Influence of cooling rate on the microstructure and ageing behavior of as-cast Al–Sc–Zr alloy

Al–0.3Sc–0.15Zr alloy was cast using copper die, insulated alumina mould, and conventional investment shell mould to obtain a wide range of cooling rates. A novel method of quenching the investment shell mould along with the liquid metal in oil was also used which resulted in a significant increase in the cooling rate. The order in increasing average cooling rate is 0.16, 0.78, 1.28, 5.93, 7.69 °C/s. The as-cast samples were aged isothermally at 300 °C and various temperatures for 2 h. Slow cooled samples (in alumina-insulated mould) showed the presence of as-cast primary precipitates as well as rod shaped discontinuous precipitates with high density of interfacial dislocation. The amount of as-cast precipitates decreased with increase in the cooling rate. These as-cast precipitates grew at the expense of Sc in solid solution reducing the number of precipitates formed during ageing process. This results in lower increment in hardness on ageing.     

Equilibrium phase of high-entropy FeCoNiCrCu0.5 alloy at elevated temperature

The phase transformations of FeCoNiCrCu_0.5 alloy with the as-cast structure and heat-treated structures were studied. The as-cast alloy specimens were first heated at 1050 °C with a holding time of 1 h. Serial heat-treatment processes at 350 °C, 500 °C, 650 °C, 800 °C, 950 °C, 1100 °C, 1250 °C and 1350 °C with a holding time of 24 h were then carried out to understand the phase evolution and the relationship between the microstructure and the hardness of the specimens. The microstructures were investigated and chemical analyses performed by optical microscopy (OM), scanning elector microscopy (SEM), X-ray diffractometer (XRD) and transmission elector microscopy (TEM). The results show that FCC peaks were observed from the X-ray diffraction of the as-cast specimens and a precipitate phase was present in the specimens that had been heated to 950 °C. The hardness of the FeCoNiCrCu_0.5 alloy remained unchanged in the specimens that underwent various heat treatments that were applied in this study.     

The oxidation behavior of high Cr and Al containing Nb-Si-Ti-Hf-Al-Cr alloys at 1200 and 1250 °C

The oxidation behavior of two alloys containing different content of Al and Cr from the Nb-Si-Ti-Hf-Al-Cr system has been evaluated at 1200 and 1250 °C. The alloy compositions in atomic percent are Nb-24Ti-16Si-2Hf-2Al-10Cr (B1), and Nb-24Ti-16Si-2Hf-6Al-17Cr (B2). The oxidation kinetic of B1 alloy at 1200 and 1250 °C followed a mixed parabolic-linear law, while the oxidation kinetic of B2 alloy at 1200 and 1250 °C followed a parabolic law. The weight gain of B2 alloy was 18.9 mg/cm² after oxidation at 1200 °C for 100 h, which was a seventh of the value of that of B1 alloy. Besides, oxidation became more severe as temperature increased to 1250 °C. The oxide scales of B2 alloy consisted of CrNbO₄, TiNb₂O₇ and SiO₂, which were relatively compact and protective. In addition, the oxidation mechanism of Nb-Si based alloys were also discussed.     

An alternative approach in ceramic shell investment casting of AZ91D magnesium alloy: In situ melting technique

In this research, the possibility of ceramic shell investment casting of a magnesium alloy using in situ melting technique was explored. AZ91D granules were charged into shell investment mould and in situ melted under various processing parameters including heating temperature, flux application, shell mould thickness and permeability. Scanning electron microscopy, energy dispersive X-ray spectroscopy and X-ray diffraction techniques were used to characterise the cast samples. Thermal analysis was employed to further investigate the effect of mould thickness on the solidification behaviour of the metal. It was found that mixing flux with the granules not only reduced the temperature at which melting can be achieved, but it also contributed to produce castings with acceptable surface quality. The use of thinner mould provided higher solidification rate, which is believed to favour in situ melting of the granules. It enabled melting of the granules at 650 °C, which in turn helped to suppress the mould–metal reaction and produce castings with good surface quality. Shell mould permeability showed no influence on suppressing the mould–metal reaction at 650 °C.     

Effect of annealing on microstructure and properties of Cu–30Ni alloy tube

The microstructure, mechanical properties and seawater corrosion resistance of annealed Cu–30Ni alloy tube were investigated using mechanical test, optical microscope, scanning electronic microscope and electrochemical measurement system, respectively. The recrystallizations gradually increased with the increase of annealing temperature and holding time. The hardness and tensile strength, which maintained invariability with annealing temperature at 680–720 °C, dramatically decreased with annealing temperature at 720–770 °C. As annealing temperature and holding time increase, corrosion potential (E_C) increased while corrosion rate (i_C) decreased at the beginning of seawater immersion. But after 15 days’ seawater immersion, as annealing temperature and holding time increase, E_C firstly increased and then decreased, on the contrary, i_C firstly decreased and then increased. The Ni-rich surface film and the Ni-rich sub-grains were responsible for the initial and extended immersion, respectively. It was found that the Cu–30Ni alloy tube annealed at 720 °C for 30 min exhibited favorable comprehensive mechanical properties and seawater corrosion resistance.     

Processing,microstructure and property aspects of a spraycast Al–Mg–Li–Zr alloy

This paper describes a microstructural and property investigation of an Al–5.31Mg–1.15Li–0.28Zr alloy produced by spraycasting and downstream processing. Following a dispersoid precipitation treatment of 4 h at 400 °C, samples were hot compressed at strain rates of 2, 1, 0.2 and 0.1 × 10⁻² s⁻¹ at temperatures between 250 and 475 °C. Electron backscattered diffraction showed a strong dependence of recrystallised grain size on deformation temperature. At 250 °C and faster strain rates at 325 °C, a network of fine recrystallised necklace grains formed by progressive lattice rotation. At 325 °C at slow strain rates and at 400 °C and higher, dynamic recrystallisation occurred by discontinuous nucleation and growth at regions of microscopic strain localisation such as grain boundaries and triple points. The microstructures from small-scale hot compression experiments were compared with larger forgings under similar conditions and microstructural evolution was broadly similar. Mechanical properties of larger-scale forgings exceeded the targets for mechanically alloyed Al–Mg–Li alloy AA5091.     

Corrosion fatigue crack growth behavior of oil-grade nickel-base alloy 718. Part 1: Effect of corrosive environment

The effect of corrosive environment on corrosion fatigue crack growth (CFCG) behavior of oil-grade nickel-base alloy 718 is studied. The results demonstrate that there is no obvious effect of 3.5 wt.% NaCl solution at RT, 50 °C and 80 °C on CGCG rates while 21 wt.% NaCl solution at 80 °C produces a deleterious effect on CFCG rates compared to the ones tested in air. Potentiodynamic polarization results show that alloy 718 exhibits passive behavior in 3.5 wt.% NaCl solution, while pitting corrosion resistance decreases with increasing solution temperature. Nevertheless, alloy 718 shows active corrosion behavior in 21 wt.% NaCl solution at 80 °C.     

Repair of NiCrAlYSi overlay coating on Ni3Al base alloy IC6

The effect of repair of NiCrAlYSi coating after long time use on the coherence of coating to substrate and mechanical properties of Ni₃Al base alloy IC6 has been studied. The alloy with NiCrAlYSi coating was stressed under the condition of 900 °C/100 MPa for 200 h to simulate the service condition of IC6 turbine vanes. The results showed that the coherence of base alloy/original coating, original coating/first repair coating, first repair coating/second repair coating or base alloy/second repair coating was firm. The interfaces between them had no cracks and porosity, for either partly or entirely repaired coatings. However, there were more Mo rich particles in the affected zone compared with original coating. Compared with IC6 alloy aged at 900 °C for 200 h, the yield strength at ambient temperature of IC6 alloy with first repair coating was almost equivalent, while the elongation decreased slightly; its stress rupture life under 1100 °C/90 MPa condition was about 100 h. For secondary coating repair, the room temperature tensile properties of base alloy had no obvious change, while stress rupture lives decreased, but still were rather long, compared to the alloy with first repair coating. Therefore, NiCrAlYSi coating repair is feasible to prolong the service lives of IC6 turbine vanes.     

Processing of ultra-high strength SiCp/Al–Zn–Mg–Cu composites

The ultra-high strength SiC_p/Al–10%Zn–3.6%Mg–1.8%Cu–0.36%Zr–0.15%Ni composite was prepared by spray co-deposition followed by extrusion process. The heat treatment processing, microstructures and mechanical properties of the as-processed composite were investigated. The well-bonded SiC/Al interfaces and fine grains of matrix alloy were obtained in the as-extruded composite. The precipitated phase MgZn₂ dissolved during solid solution treatment at 490 °C for 1 h, but the Cu-rich phase was residual in the matrix. Comparatively, the Cu-rich phase dissolved into the matrix alloy exposed at 470 °C for 1 h and then at 490 °C for 1 h. The composite heat-treated with 470 °C/1 h + 490 °C/1 h + 120 °C/28 h exhibited high modulus above 100 GPa and ultra-high strength about 785 MPa, which was 30 MPa higher than that of the same composite treated with 490 °C/1 h + 120 °C/28 h processing. The low elongation of the composite can be attributed to the breakage of SiC particulates and interfacial debonding of SiC/Al.     

Effect of aging temperature on microstructure and properties of AlCoCrCuFeNi high-entropy alloy

The microstructure and compressive properties of AlCoCrCuFeNi high-entropy alloy aged at temperatures ranging from 500 to 1000 °C were investigated. The BCC and FCC phase structures remain unchanged after aging the AlCoCrCuFeNi alloy at temperatures below 645 °C. Aging the alloy at elevated temperature causes the structure gradually to transform from stabilized BCC to FCC. Also, as the aging temperature increases, the yield strength of the material decreases but plastic strain increases. When the alloy was aged at 1000 °C, the plastic strain even reaches 27%.     

Formation of TiC via interface reaction between diamond grits and Sn-Ti alloys at relatively low temperatures

In this paper, interfacial reaction between diamond grit and Sn-6Ti alloy was systematically studied at brazing temperatures from 600 to 1030 °C. A thin and uniform layer of scallop-like nano-sized TiC grains was formed after brazing for 30 min at 600 °C, and interfacial TiC grains subsequently coarsened as brazing temperature increased to 740 and 880 °C. Strip-like columnar TiC grains in a bilayer structure was further grown as brazing temperature increased to 930 °C. After brazing at 1030 °C, a dense layer of columnar TiC grains were formed. Based on the TEM micrographs of interfacial TiC, the formation and evolution of the growth morphologies of interfacial TiC was believed to be controlled by the diffusion of C flux from diamond grits, which is dependent on the brazing temperatures.     

Comparative study of the deformation behavior of hexagonal magnesium–lithium alloys and a conventional magnesium AZ31 alloy

Specimens of a conventional magnesium AZ31 alloy and a binary α-solid solution Mg4Li alloy with similar starting textures and microstructure were subjected to plane strain deformation under various deformation temperatures ranging from 298 K to 673 K. Lithium addition to magnesium exhibited remarkable room temperature ductility improvement owing to enhanced activity of non-basal slip, particularly, 〈c + a〉-slip mode. Furthermore, the addition of lithium to magnesium seemed to reduce the plastic anisotropy, typical for commercial magnesium alloys. This was evident in the flow curves and texture development obtained at 200 °C and 400 °C. At 400 °C prismatic slip gains strong influence in accommodating the imposed deformation. In terms of thermal stability against microstructure coarsening at elevated temperatures, the lithium containing alloy undergoes significant grain growth following recrystallization.     

Hot deformation and processing maps of an Fe3Al intermetallic alloy

The deformation behavior of an Fe–28Al–5Cr–0.08Zr–0.04B (at.%) intermetallic alloy under hot compression conditions was characterized in the temperature range of 600–1100 °C and strain rate range of 0.001–100 s⁻¹. Processing maps were calculated to evaluate the efficiency of the hot working and to recognize the instability regions of the flow behavior. The investigated alloy possesses the optimum hot-working conditions at 1100 °C and 0.001 s⁻¹, since the material undergoes dynamic recrystallization to produce a fine-grained structure with a high fraction of high-angle boundaries (∼70%). At lower temperature the material exhibited “large grained superplasticity” with a peak efficiency of ∼60% at 1000 °C and 0.001 s⁻¹. These parameters are the optimum ones for superplastic working of that alloy. The occurrence of large grained superplasticity is attributed to the formation of a subgrain structure within the large original grains and higher strain-rate sensitivity. The material also exhibits flow instabilities due to flow localization at lower temperatures (<700 °C) and higher strain rates (>0.1 s⁻¹).     

Investigation the effect of B4C addition on properties of TZM alloy prepared by spark plasma sintering

TZM alloy is one of the most important molybdenum (Mo) based alloy which has a nominal composition containing 0.5–0.8 wt.% titanium (Ti), 0.08–0.1 wt.% zirconium (Zr) and 0.016–0.02 wt.% carbon (C). It is a possible candidate for high temperature applications in a variety of industries. However, the rapid oxidation of TZM alloys at high temperature in air is considered to be one of the drawback. In this study, TZM alloys with additions of 0–5 wt.% B₄C were prepared by spark plasma sintering (SPS) at 1420 °C utilizing 40 MPa pressure for 5 min under vacuum. The effects of B₄C addition on oxidation, densification behavior, microstructure, and mechanical properties were investigated. The TZM alloy with 5 wt.% B₄C have exhibited an approximately 66% reduction in mass loss under normal atmospheric conditions in oxidation tests made at 1000 °C for 60 min. And an increase from 1.9 GPa to 7.8 GPa has been determined in hardness of the alloy.     

Deformation behavior of a two-phase Mo–Si–B alloy

Mo–Si–B alloys are being considered as possible candidates for high-temperature applications beyond the capabilities of Ni-based superalloys. In this paper, the high-temperature (1000–1400 °C) compression response over a range of quasi-static strain rates, as well as the monotonic and cyclic crack growth behaviors (as a function of temperature from 20 °C to 1400 °C) of a two-phase Mo–Si–B alloy containing a Mo solid solution matrix (Mo(Si,B)) with ∼38 vol% of the T2 phase (Mo₅SiB₂) is discussed. Analysis of the compression results confirmed that deformation in the temperature–strain-rate space evaluated is matrix-dominated, yielding an activation energy of ∼415–445 kJ/mol. Fracture toughness of the Mo–Si–B alloy varies from ∼8 MPa√m at room temperature to ∼25 MPa√m at 1400 °C, the increase in toughness with temperature being steepest between 1200 °C and 1400 °C. S–N response at room temperature is shallow whereas at 1200 °C, a definitive fatigue response is observed. Fatigue crack growth studies using R = 0.1 confirm the Paris slope for the two alloys to be high at room temperature (∼20–30) but decreases with increasing temperature to ∼3 at 1400 °C. The crack growth rate (da/dN) for a fixed value of ΔK in the Paris regime in the 900–1400 °C range, increases with increasing temperature.     

Magnetron-sputtered oxidation protection coatings for Mo–Si–B alloys

Oxidation protective Mo–70Al, Mo–37Si–15B and Mo–46Si–24B (at.%) coatings with 5–10 μm thickness were deposited on Mo–9Si–8B alloys by magnetron sputtering; and their oxidation behavior was studied at 800, 1000 and 1300 °C in air. On the Mo–70Al layer a dense aluminum borate scale grew at 800 °C; however, this coating rapidly degraded at 1000 °C linked to substrate oxidation at uncoated areas. The Mo–37Si–15B and Mo–46Si–24B layers provided oxidation protection to the Mo–Si–B alloy at 800 and 1000 °C for up to 100 h due to formation of a borosilicate scale. The latter coating was protective for short times even at 1300 °C.     

Critical Al content to form external-alumina scales on Cu–Al alloys

The oxidation of Cu–6.8Al (at.%) alloy has been studied at 800 and 900 °C in 1 × 10⁵ Pa pure O₂. The scales formed at 800 °C are composed of a thin outer CuO layer and an inner protective Al₂O₃ layer. On the contrary, at 900 °C different samples of the alloy present two kinds of different oxidation behavior: one is protective, very similar to that at 800 °C, while the other is intermediate between protective and non-protective, with formation of very thick scale on the partial surface, which is mainly composed of copper oxides. The different behavior presented on a single sample is probably caused by local inhomogeneities of the alloy. It is deduced that at 900 °C the critical Al content to form external-alumina scale on Cu–Al alloy is about 6.8 at.%.     

Effect of C,Ti, Zr and B alloying on fracture mechanisms in hot-rolled Fe–40 (at.%)Al

This paper reports a study of fracture behavior of FeAl-based intermetallic alloys with the addition of carbon, titanium, zirconium and boron (Fe–40Al–1C, Fe–40Al–1Ti and Fe–40Al–Zr–B). The alloys were prepared by modified processing technology of vacuum induction melting and hot rolling in special stainless steel sheath. Tensile and fracture toughness tests were carried out at 20 °C, 400 °C, 600 °C, 700 °C and 800 °C. The alloy showed best fracture toughness and tensile properties with Zr and B addition. The fracture toughness at 600 °C was comparable with values in stainless steels and nickel-based superalloys. The fractographic analysis revealed the change of fracture micromechanisms with temperature. Moreover, under specific conditions, the fracture micromechanisms were different in tensile and fracture toughness specimens.     

Mechanical and barrier properties of MOCVD processed alumina coatings on Ti6Al4V titanium alloy

This study focuses on the implementation of different aluminum oxide coatings processed by metal-organic chemical vapor deposition from aluminum tri-isopropoxide on commercial Ti6Al4V titanium alloy to improve its high temperature corrosion resistance. Films grown at 350 °C and at 480 °C are amorphous and correspond to formulas AlOOH, and Al₂O₃, respectively. Those deposited at 700 °C are composed of γ-Al₂O₃ nanocrystals dispersed in a matrix of amorphous alumina. Their mechanical properties and adhesion to the substrates were investigated by indentation, scratch and micro tensile tests. Hardness and rigidity of the films increase with increasing deposition temperature. The hardness of the coatings prepared at 350 °C and 480 °C is 5.8 ± 0.7 GPa and 10.8 ± 0.8 GPa respectively. Their Young's modulus is 92 ± 8 GPa (350 °C) and 155 ± 6 GPa (480 °C). Scratch tests cause adhesive failures of the films grown at 350 °C and 480 °C whereas cohesive failure is observed for the nanocrystalline one, grown at 700 °C. Micro tensile tests show a more progressive cracking of the latter films than on the amorphous ones. The films allow maintaining good mechanical properties after corrosion with NaCl deposit during 100 h at 450 °C. After corrosion test only the film deposited at 700 °C yields an elongation at break comparable to that of the as processed samples without corrosion. The as established processing–structure–properties relation paves the way to engineer MOCVD aluminum oxide complex coatings which meet the specifications of the high temperature corrosion protection of titanium alloys with regard to the targeted applications.     

A thermo-gravimetric and microstructural study of the oxidation of Nbss/Nb5Si3-based in situ composites with Sn addition

The effect of Sn addition on the oxidation of the Nb–24Ti–18Si–5Al–5Cr–2Mo–5Hf–5Sn (at.%) alloy (JG6) in the as cast (AC) and heat treated (HT) conditions was studied at 800 °C and 1200 °C in static air using thermo-gravimetry and microstructural analysis. The oxidation kinetics, morphology and microstructure of the oxide scale and the microstructure of the bulk of the oxidised alloy were investigated. Oxidation occurred by inward oxygen anion diffusion. The oxidation of JG6 at 800 °C and 1200 °C is compared with the oxidation of Sn-free Nb–Ti–Si–Cr–Al–Mo–Hf alloys and is found to have been improved by the addition of Sn. At 800 °C pest oxidation, which was exhibited by the heat treated Nb–24Ti–18Si–5Al–5Cr–2Mo–5Hf alloy (JG4-HT), was eliminated by alloying with 5 at.% Sn. The elimination of pesting at 800 °C is attributed to the nature of the Nb solid solution in the alloy which consists of Sn-rich, Si-rich and Ti lean solid solution usually surrounded by Sn-poor, Si-poor and Ti-rich solid solution. The oxide scales that formed at 1200 °C on JG6 did not separate from the base metal and consisted of Nb₂O₅, TiO₂, SiO₂, HfO₂ and TiNb₂O₇. TiN, instead of TiO₂, and the (Nb,Ti)₅(Sn_1−xSi_x)₃ phase, which is considered as a ternary phase based on Nb₅Sn₂Si, are formed in the diffusion zone of the alloys JG6-AC and JG6-HT after oxidation at 1200 °C. The formation of these phases in the oxidised alloys JG6-AC and JG6-HT controlled the penetration of oxygen into the base material. The better oxidation performance of JG6-AC compared to JG6-HT at 1200 °C is attributed to the formation of Nb₃Sn in the former. It is suggested that the presence of the Sn-poor, Si-poor and Ti-rich Nb_ss in the microstructure is a key to the formation of the Nb₃Sn phase at the scale/diffusion zone interface in the JG6-AC oxidised at 1200 °C.