Experimental and Thermodynamic Exploration of the High-Temperature Microstructures of Co-30 wt.% Cr- (2.5-5.0 wt.%) C Alloys

Cobalt alloyed with high contents in Cr and C potentially may lead to hard alloys candidate for high temperature applications involving reduced wear degradations. The Co-30wt.%Cr-xC system was explored from x = 2.5 to 5 wt.% by both experiments and thermodynamic calculations. The stable microstructures at 1000, 1100 and 1200 °C and the temperatures of solidus and liquidus were of interest. When the carbon content is between 2.5 and 3.5 the alloys display (hypo-)eutectic microstructures composed of FCC Co-based matrix and M₇C₃ carbides. Between 4 and 5 wt.%C, the microstructures contain coarse pro-eutectic M₇C₃ carbides, leading to a total volume fraction of M₇C₃ close to 50% or higher. The C-richest alloys also contain graphite, instead cementite as predicted by calculations. A better agreement between experiments and calculations about microstructures and solidus temperature can be obtained by forbidding cementite in the calculation conditions. The obtained hardness level is about 650 Hv but decreases when the heat-treatment temperature increases.     

Microstructure and Thermal Properties of Nanostructured 8 wt.% CeO2 Doped YSZ Coatings Prepared by Atmospheric Plasma Spraying

Nanostructured 8 wt.% CeO₂-5.4 wt.% Y₂O₃-ZrO₂ (CeYSZ) coatings were prepared by atmospheric plasma spraying technology. The microstructure, thermal diffusivity, and thermal cycle behavior of CeYSZ were investigated. The results show that the as-sprayed nano-CeYSZ coatings consist of tetragonal ZrO₂ and Ce element is in solid solution with ZrO₂. The CeYSZ coatings are characterized by nano-zones (unmelted nanoparticles), melted dense areas, splats, and pores. The thermal diffusivity of nano-CeYSZ coatings is 0.548 × 10^?6 m²/s at room temperature. The addition of CeO₂ decreases the thermal diffusivity of nano-YSZ coatings, which is mainly caused by the point defect scattering and grain-boundary scattering. The thermal cycle life of nano-CeYSZ coatings is about 860 cycles at 1050 °C. The spallation of the coatings occurs at the interface of CeYSZ/TGO.     

Microstructure,Tensile and Fatigue Properties of Al–5 wt.%Mg Alloy Manufactured by Twin Roll Strip Casting

This study investigated the microstructure, tensile and fatigue properties of Al–5 wt.%Mg alloy manufactured by twin roll strip casting. Strips cast as a fabricated (F) specimen and a specimen heat treated (O) at 400 °C/5 h were produced and compared. In the F specimen, microstructural observation discovered clustered precipitates in the center area, while in the O specimen precipitates were relatively more evenly distributed. Al, Al₆(Mn, Fe), Mg₂Al₃ and Mg₂Si phases were observed. However, most of the Mg₂Al₃ phase in the heat-treated O specimen was dissolved. A room temperature tensile test measured yield strength of 177.7 MPa, ultimate tensile strength of 286.1 MPa and elongation of 11.1% in the F specimen and 167.7 MPa (YS), 301.5 MPa (UTS) and 24.6% (EL) in the O specimen. A high cycle fatigue test measured a fatigue limit of 145 MPa in the F specimen and 165 MPa in the O specimen, and the O specimen achieved greater fatigue properties in all fatigue stress conditions. The tensile and fatigue fracture surfaces of the above-mentioned specimens were observed, and this study attempted to investigate the tensile and fatigue deformation behavior of strip cast Al–5 wt.%Mg based on the findings.     

Analysis of Plastic Flow Instability During Superplastic Deformation of the Zn-Al Eutectoid Alloy Modified with 2 wt.% Cu

The aim of this work is to analyze the plastic flow instability in Zn-21Al-2Cu alloy deformed under 10^?3 s^?1 and 513 K, which are optimum conditions for inducing superplastic behavior in this alloy. An evaluation using the Hart and Wilkinson–Caceres criteria showed that the limited stability of plastic flow observed in this alloy is related to low values of the strain-rate sensitivity index (m) and the strain-hardening coefficient (γ), combined with the tendency of these parameters to decrease depending on true strain (ε). The reduction in m and γ values could be associated with the early onset of plastic instability and with microstructural changes observed as function of the strain. Grain growth induced by deformation seems to be important during the first stage of deformation of this alloy. However, when ε > 0.4 this growth is accompanied by other microstructural rearrangements. These results suggest that in this alloy, a grain boundary sliding mechanism acts to allow a steady superplastic flow only for ε < 0.4. For ε values between 0.4 and 0.7, observed occurrences of microstructural changes and severe neck formation lead to the supposition that there is a transition in the deformation mechanism. These changes are more evident when ε > 0.7 as another mechanism is thought to take over.     

Tribological Analysis of Copper-Coated Graphite Particle-Reinforced A359 Al/5 wt.% SiC Composites

Copper-coated graphite particles can be mass-produced by the cementation process using simple equipment. Graphite particulates that were coated with electroless copper and 5 wt.% SiC particulates were introduced into an aluminum alloy by compocasting to make A359 Al/5 wt.% SiC(p) composite that contained 2, 4, 6, and 8 wt.% graphite particulate composite. The effects of SiC particles, quantity of graphite particles, normal loading, sliding speed and wear debris on the coefficient of friction, and the wear rate were investigated. The results thus obtained indicate that the wear properties were improved by adding small amounts of SiC and graphite particles into the A359 Al alloy. The coefficient of friction of the A359 Al/5 wt.% SiC(p) composite that contained 6.0 wt.% graphite particulates was reduced to 0.246 and the amount of graphite film that was released on the worn surface increased with the graphite particulate content. The coefficient of friction and the wear rate were insensitive to the variation in the sliding speed and normal loading.     

Effects of 0.1 wt.% Manganese, Aluminum, and Silicon on Oxidation and Copper-rich Liquid Phase Formation in an Iron–0.3 wt.% Copper–0.15 Wt.% Nickel Alloy

This study investigated the effect of easily oxidizable impurities on the oxidation behavior of iron containing small amounts of copper and nickel. The motivation for this work stems from a cracking phenomenon in low carbon steels known as hot shortness. This type of cracking is caused by formation of a copper-rich liquid layer and is reduced in the presence of easily oxidizable impurities. This work studied iron alloys with 0.3 wt.% copper, 0.15 wt.% nickel, and 0.1 wt.% (manganese, aluminum, or silicon) oxidized in air at 1,150 °C. Parabolic oxidation rates were not affected by manganese or aluminum but were decreased with silicon additions. Manganese and aluminum additions led to internal MnO and hercynite formation. These slightly increased the amount of material entrapped into the oxide. Silicon additions led to a nearly continuous fayalite layer near the oxide/metal interface that decreased the oxidation rate and therefore the amount of copper-rich liquid.     

Effect of 0.1 wt.% Co on the Hot Deformation and Toughness of Fine-Grained Low-Carbon Steel at Sub-zero Temperatures

The effect of 0.1 wt.% Co on the hot deformation behavior of fine-grained low-carbon microalloyed steel was investigated at temperatures of 850-1200 °C and a strain rate of 5 s^?1. Furthermore, the toughness of the steel with and without Co at sub-zero temperatures was evaluated. The results suggest that the addition of 0.1 wt.% Co increases the flow stress and delays the occurrence of dynamic recrystallization (DRX) at the same deformation temperature and strain. The DRX fraction of steel specimens without and with 0.1 wt.% Co was about 67.4 and 43.9% at 850 °C, respectively. Then, it increased to 100% at 1100 °C. Compared with steel without Co, cementite particles in the tempered sorbite of steel with 0.1 wt.% Co decreased in size but increased in quantity, yield strength increased from 756 to 787 MPa, and Charpy V-notch energy at ? 20 and ? 50 °C improved from 69 and 41 to 102 and 65 J, respectively. The fracture morphology and crack propagation characteristics were consistent with the variation in impact energy.     

Columnar and Equiaxed Solidification of Al-7 wt.% Si Alloys in Reduced Gravity in the Framework of the CETSOL Project

During casting, often a dendritic microstructure is formed, resulting in a columnar or an equiaxed grain structure, or leading to a transition from columnar to equiaxed growth (CET). The detailed knowledge of the critical parameters for the CET is important because the microstructure affects materials properties. To provide unique data for testing of fundamental theories of grain and microstructure formation, solidification experiments in microgravity environment were performed within the European Space Agency Microgravity Application Promotion (ESA MAP) project Columnar-to-Equiaxed Transition in SOLidification Processing (CETSOL). Reduced gravity allows for purely diffusive solidification conditions, i.e., suppressing melt flow and sedimentation and floatation effects. On-board the International Space Station, Al-7 wt.% Si alloys with and without grain refiners were solidified in different temperature gradients and with different cooling conditions. Detailed analysis of the microstructure and the grain structure showed purely columnar growth for nonrefined alloys. The CET was detected only for refined alloys, either as a sharp CET in the case of a sudden increase in the solidification velocity or as a progressive CET in the case of a continuous decrease of the temperature gradient. The present experimental data were used for numerical modeling of the CET with three different approaches: (1) a front tracking model using an equiaxed growth model, (2) a three-dimensional (3D) cellular automaton–finite element model, and (3) a 3D dendrite needle network method. Each model allows for predicting the columnar dendrite tip undercooling and the growth rate with respect to time. Furthermore, the positions of CET and the spatial extent of the CET, being sharp or progressive, are in reasonably good quantitative agreement with experimental measurements.     

Hot Workability and Flow Characteristics of Aluminum-5 wt.% B4C Composite

Flow behavior of aluminum-5 wt.% boron carbide (Al-B₄C) composite was investigated by carrying out compression tests over a range of strain rates (10^?4-10⁰ s^?1) and temperatures (200-500 °C). The flow stress data obtained from these tests at true strain 0.5 were used to develop processing map. The stable and instable flow regimes in the map were characterized by the microstructural examination using Scanning Electron Microscopy and Electron Backscattered Diffraction. The optimum condition for processing of Al-5%B₄C composite was found to lie between 425 and 475 °C at the strain rate of around 10^?4 s^?1. A strain-compensated Sellars-McG Tegart constitutive equation was established to model high-temperature deformation behavior of the material.     

Influence of Hot Isostatic Pressing on the Microstructure and Mechanical Properties of a Spray-Formed Al-4.5 wt.% Cu Alloy

Al-4.5 wt.% Cu alloy was spray atomized and deposited at varied spray heights ranging from 300 to 390 mm. The average grain sizes decreased from ~ 29 to ~ 18 μm and a concomitant increase in the hardness and the 0.2% yield strength (YS) with increase in the spray height. The respective hardness values of SF-300, SF-340, and SF-390 are 451 ± 59, 530 ± 39, and 726 ± 39 MPa and the YS are 108 ± 7, 115 ± 8, and 159 ± 10 MPa. The transmission electron micrographs revealed the morphological changes of the Al₂Cu phase from irregular shaped to small plate-shaped and then subsequently to spheroidal shape due to high undercooling encountered during spray atomization with increase in spray height from 300 to 390 mm. The porosity of the spray formed deposits varied between 5 to 12%. Hot isostatic pressing of spray deposits reduced the porosity to less than 0.5% without any appreciable increase in grain size. A dislocation creep mechanism seems to be operative during the secondary processing. A comparison between as-spray formed and hot isostatically pressed deposits exemplifies improvement in mechanical properties as a result of elimination of porosity without affecting the fine grain sizes achieved during the spray-forming process.     

Structural and Tribological Properties of Nanostructured Supersonic Cold Sprayed Ni-20 wt.% Sn Coatings

80-μm-thick nanostructured coatings consisting of a Ni solid solution, Ni₃Sn, Ni₃Sn₂, and metastable NiSn intermetallic phases were deposited via supersonic cold spraying onto inconel 718 alloy substrates. These coatings have complex nanostructured metallurgical phases as revealed by transition electron microscopy, scanning electron microscopy, and x-ray diffraction techniques. Their mechanical properties were determined by nanoindentation measurements. Furthermore, the wear behavior of these nanostructured sprayed coatings was compared to the one of the industrial bulk or sprayed coated benchmark materials. It was found that the nanostructured coatings exhibit higher wear resistance than the industrial benchmarks, thanks to an appropriate balance of hard intermetallic phases and soft Ni matrix, as well as to their nanostructuring. Their frictional characteristics under reciprocating sliding are mainly determined by the formation of an oxide-based tribo-layer, which was analyzed by x-ray photoelectron spectroscopy. The role of intermetallic phases in these coatings on the friction and wear is also discussed.     

Deposition Mechanism and Microstructure of Laser-Assisted Cold-Sprayed (LACS) Al-12 wt.%Si Coatings: Effects of Laser Power

Surface treatment is one of the most costly processes for treating metallic components against corrosion. Laser-assisted cold spray (LACS) has an opportunity to decrease those costs particularly in transportation systems, chemical industries, and renewable energy systems. This article highlights some of those potential applications. In the LACS process, a laser beam irradiates the substrate and the particles, thereby softening both of them. Consequently, the particles deform upon impact at the substrate and build up a coating. To circumvent the processing problems associated with cold-spray (CS) deposition of low-temperature, corrosion-resistant Al-12 wt.%Si coatings, a preliminary investigation detailing the effect of laser power on its LACS deposition mechanism and microstructural properties is presented. The deposition efficiency, the microstructure, and the microhardness of the LACS-deposited coatings produced by a 4.4-kW Nd:YAG laser system were evaluated. The outcome of this study shows that pore- and crack-free Al-12 wt.%Si coatings were deposited via softening by laser irradiation and adiabatic shearing phenomena at an optimum laser power of 2.5 kW.     

Heat Treatment of Closed-Cell A356 + 4 wt.%Cu + 2 wt.%Ca Foam and Its Effect on the Foam Mechanical Behavior

In this investigation, aluminum-silicon alloy foam is developed by adding certain amounts of copper and calcium elements in A356 alloy. Addition of 4 wt.%Cu + 2 wt.%Ca to the melt changed bubbles morphology from ellipsoid to spherical by decreasing Reynolds number and increasing Bond number. Compression behavior and energy absorption of the foams are assessed before and after aging. Solid solution treatment and aging lead to the best mechanical properties with 170% enhancement in yield strength and 185% improvement in energy absorption capacity as compared to non-heat-treated foams. The metallographic observations showed that bubbles geometry and structure in the A356 + 4wt.% Cu + 2 wt.%Ca foam are more homogeneous than the A356 foam.     

Comparative study on biosorption of Pb（ Ⅱ ） and Cr（Ⅵ） by Synechococcus sp.

The comparative study on adsorptions of Pb（ Ⅱ ） and Cr（Ⅵ） ions by free cells and immobilized cells of Synechococcus sp. was performed, in which different aspects including Zeta potential of the cells, the influence of pH, temperature and initial concentration of metal ions, as well as adsorption kinetics and mechanism were referred. The lyophilized free cells have a surface isoelectric point at pH 3, and the correlative experiment indicates that there is an electrostatic adsorption feature of Cr（Ⅵ） and Pb（ Ⅱ ） The immobilization of the free cells by Ca-alginate does not significantly modify the adsorption features of the biosorbent. The absorption processes of Cr（Ⅵ） and Pb（Ⅱ） on both free and immobilized cells are apparently affected by pH and the initial concentration of metal ions in the bulk solution, but are much weakly affected by temperature in the test range of 10-50 ℃. The slow course of biosorption follows the first order kinetic model, the adsorption of Pb（Ⅱ） obeys both Langmuir and Freundlich isotherm models, while the adsorption of Cr（Ⅵ） obeys only Freundlich model. FT-IR results indicate that carboxylic, alcoholic, amide and amino groups are responsible for the binding of the metal ions, and reduction of Cr（Ⅵ） to Cr（Ⅲ） takes place after Cr（Ⅵ） adsorbs electrostatically onto the surface of the biosorbents.     

An Investigation of Microstructure and Phase Transformation Behavior of Cu40Zn-1.0 wt.% Ti Brass Via Powder Metallurgy

The effects of Ti addition on phase transformation, precipitation behavior, and microhardness response of Cu40Zn brass were investigated at elevated heat treatment (HT) temperatures using the powder metallurgy method. The volume fraction of the α phase increased with the elevated temperatures, which showed an equal value as that of the β phase at 400 °C, and reached a maximum value of 55.9% at 500 °C. The solid solubility of Ti in Cu40Zn brass matrix decreased as the HT temperature increased. Supersaturated Ti showed high chemical potential for precipitates' reaction in Cu40Zn brass. Lower HT temperature retained higher Ti solid solubility and fine precipitates. The precipitates presented in form of Cu₂TiZn intermetallic compound, distributing uniformly in brass matrix which suppressed the phase and grain growth. After HT at elevated temperature, the precipitates coalesced, grew coarser, and segregated at the primary particle boundaries. The microhardness of the BS40-1.0Ti compact was primarily not only dependent on the solid solubility of Ti, but also dependent on the phase volume fraction of the α and β phases.     

Comparative study on biosorption of Pb(Ⅱ)and Cr(Ⅵ)by Synechococcus sp.

The comparative study on adsorptions of Pb(Ⅱ)and Cr(Ⅵ)ions by free cells and immobilized cells of Synechococcus sp. was performed,in which different aspects including Zeta potential of the cells,the influence of pH,temperature and initial concentration of metal ions,as well as adsorption kinetics and mechanism were referred.The lyophilized free cells have a surface isoelectric point at pH 3,and the correlative experiment indicates that there is an electrostatic adsorption feature of Cr(Ⅵ)and Pb(Ⅱ). The i...     

Comparative study on biosorption of Pb(Ⅱ) and Cr(Ⅵ) by Synechococcus sp.

The comparative study on adsorptions of Pb(Ⅱ) and Cr(Ⅵ) ions by free cells and immobilized cells of Synechococcus sp.was performed,in which different aspects including Zeta potential of the cells,the influence of pH,temperature and initial concentration of metal ions,as well as adsorption kinetics and mechanism were referred.The lyophilized free cells have a surface isoelectric point at pH 3,and the correlative experiment indicates that there is an electrostatic adsorption feature of Cr(Ⅵ) and Pb(Ⅱ).The immobilization of the free cells by Ca-alginate does not significantly modify the adsorption features of the biosorbent.The absorption processes of Cr(Ⅵ) and Pb(Ⅱ) on both free and immobilized cells are apparently affected by pH and the initial concentration of metal ions in the bulk solution,but are much weakly affected by temperature in the test range of 10-50 ℃.The slow course of biosorption follows the first order kinetic model,the adsorption of Pb(Ⅱ) obeys both Langmuir and Freundlich isotherm models,while the adsorption of Cr(Ⅵ) obeys only Freundlich model.FT-IR results indicate that carboxylic,alcoholic,amide and amino groups are responsible for the binding of the metal ions,and reduction of Cr(Ⅵ) to Cr(Ⅲ) takes place after Cr(Ⅵ) adsorbs electrostatically onto the surface of the biosorbents.