C and fracture toughness at 25 °C of these alloys produced with wide variations in dispersoids size and grain size were determined. Under optimum conditions, the alloy has ultimate tensile strength of 281 MPa and 9.5 pct ductility in the as-deposited condition. Upon hot-isostatic pressing and extrusion, the ultimate tensile strength increased to 313 MPa and ductility increased to 18 pct.     

Fatigue crack growth rates and fracture toughness of rapidly solidified Al-8.5 pct Fe-1.2 pct V-1.7 pct Si alloys

The room-temperature fatigue crack growth rates (FCGR) and fracture toughness were evaluated for different crack plane orientations of an Al-8.5 Pct Fe-1.2 Pct V-1.7 Pct Si alloy produced by planar flow casting (PFC) and atomized melt deposition (AMD) processes. For the alloy produced by the PFC process, properties were determined in six different orientations, including the short transverse directions S-T and S-L. Diffusion bonding and adhesive bonding methods were used to prepare specimens for determining FCGR and fracture toughness in the short transverse direction. Interparticle boundaries control fracture properties in the alloy produced by PFC. Fracture toughness of the PFC alloy varies from 13.4 MPa√m to 30.8 MPa√m, depending on the orientation of the crack plane relative to the interparticle boundaries. Fatigue crack growth resistance and fracture toughness are greater in the L-T, L-S, and T-S directions than in the T-L, S-T, and S-L orientations. The alloy produced by AMD does not exhibit anisotropy in fracture toughness and fatigue crack growth resistance in the as-deposited condition or in the extruded condition. The fracture toughness varies from 17.2 MPa√m to 18.5 MPa√m for the as-deposited condition and from 19.8 MPa√m to 21.0 MPa√m for the extruded condition. Fracture properties are controlled by intrinsic factors in the alloy produced by AMD. Fatigue crack growth rates of the AMD alloy are comparable to those of the PFC alloy in the L-T orientation. The crack propagation modes were studied by optical metallographic examination of crack-microstructure interactions and scanning electron microscopy of the fracture surfaces.     

Solidification characteristics of the Al-8.3Fe-0.8V-0.9Si alloy

Studies of solidification behavior have been conducted on cast Al-Fe-V-Si alloys. The first phase to precipitate during solidification of an Al-8.3Fe-0.8V-0.9Si alloy is Al₃Fe(V,Si), which is isostructural with the Al₃Fe phase. Thereafter, the solidification proceeds through several invariant reactions. The final invariant reaction is associated with a pronounced arrest. The temperature of this arrest is a function of the cooling rate and modification treatment, with magnesium added as an Al-20 pct Mg or Ni-20 pct Mg master alloy. The coarse iron aluminide precipitates in a slow-cooled (>1 °C/s) cast structure transform to a ten-armed, star-like morphology upon chill casting the melt (cooling rate >10 °C/s) from 900 °C or upon water quenching from above 800 °C. Treatment with magnesium refines the morphology, size, and distribution of iron aluminide precipitates in slow-cooled alloys.     

喷射成形Al-8.5Fe-1.1V-1.9Si耐热铝合金的组织演变及性能分析

研究了喷射成形Al—8．5Fe—1．1V—1．9Si耐热铝合金组织结构的演变规律，测试了挤压态合金在室温及高温条件下的力学性能。与铸态组织特征相比较，喷射成形工艺有效地消除了铸态合金中粗大的富Fe析出相，获得了细小均匀的组织结构。利用OM，SEM，TEM，XRD等材料分析测试手段，探索了材料中可能的组织演变过程及规律，结果表明：喷射成形制备的Al—Fe—V—Si耐热铝合金中，形成了大量的弥散分布的球状相，有效的保证了合金在室温及高温下的力学性能。室温下，合金的抗拉强度可以达到445MPa，屈服强度也达到了398MPa，延伸率为16％；在315℃，合金的抗拉强度和屈服强度分别为229和209MPa。     

喷射成形Al-8.5Fe-1.1V-1.9Si耐热铝合金中弥散强化相体积分数的确定

利用喷射成形工艺制备了Al 8.5Fe 1.1V 1.9Si耐热铝合金 ,观察了合金中耐热相的形貌 ,发现弥散强化相的尺寸在 5 0～ 10 0nm之间。采用Rietveld全谱拟合的方法初步测定了铝合金中弥散强化相的重量百分数为 2 8.4% ,通过换算得出弥散强化相的体积分数为 2 2 .4%。同时分析了与平面流铸造 (PFC)所制备的合金中耐热相体积分数的差异 ,并探讨了合金耐热相体积分数的变化对合金力学性能的影响     

Morphology and kinetics of discontinuous precipitation and dissolution in an Fe-8.5Al-27Mn-1.0Si-0.92C alloy

The morphology and growth kinetics of discontinuous precipitation (DP) and discontinuous dissolution (DD) in an Fe-8.5Al-27Mn-1.0Si-0.92C alloy are investigated. The results indicate that the solid-solution-treated austenite phase decomposes into lamellar DP after aging at temperatures ranging from 900 to 1050 K. After the specimens of a preaged DP structure go through further aging at temperatures ranging from 1118 to 1173 K, the lamellar DP falls into dissolution because of the DD reaction. The lamellar spacings of the DP structure, as well as the reaction-front migration rates during DP and DD reactions, are measured. Based on Aaronson and Liu’s simplified kinetics model, the grain-boundary diffusivities are estimated. They are found to be slightly lower than the grain-boundary diffusion data of Mn in Fe and Fe in Fe as reported by Aaronson and Liu.     

Phase transition in an Fe-23.2Al-4.1Ni alloy

The phase transition in an Fe-23.2 at. pct Al-4.1 at. pct Ni alloy has been investigated by means of transmission electron microscopy. In the as-quenched condition, the microstructure of the alloy is a mixture of (A2 + B2) phases. When the as-quenched alloy is aged at temperatures ranging from 500 °C to 1050 °C, the phase transition sequence is found to be (A2 + B2∗) → (B2 + B2∗) → B2 → A2, where B2∗ is also a B2-type phase. It is worthwhile to note that the coexistence of two kinds of ordered B2 phase has not previously been observed by other workers in the Fe-Al-Ni ternary alloy system.     

High-temperature deformation behavior of an Al-8.4Fe-3.6Ce dispersion-strengthened material

The high-temperature deformation behavior of a dispersion-strengthened Al-8.4Fe-3.6Ce material studied by Yaney and Nix^[1] has been reanalyzed using concepts used in the analysis of the creep behavior of Al-Fe-V-Si materials. The Al-8.4Fe-3.6Ce material presents a high volume fraction of submicron dispersoids. The stress exponent and the activation energy values are anomalously high-temperature dependent, as it is usually found in most reinforced materials. Although the creep behavior of this material has been described by the deformation of dispersoids, however, direct evidence of the deformation of the second-phase precipitates was not obtained. In this work, a new approach is further developed. This approach is based on the constant substructure slip creep equation modified by the presence of an interaction between dislocations and dispersoids. This approach is able to satisfactorily predict the creep behavior of the Al-8.4Fe-3.6Ce material.     

High temperature creep in Fe-3 pct Si

The kinetics and structure dependence of the high temperature-low stress creep of Fe-3 pct Si has been studied and compared with the predictions of current creep theories. It is shown that the steady state creep rate is diffusion controlled and exhibits a power law stress dependence in the temperature range 1393 to 1678 K and stress range 6.9×10⁴ to 1.03×10⁶ Pa. In this same range of experimental conditions the dislocation density present during steady state creep is essentially stress independent. It is shown that current creep theories are incompatible with the experimental results.     

L12-type Ni-Al-Cr alloys processed by rapid solidification

A study of the effect of Cr additions (5, 10, and 12.5 at. pct) on the microstructure of melt-spun Ni₃Al-base alloys has been carried out using analytical electron microscopy. The analyses showed that the formation of the β-NiAl phase could not be totally avoided at all three levels of Cr additions studied. However, its volume fraction, morphology, and distribution were affected by the Cr concentration as well as by changes in the rapid solidification conditions. The ordering structure of the matrix γ contains anisotropic antiphase boundaries or cube-plane-oriented thin layers of disordered γ, depending on the local chemistry. A series of microchemistry measurements along the radius of a grain was used to trace the route of Al and Cr segregation, and an unexpected reverse segregation with a partition coefficient greater than 1 was observed for Cr. The bend ductility and tensile properties of the melt-spun ribbons were also studied. It was shown that the Cr additions substantially increased the ribbon strength and modified the mode of failure toward transgranular fracture. The improved tensile properties were partially attributed to the fine matrix γdomains which had mixed interfaces of antiphase boundaries and y thin layers.     

Phase transformation in an Fe-10.1Al-28.6Mn-0.46C alloy

The microstructure of an (α + γ) duplex Fe-10.1Al-28.6Mn-0.46C alloy has been investigated by means of optical microscopy and transmission electron microscopy (TEM). In the as-quenched condition, extremely fine D0₃ particles could be observed within the ferrite phase. During the early stage of isothermal aging at 550 °C, the D0₃ particles grew rapidly, especially the D0₃ particles in the vicinity of the α/γ grain boundary. After prolonged aging at 550 °C, coarse K’-phase (Fe, Mn)₃AlC precipitates began to appear at the regions contiguous to the D0₃ particles, and —Mn precipitates occurred on the α/γ and α/α grain boundaries. Subsequently, the grain boundary β-Mn precipitates grew into the adjacent austenite grains accompanied by a γ→ α + β-Mn transition. When the alloy was aged at 650 °C for short times, coarse. K-phase precipitates were formed on the α/γ grain boundary. With increasing the aging time, the α/γ grain boundary migrated into the adjacent austenite grain, owing to the heterogeneous precipitation of the Mn-enrichedK phase on the grain boundary. However, the α/γ grain boundary migrated into the adjacent ferrite grain, even though coarse K-phase precipitates were also formed on the α/γ grain boundary in the specimen aged at 750 °C.     

The interrelationship of fracture toughness and microstructure in a Ti-5.25Al-5.5V-0.9Fe-0.5Cu alloy

Fracture toughness of anα-Β titanium alloy heat treated to a constant yield strength has been found to depend upon the morphology of α produced or remaining after the initial solution treatment. In equiaxed α structures, fracture toughness depends linearly upon the grain boundary area per unit volume,S _v, and is independent of equiaxed α particle size or spacing. In a grain boundary α structure fracture toughness depends both onS _v and, within limits, linearly on the thickness of the α. Explanations are offered for the observed propagation of cracks at α-@#@ Β interfaces and for the observation that high fracture toughness can accompany low tensile ductility. This paper is based on a thesis to be submitted by M. A. Greenfield in partial fulfillment of the requirements for the Ph.D. degree in metallurgy at New York University.     

Atom-probe analysis of GP zones in an Al-1.7 At. pct Cu alloy

Guinier-Preston (GP) zones in an Al-1.7 at. pct Cu alloy aged at 383 K for 8000 minutes were analyzed by atom-probe field ion microscopy (AP-FIM). Layer-by-layer concentration profiles in the 〈100〉 direction were obtained from several GP zones. Generally, the GP zones were found to consist of several copper-enriched layers, with the highest measured concentration of copper in any of these layers being 50 at. pct. Although some uncertainty exists as to the copper content of the GP zones, these results appear to be inconsistent with the existence of layers that approach 100 pct copper. Some GP zones showed two well-separated copper-enriched regions; others showed a broad single peak in copper concentration. Therefore, it was concluded that aging at 383 K for 8000 minutes causes a transition from GP 1 to GP 2. The present results together with the previous atom-probe data indicate that there is a distinct stage for GP 2 zones which have two separated copper-enriched layers of 200 planes. Formerly Graduate Student, Department of Materials Science and Engineering, The Pennsylvania State University     

Pulsed laser induced deformation in an Fe-3 Wt Pct Si alloy

The plastic deformation produced by laser induced stress waves was investigated on an Fe-3 wt pct Si alloy. The intensity and duration of the stress waves were varied by changing the intensity and pulse length of the high energy pulsed laser beam, and also by using different overlays on the surfaces of the specimens. The resulting differences in the distribution and intensity of the deformation caused by the stress waves within the samples were determined by sectioning the specimens and etching (etch pitting) the transverse sections. The magnitude of the laser shock induced deformation depended on the laser beam power density and the type of surface overlay. A combination transparent plus opaque overlay of fused quartz and lead generated the most plastic deformation. For both the quartz and the quartz plus lead overlays, intermediate laser power densities of about 5×10⁸ w/cm² caused the most deformation. The shock induced deformation became more uniform as the thickness of the material decreased, and uniform shock hardening, corresponding to about 1 pct tensile strain, was observed in the thinnest specimens (0.02 cm thick). 200 ns laser pulses caused some surface melting, which was not observed for 30 ns pulses, the pulse length used in most of the experiments. Deformation of the Fe-3 wt pct Si alloy occurred by both slip and twinning. B. A. WILCOX, formerly affiliated with Battelle, Columbus Laboratories     

Phase transformation in an Fe-9.0AI-29.5Mn-1.2Si alloy

The microstructure of an (α + γ) duplex Fe-9.0Al-29.5Mn-l.2Si alloy has been investigated by means of transmission electron microscopy. In the as-quenched condition, extremely fine D0₃ particles were formed within the ferrite matrix by a continuous ordering transition during quenching. After being aged at 550 °C, the extremely fine D0₃ particles existing in the as-quenched specimen grew preferentially along (100) directions. With increasing the aging time at 550 °C, a (Si, Mn)-rich phase (designated as “L phase”) began to appear at the regions contiguous to the D0₃ particles. The L phase has never been observed in various Fe-Al-Mn, Fe-Al-Si, Fe-Mn-Si, and Mn-Al-Si alloy systems before. When the as-quenched specimen was aged at temperatures ranging from 550 °C to 950 °C, the phase transformation sequence occurring within the (α + D0₃) region as the aging temperature increases was found to be (α + D0₃ + L phase) → (α + D0₃ + A13 β-Mn)→ (B2 + D0₃ + A13 β-Mn)→ (B2 + A13β-Mn)→ (α + A13 β-Mn)→ (α +γ)→α.     

Sintering behaviour of Al-6061 powder produced by rapid solidification process

Abstract

Complex aluminium alloy components fabricated by powder metallurgy (P/M) offer the promise of a low cost and high strength-to-weight ratio, which meets the demands of the automotive sector. This paper describes the die compaction and sintering response of an atomised Al-6061 alloy powder containing Mg and Si produced by rapid solidification. A design of experiments is used involving three levels for each of the die compaction pressure, sintering temperature, peak temperature hold time and heating rate. Three trials were used to obtain the optimum press sinter processing conditions. Besides the mechanical properties, phase transformation and microstructure are investigated. Supplemental insight is gained through thermogravimetric analysis, differential scanning calorimetry and SEM with energy dispersive spectroscopy. Analysis of variation is used to quantify the contribution of each design variable to the mechanical properties.     

Phase transformations in an Fe-7.8Al-29.5Mn-1.5Si-1.05C alloy

Phase transformations in an Fe-7.8Al-29.5Mn-l.5Si-1.05C alloy have been investigated by means of optical microscopy and transmission electron microscopy. In the as-quenched condition, a high density of fine (Fe,Mn)₃AlC carbides could be observed within the austenite matrix. When the as-quenched alloy was aged at temperatures ranging from 550 °C to 825 °C, aγ → coarse (Fe,Mn)₃AlC carbide + DO₃ reaction occurred by a cellular precipitation on theγ/γ grain boundaries and twin boundaries. Both of the observations are quite different from those observed by other workers in Fe-Al-Mn-C alloys. In their studies, it was found that the as-quenched microstructure was austenite phase(γ), and (Fe,Mn)₃AlC carbides could only be observed within the austenite matrix in the aged alloys. In addition, aγ →α (ferrite) + coarse (Fe,Mn)₃AlC carbide reaction or aγ →α + coarse (Fe,Mn)₃AlC carbide +β-Mn reaction was found to occur on theγ/γ grain boundary in the aged Fe-Al-Mn-C alloys.     

A new phase in an Fe-9.0AI-29.5Mn-1.2Si alloy

A new type of precipitate (designated L phase) was observed within the ferrite matrix in an Fe-9.0Al-29.5Mn-l.2Si alloy after being aged at 550 °C. Transmission electron microscopy examinations indicated that the L-phase precipitate has a monoclinic structure with lattice parametersa = 0.656 nm,b = 0.797 nm,c = 0.637 nm, and β = 109.4 deg, and the orientation relationship between the L-phase precipitate and the ferrite matrix could be stated as follows: (-101)_α//(001)_L-phase (-110)_α//(-111)_L-phase with a deviation of 0.3 deg (01l)_α//(131)_L-phase with a deviation of 1.5 deg The L phase has never been observed in various Fe-Al-Mn, Fe-Mn-Si, Fe-Al-Si, and Mn-Al-Si alloy systems before.