Mechanical Properties of Solid‐Sintered Porous Silicon Carbide Ceramics

The freeze‐drying combining solid sintering is a good method to fabricate porous SiC ceramics with good high temperature mechanical properties. Though SiC ceramics are sintered at a high temperature of 2150 °C, there are still large quantity of macropores generated by sublimating large ice crystals and micropores in the ceramic wall caused by small ice crystals sublimating, SiC particles stacking, and burning out of polyvinyl alcohol (PVA). The content of PVA affects the microstructure and strength. As increasing the content of PVA, the size of pores caused by sublimating the ice crystals decreases while both open porosity and room temperature strength increase. After being treated at a temperature of 1200 and 1500 °C, the ceramics exhibit good thermal shock damage resistance.     

Influence of cooling rates on temperatures phase transitions and on microstructure of aluminium alloy EN AW‐5083

The casting of different forms and dimensions of aluminium alloy EN WA‐5083 test samples and the usage of different types of mould materials resulted in achieving different cooling rates of samples. The methods used were simple thermal analysis, using casting into a measuring cell made by the Croning process and using casting into a cone‐shaped measuring cell, as well as simultaneous thermal analysis using the method of differential scanning calorimetry. Significant temperature phase transitions and times of solidification were determined, and the dependence model of the solidification time on the sample cooling rate was obtained. Determining the mean number of grains per unit area on samples after having performed the simple thermal analysis and differential scanning calorimetry makes it possible to develop a dependence model of the mean number of grains per unit area on the cooling rate. These models are the basis for carrying out numerical simulations of solidification and microstructure development in the cone‐shaped measuring cell, and the comparison of the distribution of the mean number of grains per unit area obtained by simulation with the one obtained experimentally. The obtained results represent a part of the preliminary tests of the microstructure development of industrially cast ingots of EN AW‐5083 alloy depending on the local ingot cooling rate.     

Barium Titanate-Polymer Composites Produced via Directional Freezing

In this study, we use a freeze casting technique to construct ceramic-polymer composites in which the 2 phases are arranged in an electrically parallel configuration. By doing so, the composites exhibit dielectric constant (K) up to 2 orders of magnitude higher than that of composites with ceramic particles randomly dispersed in a polymer matrix. In this technique, an aqueous ceramic slurry was frozen unidirectionally to form ice platelets and ceramic aggregates that were aligned in the temperature gradient direction. Upon freeze-drying, the ice platelets sublimed and left the lamellar ceramic structure intact. The green ceramic body was fired to retain the microstructure, and then the space between ceramic lamellae was infiltrated with a polymer material. The finished composites exhibit the high dielectric constant (1000) of ferroelectric ceramics while maintaining the unique properties of polymer materials such as graceful failure, low dielectric loss, and high dielectric breakdown.     

Phase‐field modelling of solidification microstructure formation using the discontinuous finite element method

This paper presents a discontinuous Galerkin finite element computational methodology for solving the coupled phase‐field and heat diffusion equations to predict the microstructure evolution during solidification. The phase‐field modelling of microstructure formation is briefly discussed. The discontinuous Galerkin finite element formulation for the phase‐field model systems for solidification microstructure formation is described in detail. Numerical stability is performed using the Neumann method. The accuracy of the discontinuous model is verified by the analytic solution of a simple 1‐D solidification problem. Numerical calculations using the discontinuous finite element phase‐field model have been performed for simulating the complex 2‐D and 3‐D dendrite structures formed in supercooled melts and the results are compared well with those in literature using the finite difference methods. Parallel computing algorithm is presented and results show that the minimization of the intercommunication between microprocessors is the key to increase the effectiveness in parallel computing with the discontinuous finite element phase‐field model for solidification microstructure formation. Copyright © 2006 John Wiley & Sons, Ltd.     

Template‐Free,Surfactant‐Mediated Orientation of Self‐Assembled Supercrystals of Metal–Organic Framework Particles

Mesoscale self‐assembly of particles into supercrystals is important for the design of functional materials such as photonic and plasmonic crystals. However, while much progress has been made in self‐assembling supercrystals adopting diverse lattices and using different types of particles, controlling their growth orientation on surfaces has received limited success. Most of the latter orientation control has been achieved via templating methods in which lithographic processes are used to form a patterned surface that acts as a template for particle assembly. Herein, a template‐free method to self‐assemble (111)‐, (100)‐, and (110)‐oriented face‐centered cubic supercrystals of the metal–organic framework ZIF‐8 particles by adjusting the amount of surfactant (cetyltrimethylammonium bromide) used is described. It is shown that these supercrystals behave as photonic crystals whose properties depend on their growth orientation. This control on the orientation of the supercrystals dictates the orientation of the composing porous particles that might ultimately facilitate pore orientation on surfaces for designing membranes and sensors.     

Virtuelles Werkstoff‐ und Prozessdesign funktionaler Schichten

Virtual Material‐ and Processdesign of Functional Coatings Thermally sprayed and plasma transferred arc clad coatings are often used to improve the surface properties of mechanical parts with regard to an improved wear and corrosion behavior. New coating processes and applications can be developed, if it is possible to control the coating microstructure by a defined management of the process parameters. Simulation can be used to get a detailed understanding of the process‐material interaction for a defined controlling of the process parameters with less experimental effort. This allows a systematic variation of the coating structure and to calculate the parameter set which represents the best compromise between a high deposition rate and low residual stresses in the coating. In order to model thermal spraying, the following sub‐processes are considered: gas flow, material supply, heating and accelerating of particles, particle impact on the substrate, coating formation, solidification and formation of residual stresses. The results presented in this paper will demonstrate the influence of the process parameters on particle properties and subsequently on the splat formation, the coating formation and the coating microstructure. Controlling different process parameters like material injection conditions and substrate properties, the heating, cooling and solidification behavior of the particles and the coating structure can be influenced significantly.     

Effect of Microstructure and Hydrogen Pores on the Mechanical Behavior of an Al7%Si0.3%Mg Alloy Studied by a Combined Phase‐Field and Micromechanical Approach

A combination of the phase‐field method for the simulation of the microstructure evolution during solidification with subsequent finite element simulation of fracture appearance in the final solidification structure is proposed for the prediction of the mechanical behavior of Al? Si based casting alloys, including the effect of solidification porosity caused by hydrogen. Metallographic investigations and computer tomographic observations of the as cast microstructure of an Al7%Si0.3%Mg alloy together with the data obtained from mechanical tensile testing are used to compare and validate the simulation results to demonstrate the capabilities as well as current limitations in micromechanical modeling of void containing materials. In micromechanical simulations with the element elimination technique (EET) it is shown that porosity influences the crack path as well as crack propagation by connecting the pores. In the eutectic microstructure without porosity, failure starts to develop in silicon lamellae and proceeds in the ductile matrix. However, in the presence of pores fracture also initiates in silicon, and in the later stages of loading, porosity affects the path of the crack and results in additional crack nucleation, and thus, these pores also influence crack propagation in the matrix.     

Quantitative relationship between microstructure characteristics and fatigue parameters of A319 casting alloy

This paper describes a microstructure‐based uniaxial strain‐controlled fatigue life prediction model applied to A319 aluminum alloy which is widely used in automobile industry. The materials made with different casting conditions are characterized and quantified in terms of secondary dendrite arm spacing (SDAS), size, and aspect ratio of eutectic Si particles. Uniaxial low cycle fatigue tests have been performed on four groups of A319 alloy under different casting conditions in which cooling rate and Sr addition are variables. It is shown that the effect of various degrees of microstructure on the fatigue life and fatigue behavior is obvious. The first part of the paper is quantitatively characterizing the microstructure of samples to identify the influence of different casting conditions. With regard to mechanic properties, the tensile properties and fatigue behavior of samples are analyzed combining with microstructure. Finally, a microstructure‐based Manson‐Coffin‐Basquin model is proposed to predict fatigue life of Al‐Si alloy.     

Spray formed and rolled aluminium‐magnesium‐scandium alloys with high scandium content

Aluminium‐magnesium‐scandium alloys offer good weldability, high corrosion resistance, high thermal stability and the potential for high strength by precipitation hardening. A problem of aluminium‐scandium alloys is the low solubility of about 0.3 mass‐% scandium when using conventional casting methods. The solution of scandium can be raised by higher cooling rates during solidification. This was realised by spray forming of Al‐4.5Mg‐0.7Sc alloys as flat deposits. Further cooling rates after solidification should also be high to prevent coarse precipitation of secondary Al₃Sc. Therefore a cooling device was designed for the spray formed flat deposits. The flat deposits were rolled at elevated temperatures to close the porosity from spray forming. Microstructures, aging behaviour and tensile properties of the rolled sheets were investigated. Strength enhancements of about 100 MPa compared to conventional Al‐Mg‐Sc alloys were achieved.     

Modelling the pressure die casting process using a hybrid Finite‐Boundary Element model

In this paper an efficient three‐dimensional hybrid thermal model for the pressure die casting process is described. The Finite Element Method (FEM) is used for modelling heat transfer in the casting, and the Boundary Element Method (BEM) for the die. The FEM can efficiently account for the non‐linearity introduced by the release of latent heat on solidification, whereas the BEM is ideally suited for modelling linear heat conduction in the die, as surface temperatures are of principal importance. The FE formulation for the casting is based on the modified effective capacitance method, which provides high accuracy and unconditional stability. This is essential for accurate modelling of the pressure die casting process and efficient coupling to the BEM. The BE model caters for surface phenomena such as boiling in the cooling channels, which is important, as this effectively controls the manner in which energy is extracted. The die temperature is decomposed into two components, one a steady‐state part and the other a time‐dependent perturbation. This approach enables the transient die temperatures to be calculated in an efficient way, since only die surfaces close to the die cavity are considered in the perturbation analysis. A multiplicative Schwarz method for non‐overlapping domains is used to couple the individual die blocks and casting. The method adopted makes use of the weak coupling between the domains, which is a result of the relatively high interfacial thermal resistance that is present. Numerical experiments are performed to demonstrate the computational effectiveness of the approach. Predicted die and casting temperatures are compared with thermocouple measurements and good agreement is indicated. Copyright © 1999 John Wiley & Sons, Ltd.     

Microstructural Analysis of the Reinforced Al‐Cu5mgti/Tib2 5 wt % Alloy for Investment Casting Applications

The paper describes the influence of 5 wt % titanium diboride (TiB₂) particles on the microstructure of an Al‐Cu alloy produced by plaster casting process. The elaboration route leads to a composite material with 1% of in situ TiB₂ particles and 4% ex situ of TiB₂ particles. The comparison of the reinforced alloy with the corresponding non‐reinforced counterpart makes clear that the presence of TiB₂ particles has a large influence in the observed microstructure. The presence of TiB₂ particles decreases the grain sizes and the porosity level. It is also found that TiB₂ particles play an important role in the precipitation events of Al₂Cu precipitates that are formed during solidification at the TiB₂/aluminum matrix interfaces.     

Microstructure evolution of ceramic materials during solidification from melts in high-gravity combustion synthesis

A variety of bulk ceramic materials were prepared via melt-casting by high-gravity combustion synthesis, and the microstructure evolution during solidification was investigated. Most single-phase ceramics like Al₂O₃, YAG, and MgAl₂O₄ showed a faceted crystal shape because they have higher melting entropies. The cooling condition had an evident influence on the solidification process, resulting in different microstructures. As an example, a strongly textured structure consisting of well-arranged faceted crystals was observed in the surface layer of Al₂O₃ samples. Compared with single-phase ceramic materials, multiphase eutectic ceramics have lower melting temperatures and can provide more opportunity for tailoring microstructures. From the experimental results, the microstructure of eutectic ceramics was related with the volume fraction of each component, and various eutectic structures with submicron interphase spacings were produced such as lamellae, fibers, and three-dimensional interpenetrating frameworks. No cracks were found at the interface between different phases in the eutectic ceramics, indicating an excellent interfacial bonding strength.     

Multi‐Step Crystallization of Self‐Organized Spiral Eutectics

A method for the solidification of metallic alloys involving spiral self‐organization is presented as a new strategy for producing large‐area chiral patterns with emergent structural and optical properties, with attention to the underlying mechanism and dynamics. This study reports the discovery of a new growth mode for metastable, two‐phase spiral patterns from a liquid metal. Crystallization proceeds via a non‐classical, two‐step pathway consisting of the initial formation of a polytetrahedral seed crystal, followed by ordering of two solid phases that nucleate heterogeneously on the seed and grow in a strongly coupled fashion. Crystallographic defects within the seed provide a template for spiral self‐organization. These observations demonstrate the ubiquity of defect‐mediated growth in multi‐phase materials and establish a pathway toward bottom‐up synthesis of chiral materials with an inter‐phase spacing comparable to the wavelength of infrared light. Given that liquids often possess polytetrahedral short‐range order, our results are applicable to many systems undergoing multi‐step crystallization.     

Directional Solidification of TiAl‐based Alloys and Properties of Directionally Solidified Ingots

The mechanical properties of TiAl‐based alloys with lamellar microstructure are extremely anisotropic. However, if the lamellar microstructure can be aligned parallel to the growth direction, the resulting material should possess a good combination of mechanical properties. Unfortunately, simple casting operations often lead to a solidification texture with the lamellar boundaries perpendicular to the heat flow direction. This difficulty can be overcome by directionally solidifying TiAl‐based alloys. We have been performing directional solidification experiments with and without using a seeding technique. The current status of directional solidification of TiAl‐based alloys is reviewed.     

Effect of Processing on Microstructure and Physical Properties of Three Nickel‐Based Superalloys with Different Hardening Mechanisms

The nickel‐based superalloys Inconel alloy 600, Udimet alloy 720, and Inconel alloy 718 were produced by electron beam melting (EBM), casting, and directional solidification (DS). The distance between dendrites and the size of the precipitates indicated the difference in solidification rates between the three processes. In this study, the solidification rate was fastest with EBM, closely followed by casting, whereas it was much slower with DS. In the directional solidified materials the <100> direction was the fastest and thus, preferred growth direction. The EBM samples show a sharp (001)[100] texture in the building direction and in the two scanning directions of the electron beam. Macrosegregation was observed in some cast and directionally solidified samples, but not in the EBM samples. The melting temperatures are in good agreement with literature and the narrow melting interval of IN600 compare to UD720 and IN718 might reduce the risk of incipient melting during EBM processing. Porosity was observed in the EBM samples and the reasons are discussed. However, EBM seems to be a feasible process route to produce nickel‐based superalloys with well‐defined texture, no macrosegregation and a rapidly solidified microstructure.     

Fluid flow behavior and solidification process of welding pool under rapid cooling condition based on cellular automata-lattice Boltzmann method (CA-LBM) couple model

Based on the basic principle of lattice Boltzmann method (LBM), this paper first establishes a numerical model for simulating the evolution process of flow field, temperature field and concentration field. Then the cellular automata-lattice Boltzmann method (CA-LBM) coupling model is established to simulate the solidification process of welding pool. Finally, the solidification process of the welding pool under different rapid cooling powers is analyzed. It is found that the solidification process of the welding pool is significantly correlated with the magnitude of the rapid cooling power. As the rapid cooling power increases, the maximum temperature, the temperature interval and the size of the welding pool decrease, which lead to the Marangoni convection effect in the welding pool increases obviously and the unevenness of the concentration field is reduced. Meanwhile, due to the increase in the degree of supercooling, the nucleation rate increases. Finally, under the combined action, the microstructure of the weld is refined. The results of the coupling model accurately reflect the complex changes of the physical fields in the solidification process of welding pool under different cooling power. It lays a foundation for solving practical engineering problems in large calculation area.     

Analysis of the Solidification and Microstructure of Two Aluminium Alloys Reinforced with TiB2 Particles

Two aluminium alloys with 6 wt% TiB₂ particles are studied for applications where increased wear resistance and mechanical strength at high temperature are required. The incorporation of hard ceramic particles has a strong influence on the microstructure and properties of the alloys. TiB₂ particles play an important role in the nucleation of the different phases of the alloys during solidification, and in the reduction of grain size and porosity. The solidification patterns of Al‐Si₇Mg_0.3 + TiB₂ (6 wt%) and Al‐Cu₅MgTi + TiB₂ (6 wt%) materials are compared to their corresponding non‐reinforced alloys, and the microstructures are analyzed.     

Preparation of Macroscopic Block‐Copolymer‐Based Gyroidal Mesoscale Single Crystals by Solvent Evaporation

Properties arising from ordered periodic mesostructures are often obscured by small, randomly oriented domains and grain boundaries. Bulk macroscopic single crystals with mesoscale periodicity are needed to establish fundamental structure–property correlations for materials ordered at this length scale (10–100 nm). A solvent‐evaporation‐induced crystallization method providing access to large (millimeter to centimeter) single‐crystal mesostructures, specifically bicontinuous gyroids, in thick films (>100 µm) derived from block copolymers is reported. After in‐depth crystallographic characterization of single‐crystal block copolymer–preceramic nanocomposite films, the structures are converted into mesoporous ceramic monoliths, with retention of mesoscale crystallinity. When fractured, these monoliths display single‐crystal‐like cleavage along mesoscale facets. The method can prepare macroscopic bulk single crystals with other block copolymer systems, suggesting that the method is broadly applicable to block copolymer materials assembled by solvent evaporation. It is expected that such bulk single crystals will enable fundamental understanding and control of emergent mesostructure‐based properties in block‐copolymer‐directed metal, semiconductor, and superconductor materials.     

差压铸造薄壁铝硅合金铸件的位置效应

采用差压铸造工艺,研究垂直缝隙式浇注系统浇注的铝合金硅铸件不同位置的组织和力学性能变化.采用石英砂型、SiC砂型和冷铁,浇口处铸件的晶粒最细小,致密度高、力学性能最好;铸件冷端的组织和性能次之;位于两者之间的铸件的组织和性能最差.分析表明对于具有垂直缝隙式浇注系统,差压铸造凝固压力对金属的凝固作用具有位置效应,浇口处液态金属温度高,凝固时间长,凝固压力对浇口处金属的凝固作用显著;铸件冷端金属凝固时间短,凝固压力对该处金属的凝固作用不显著,铸型的冷却速度对铸件组织和性能的影响起显著作用.浇口处与冷端之间的金属液体的凝固受压力和冷却速度的影响小,铸件的晶粒尺寸最大、密度最小、性能最低.冷却速度提高,铸件的任意位置的组织和性能都相应得到提高.     

On the optimal cooling strategy for variable‐speed continuous casting

In this paper, we consider the inverse problem of determining the optimal cooling parameters for continuous casting under changing casting speed. We rely on automatic differentiation to support different search methods for the parameter values that will minimize a given cost functional, which can include a variety of criteria: surface temperature evolution and variation, interface position, full solidification point. In the direct problem we use a fixed‐domain transformation to solve the corresponding free‐boundary problem to high accuracy. Numerical experiments are provided to illustrate and support the effectiveness of the present concept. Copyright © 2001 John Wiley & Sons, Ltd.