Magneto-elastic interchange in ferromagnetic alloys

The internal friction δ, exchange integral A, magnetocrystalline anisotropic constant K_I and saturation magnetization M_s of Fe–Cr–Al and Fe–Cr–Al–Si alloys annealed at 1373 and 1473 K are measured. The energy density and volume fraction of domain walls (DWs) of these alloys are calculated based on the theories of ferromagnetism and the magnetic parameters measured. The physical process of irreversible movement of 90° DWs is suggested. The results indicate the dissipated elastic energy per unit volume due to the irreversible movements of 90° DWs is equal in value to the energy density of DWs, that is γ_w/δ_w=λ_sE/2. It is an effect of magneto-elastic interchange in ferromagnetic alloys.     

The relationship of the volume fraction of martensite vs. plastic strain in an Fe–Mn–Si–Cr–N shape memory alloy

The volume fractions of stress-induced martensite formed by certain plastic strains were determined by X-ray diffraction and quantitative metallography in an Fe–Mn–Si–Cr–N alloy at room temperature. The results are fitted by least square method and are well consistent with an exponential function f_M=1−exp{−β[1−exp(−η)]ⁿ} deduced by Olson and Cohen, who used it to fit with experimental data for AISI304 stainless steel. The similarity of and β, as well as the difference in n for these two alloys are discussed in relation to their nucleation mechanisms.     

Crystal chemistry and Calphad modelling of the χ phase

This article is a comprehensive review devoted to the phase diagram and crystal structure properties of the χ phase intermetallic compound. An extensive study of the available literature has been performed and completed by key experimental measurements performed in the following systems: Fe–Re, Mn–Mo, Mn–Re, Mn–Ru, Mn–V, Mo–Re, Nb–Os, Nb–Re, Re–Ti, Re–Zr. The χ phase is an important Frank–Kasper (topologically close-packed) phase whose presence in certain systems has implications in the process of industrial materials such as Ni-based super-alloys. As a binary phase, it exists mainly in transition metal systems of Tc, Re and Os with elements of groups 3–6, rare earths-Mg systems and (αMn) solid solutions. It has the peculiarity to exist in three ordered variants corresponding to the different prototypes αMn, Ti₅Re₂₄ and Mg₁₇Al₁₂. Particular attention has been paid to the way the composition of the binary compounds is accommodated by atom mixing on the different sites. In our experimental work, occupancy parameters on the four crystallographic sites have been obtained by Rietveld analysis of X-ray powder diffraction data. The investigation has been made as a function of composition when possible. In addition to the study of the intermetallic compounds, particular emphasis has been placed on the study of the ordering in (αMn) solid solutions. This study has implications on the modelling of the χ phase with the Calphad method. Different models are reviewed and recommendations are made for future thermodynamic assessments.     

Thermodynamic calculation of stacking fault energy in Fe–Mn–Si shape memory alloys

Based on thermodynamic considerations together with measurement of the stacking fault probability (Psf) by X-ray diffraction profile analysis, the stacking fault energy (SFE, γ) of austenite in Fe–Mn–Si shaped memory alloys can be estimated. For instance, the stacking fault energy of an fcc(γ) phase in an Fe–30.3Mn–6.06Si was calculated as 7.8 mJ/m². Compositional dependence of stacking fault energy in these alloys with certain composition range has also been derived as SFE(γ)=180.54+7.923 wt.% Mn–46.38 wt.% Si (J/mol), showing that the stacking fault energy increases with the addition of Mn and decreases with the addition of Si.     

Determination of matrix and precipitate elastic constants in (γ–γ′) Ni-base model alloys, and their relevance to rafting

A complete set of high-temperature data relevant to rafting, i.e. the elastic constants of the individual γ and γ′ phases and the elevated temperature lattice mismatch between the phases, was generated for two model ternary Ni–Al–Mo single crystal alloys. The directionality of rafting was examined experimentally in the same alloys upon uniaxial loading in compression and tension along a 100 cube axis. The key material properties and corresponding directional coarsening observations are discussed in view of the various models for rafting published in the literature.     

Analysis of the microstructure of Cr–Ni surface layers deposited on Fe3Al by TIG

A series of Cr–Ni alloys were overlaid on a Fe₃Al surface by tungsten inert gas arc welding (TIG) technology. The microstructure of the Cr–Ni surface layers were analysed by means of optical metallography, scanning electron microscopy (SEM) and X-ray diffraction (XRD). The results indicated that when the appropriate TIG parameters were used and Cr25–Ni13 and Cr25–Ni20 alloys were used for the overlaid materials, the Cr–Ni surface layers were crack-free. The matrix of the surface layer was austenite (A), pro-eutectoid ferrite (PF), acicular ferrite (AF), carbide-free bainite (CFB) and lath martensite (LM), distributed on the austenitic grain boundaries as well as inside the grains. The phase constituents of the Cr25–Ni13 surface layer were γ-Fe, Fe₃Al, FeAl, NiAl, an Fe–C compound and an Fe–C–Cr compound. The microhardness of the fusion zone was lower than that of the Fe₃Al base metal and Cr25–Ni13 surface layer.     

Microstructures in Advanced Materials Characterized by HREM and Nanoscale Analysis

Segregation of yttrium induces the formation of Y_0.25Zr_0.75O_2-x and Y_0.5Zr_0.5O_2-y microdomains, with L1₂- and L1₀-like ordered structures, in ZrO₂–6mol%Y₂O₃ ceramics in both the sintered and annealed states. The compositions of precipitates such as χ_L, χ_S, χ_SS, and small precipitates formed inside χ_L, in Cu–11.88Al–5.06Ni–1.63Mn–0.96Ti (wt.%) shape memory alloys have been determined. Under electron beam irradiation, four types of dynamic behavior of the G.P. zones were observed in the Al–6.58Zn–2.33Mg–2.40Cu (wt.%) alloy. The G.P. zone and “G.P. zone-like” defect structures were also distinguished. Lattice distortion profile in the GaAs/In_xGa_1-xAs superlattice and two-dimensional lattice distortion around a 60° dislocation core in the InAs_xP_1-x/InP superlattice were determined.     

Modulated structures of Fe–10Mn–2Cr–1.5C alloy

In Fe–10Mn–2Cr–1.5C alloy the superlattice diffraction spots and satellite reflections have been observed by transmission electron microscopy, these results show that the ordering structure and modulated structure have taken place in this alloy. X-ray diffraction proved that austenitic steel in this alloy is more stable than in traditional austenitic manganese steel. Based on this investigation, we consider that the C–Mn ordering clusters were existing in austenitic manganese steel and the chromium could strengthen this effect by linking the weaker C–Mn couples together. These structures may play an important role in the work hardening of austenitic manganese steel.     

Microstructure and mechanical properties of two-phase Cr–Cr2Nb, Cr–Cr2Zr and Cr–Cr2(Nb,Zr) alloys

The microstructures and mechanical properties of binary and ternary Cr-based alloys containing Nb, Zr, or both Nb and Zr, have been studied in both the as-cast and annealed conditions. The level of alloying in each instance was targeted to lie below, or approximately at, the maximum solubility in chromium. The as-cast microstructures of these alloys consisted of Cr-rich solid solution surrounded by small amounts of interdendritic Cr–Cr₂X eutectic structure. Annealing at 1473 K resulted in solid-state precipitation of the Cr₂X Laves phase in the Cr–Nb and Cr–Nb–Zr alloys, but not in the Cr–Zr alloys. The binary Cr₂Nb phase consisted of an extensively twinned ({111}<112> twins) C15 structure whereas the presence of Zr modifies its appearance substantially; the twinned C15 structure persists. Oxides were occasionally present and their compositions were qualitatively determined. Vickers hardness primarily depended upon the volume fraction of the Cr₂X Laves phase present. Age hardening due to solid-state precipitation of Cr₂X Laves phase within the Cr-rich matrix was observed in the Nb-containing alloys. The room temperature bend strength of the alloys was strongly affected by the presence of grain-boundary Cr₂X phase. It is considered that porosity as well as oxides in the alloys also lowers their bend strength.     

Long crack growth behavior of implant material Ti–5Al–2.5Fe in air and simulated body environment related to microstructure

The fatigue crack propagation behavior of Ti–5Al–2.5Fe with various microstructures for biomedical applications was investigated in air and in a simulated body environment, Ringer's solution, in comparison with that of Ti–6Al–4V ELI and that of SUS 316L stainless steel. The crack propagation rate, da/dN, of Ti–5Al–2.5Fe in the case of each microstructure is greater than that of the Widmanstätten structure in Ti–6Al–4V ELI in air whereas da/dN of Ti–5Al–2.5Fe is nearly equal to that of the equiaxed structure in Ti–6Al–4V ELI in air when da/dN is plotted versus the nominal cyclic stress intensity factor range, ΔK. da/dN of the equiaxed structure and that of the Widmanstätten structure in Ti–5Al–2.5Fe are nearly the same in air when da/dN is plotted versus ΔK. da/dN of Ti–5Al–2.5Fe is nearly equal to that of SUS 316L stainless steel in the Paris Law region, whereas da/dN of Ti–5Al–2.5Fe is greater than that of SUS 316L stainless steel in the threshold region in air, when da/dN is plotted versus ΔK. da/dN of Ti–5Al–2.5Fe or Ti–6Al–4V ELI is nearly the same in air and in Ringer's solution when da/dN is plotted versus the effective cyclic stress intensity factor range, ΔK_eff, whereas da/dN of Ti–5Al–2.5Fe or Ti–6Al–4V ELI is greater in Ringer's solution than in air when da/dN is plotted versus ΔK.     

Internal friction behaviour of Ni–Mn–Ga

The internal friction (IF) behaviour of shape memory alloys (SMA) is characterised by an IF peak and a minimum of the elastic modulus during the martensitic transformation (MT), and a higher IF value in the martensitic state than in parent phase. The IF peak is considered to be built of three contributions, the most important of them being the so-called “transient” one, existing only at non-zero temperature rate. On the other hand, the ferromagnetic Ni–Mn–Ga system alloys undergoes a MT from the L2₁ ordered parent phase to martensite, the characteristics of the transformation depending largely on the e/a ratio of the alloys. Indeed, a variety of transformation sequences, including intermediate phases between parent and martensite and intermartensitic transformations, have been observed for a wide set of studied alloys. Furthermore, the IF and modulus behaviour during cooling and heating these alloys show specific characteristics, such as modulus anomalies, strong temperature dependence of the elastic modulus, temperature dependent internal friction in martensite, and, as a general trend, a low transient contribution to the IF. In the present work, the IF and modulus behaviour of several Ni–Mn–Ga alloys will be reviewed and compared to that observed for “classical” systems like Cu- or NiTi-based shape memory alloys.     

Research and Improvement on structure stability and corrosion resistance of nickel-base superalloy INCONEL alloy 740

INCONEL alloy 740 is a newly developed Ni–Cr–Co–Mo–Nb–Ti–Al superalloy in the application to ultra-supercritical boilers with steam temperatures up to 700 °C. By means of scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), micro-chemical phase analyses, and corrosion-resisting test, this paper investigates the structure stability of the alloy at elevated temperature and concentrates on coal ash corrosion performance of the alloy under the simulated coal ash/flue gas condition. Experimental results show that the most important structure instabilities of the alloy during prolonged aging are γ′ coarsening, γ′ to η transformation and G phase formation at grain boundary. The performance of corrosion resistance of the alloy would meet the requirement of ultra-supercritical boiler tubes. The phase computation by means of Thermo-Calc has been adopted in chemical composition modification for structure stability improvement. Two suggested new modified alloys in adjustment of the Al and Ti contents and in control of Si level, and also in maintenance of Cr content of the alloy were designed and melted for experimental investigation. These two modified alloys exhibit more stable microstructure during 760 °C long time aging.     

Formation of amorphous and nanocrystalline phases in high velocity oxy-fuel thermally sprayed a Fe–Cr–Si–B–Mn alloy

High velocity oxy-fuel (HVOF) thermal spray was used to deposit a Fe–Cr–Si–B alloy coating onto stainless steel (1Cr18Ni9Ti) substrate. Microstructures of the powder and the coating were investigated by X-ray diffraction (XRD), scanning election microscopy (SEM), transmission election microscopy (TEM) and differential scanning calorimeter (DSC). The coating had layered morphologies due to the deposition and solidification of successive molten or half-molten splats. The microstructures of the coating consisted of a Fe–Cr-rich matrix and several kinds of borides. The Fe–Cr-rich matrix contained both amorphous phase and nanocrystalline grains with a size of 10–50 nm. The crystallization temperature of the amorphous phase was about 605 °C. The formation of the amorphous phase was attributed to the high cooling rates of molten droplets and the proper powder compositions by effective addition of Cr, Mn, Si and B. The nanocrystalline grains could result from crystallization in amorphous region or interface of the amorphous phase and borides by homogeneous and heterogeneous nucleation.     

Formation of metal–TiN/TiC nanocomposite powders by mechanical alloying and their consolidation

Fe–TiN, Ni–TiN, and SUS316–TiC nanocomposite powders were prepared by ball-milling Fe–Ti, Ni–Ti, and SUS316–TiC powder mixtures in a nitrogen or argon gas atmosphere. Fe–63vol.% TiN and Ni–44–64vol.% TiN milled powders were dynamically compacted by use of a propellant gun to produce bulk materials of nanocrystalline structure and having grain sizes between about 5 and 400 nm. SUS316–2.8–5.6vol.% TiC milled powders were consolidated by hot isostatic pressing (HIP) to produce bulk materials having grain sizes between about 100 and 400 nm. The possibility of using fine-dispersed TiN/TiC particles to pin grain boundaries and thereby maintain ultra-fine grained structures of grain sizes down to the nanocrystalline scale has been discussed.     

Morphology of sputter deposited Al alloy films

Morphology of Al–2.0at%Ta and Al–2.0 at.% Nd alloy films before and after annealing was investigated for applications of interconnections for liquid crystal displays. It was found that the morphology and the microstructure of Al–2.0 at.% Nd alloy films changed markedly by annealing at the temperature region from 200°C to 300°C, while the morphology of Al–2.0 at.% Ta alloy films did not change by annealing up to 400°C. For the case of Al–2.0 at.% Nd alloy films, the incline of the <111> fiber texture to the substrate normal was observed during annealing. Structural characteristics of the Al films were investigated by TEM, SAD and XRD to determine the influence of alloying elements on the morphology and the fiber texture. From these results, it was concluded that the microstructures strongly influence the morphology and the grain orientation of Al alloy films.     

Investigation of interfacial segregation at antiphase boundaries in a ternary alloy 84.8Ni–12.8Al–2.4Ta

A thin interphase layer (4 nm) between the merging γ′ precipitates in a chosen model alloy 84.8Ni–12.8Al–2.4Ta was investigated. It is demonstrated that interfacial segregation may occur at an antiphase boundary (APB) interface between the thin layer and one of the merging γ′ precipitates. The magnitude of the lattice displacement (about 1/10[010]) caused by interfacial segregation has been measured both by comparing experimental images with computer simulations, and from high resolution electron microscopy (HREM) fringe spacings using linear regressional analysis. These measurements show a consistent lattice spacing reduction across the APB. Image simulations also highlight the way that the contrast of the bounding partial dislocation affects the APB interface image and can be used to obtain the lattice shift across the interface when the segregation effects on -fringe contrast are significant.     

Effect of various surface conditions on fretting fatigue behavior of Ti–6Al–4V

An experimental investigation was conducted to explore the fretting fatigue behavior of Ti–6Al–4V specimens in contact with varying pad surface conditions. Four conditions were selected: bare Ti–6Al–4V with a highly polished finish, bare Ti–6Al–4V that was low-stress ground and polished to RMS #8 (designated as ‘as-received’), bare Ti–6Al–4V that was grit blasted to RMS #64 (designated as ‘roughened’) and stress relieved, and Cu–Ni plasma spray coated Ti–6Al–4V. Behavior against the Cu–Ni coated and as-received pads were characterized through determination of a fretting fatigue limit stress for a 10⁷ cycle fatigue life. In addition, the behavior against all four-pad conditions was evaluated with S-N fatigue testing, and the integrity of the Cu–Ni coating over repeated testing was assessed and compared with behavior of specimens tested against the as-received and roughened pads. The coefficient of friction, μ, was evaluated to help identify possible crack nucleation mechanisms and the contact pad surfaces were characterized through hardness and surface profile measurements.

An increase in fretting fatigue strength of 20–25% was observed for specimens tested against Cu–Ni coated pads as compared to those tested against as-received pads. The experimental results from the S-N tests indicate that surface roughness of the coated pad was primarily responsible for the increased fretting fatigue capability. Another factor was determined to be the coefficient of friction, μ, which was identified as ˜0.3 for the Cu–Ni coated pad against an as-received specimen and ˜0.7 for the bare as-received Ti–6Al–4V. Specimens tested against the polished Ti–6Al–4V pads also performed better than the specimens tested against as-received pads. Fretting wear was minimal for all cases, and the Cu–Ni coating remained intact throughout repeated tests. The rougher surfaces got smoother during cycling, while the smoother surfaces got rougher.     

Influence of alloying elements on as-cast microstructure and strength of gray iron

Casting experiments were carried out to produce gray cast irons with compositions in the range (wt.%): Fe–3.2C–wCu–xMo–yMn–zSi, where w = 0.78–1.79, x = 0.11–1.17, y = 0.68–2.34 and z = 1.41–2.32. These key elements were varied systematically during sand casting into 30-mm diameter bars to assess their influence on the development of microstructure and mechanical properties. It was found that microstructures ranging from fully pearlitic to an intimate mixture of retained austenite and bainitic ferrite, termed ausferrite, were produced and a reasonable linear correlation was observed between ausferrite volume fraction and strength. The optimum combination of mechanical properties was achieved in an alloy of approximate composition Fe–3.2C–1.0Cu–0.7Mo–0.55Mn–2.0Si, which generated 100% ausferrite without alloy carbides. This alloy has a microstructure and mechanical properties comparable to austempered gray iron without many of the problems associated with austempering.     

Evaluation of hot corrosion resistance of HVOF coatings on a Ni-based superalloy in molten salt environment

High-velocity oxy-fuel (HVOF) has the advantage of being a continuous and most convenient process for applying coatings to industrial installations at site. In this study, Cr₃C₂–NiCr, NiCrBSi, Stellite-6 and Ni–20Cr coatings were deposited on a Ni-based superalloy (19.5Cr–3Fe–0.3Ti–0.1C–balance Ni) using an HVOF process. Hot corrosion studies were performed on bare as well as coated superalloy specimens after exposure to a molten salt environment at 900 °C under cyclic conditions. The thermogravimetric technique was used to establish the kinetics of corrosion. XRD, SEM/EDAX and EPMA techniques were used to analyse the corrosion products. The hot corrosion resistance of all the coatings were superior to bare superalloy. Among the coatings studied, the Ni–20Cr coated superalloy imparted maximum hot corrosion resistance, whereas the Stellite-6 coated indicated minimum resistance. The hot corrosion resistance of all coatings may be attributed to the formation of oxides and spinels of nickel, chromium or cobalt.