A computational fluid dynamic analysis of gas and particle flow in flame spraying

The flame spraying process, which is a common industrial thermal spraying application, has been analyzed by means of three-dimensional computational fluid dynamics (CFD) simulations. The process used at the Volvo Aero Corporation for the coating of fan and compressor housings has been modeled. The process uses the Metco 6P torch (Metco, Westbury, NY), which ejects a mixture of acetylene and oxygen at high speed through a ring of 16 orifices to form the flame. A stream of argon gas flowing through an orifice in the center of the ring carries a powder of nickel-covered bentonite through the flame to the spray substrate. The torch is cooled by a flow of air through an outer ring of 9 orifices. The simulation emulated reality closely by including the individual inlets for fuel, cooling air, and injected particles. The gas combustion was simulated as a turbulent, multicomponent chemically reacting flow. The standard, two-equation k-ε turbulence model was used. The chemical reaction rates appeared as source terms in the species transport equations. They were computed from the contributions of the Arrhenius rate expressions and the Magnussen and Hjertager eddy dissipation model. The first simulations included several intermediate chemical substances whose predicted concentration agreed favorably with measurements. Later, more simplified simulations incorporated only the global chemical reaction involving the initial and the final products, with corrections to the thermal properties being made to account for the missing intermediaries. The gas velocity and temperature fields predicted by the later simulations compared satisfactorily to those predicted by the earlier, more elaborate, ones. Therefore, the final simulations, which incorporated injected particles, were conducted employing the simplified model with only the global reaction. An in-house finite difference code was developed to calculate particle properties. Allowance was made for elliptical shapes, phase changes, and internal heat transfer with regard to the composite material. The particle velocities and temperatures predicted by the final simulations compared fairly well with experimental results obtained with the optical DPV2000 system.     

Influence of the post-deformation annealing heat treatment on the low-cycle fatigue of NiTi shape memory alloys

Shape memory alloys (SMA) suffer from the same impairing mechanisms experienced during cycling loading by classic alloys. Moreover, SMA fatigue behavior is greatly influenced by thermomechanical cycling through the zone of thermoelastic phase transformation, which is the basis of shape memory and superelasticity effects. Since the fatigue resistance of any material can be improved by an appropriate thermomechanical treatment, in the present work combined differential scanning calorimetry and microhardness testing were used to determine an optimum annealing temperature for the cold-worked Ni-50.1%Ti alloy. The optimization is based on the assumption that latent heat of transformation is proportional to the mechanical work generated by SMA upon heating, while material hardness is related to the yield stress of the material. It is supposed that an optimum trade-off in these two properties guarantees the best dimensional and functional stability of SMA devices. The level and stability of the mechanical work generated by the material during low-cycle fatigue testing are considered criteria for the material performance and thus of the validity of the proposed optimization procedure.     

Elevated temperature Mg-Al-Sr: Creep resistance,mechanical properties,and microstructure

Mg-Al-Sr-based alloys (AJ alloys) have shown superior creep performance and tensile strength at temperatures as high as 175° with stresses up to 70 MPa. Mg-6Al-2.4Sr (AJ62x) exhibits an optimum combination of creep resistance and excellent castability, while AJ62Lx (strontium <2.1) has better ductility than other AJ formulations. The AJ alloy microstructure is characterized by the Al₄Sr-α(Mg) lamellar phase that forms at the interdendritic/grain boundary region of the primary magne sium matrix. Mg-5Al-2Sr (AJ52x) contains a ternary phase that was tentatively named Al₃Mg₁₃Sr. When the strontium level is low in AJ62x, the volume fraction of Al₄Sr is reduced, the aluminum supersaturation of the magnesium primary phase increases, and Mg₁₇Al₁₂ forms. In this article, a mechanism is proposed whereby the creep resistance decreases with the strontium level but the tensile strength and ductility increase. For more information, contact Eric Baril, Noranda, Noranda Technologies Centre, 240 Hymus Pointe-Claire (Montréal), Québec, H9R 1G5 Canada; (514) 630-9347; fax (514) 630-9379; e-mail eric.baril@ntc.noranda.com.     

Phase diagrams for lead-free solder alloys

The need for new, improved solder alloys and a better understanding of reactions during the soldering process grows steadily as the need for smaller and more reliable electronic products increases. Information obtained from phase equilibria data and thermodynamic calculations has proven to be an important tool in the design and understanding of new lead-free solder alloys. A wide range of candidate alloys can be rapidly evaluated for proper freezing ranges, susceptibility to contamination effects, and reactions with substrate materials before the expensive process of preparing and testing candidate alloys is initiated.     

The use of severe plastic deformation techniques in grain refinement

Severe plastic deformation (SPD) has emerged as a promising method to produce ultrafine-grained materials with attractive properties. Today, SPD techniques are rapidly developing and are on the verge of moving from lab-scale research into commercial production. This paper discusses new trends in the development of SPD techniques suchas high-pressure torsion and equal-channel angle pressing, as well as new alternative techniques for introducing SPD. The paper also contains a comparative analysis of SPD techniques in terms of their relative capabilities for grain refinement, enhancement of properties, and potential to economically produce ultrafine-grained metals and alloys. For more information, contact Terry C. Lowe, Science and Technology Base Programs, Los Alamos National Laboratory, Los Alamos, NM 87545; (505) 667-7824; fax (505) 665-3199; e-mail tlowe@lanl.gov.     

Casting/mold thermal contact heat transfer during solidification of Al-Cu-Si alloy (LM 21) plates in thick and thin molds

Heat flow at the casting/mold interface was assessed and studied during solidification of Al-Cu-Si (LM 21) alloy in preheated cast iron molds of two different thicknesses, coated with graphite and alumina based dressings. The casting and the mold were instrumented with thermocouples connected to a computer controlled temperature data acquisition system. The thermal history at nodal locations in the mold and casting obtained during experimentation was used to estimate the heat flux by solving the one-dimensional inverse heat conduction problem. The cooling rate and solidification time were measured using the computer-aided cooling curve analysis data. The estimated heat flux transients showed a peak due to the formation of a stable solid shell, which has a higher thermal conductivity compared with the liquid metal in contact with the mold wall prior to the occurrence of the peak. The high values of heat flux transients obtained with thin molds were attributed to mold distortion due to thermal stresses. For thin molds, assumption of Newtonian heating yielded reliable interfacial heat transfer coefficients as compared with one-dimensional inverse modeling. The time of occurrence of peak heat flux increased with a decrease in the mold wall thickness and increase in the casting thickness.     

Effect of Powder Type and Compaction Pressure on the Density,Hardness and Oxidation Resistance of Sintered and Steam-treated Steels

Two types of Hoganas iron powders—sponge (NC), and highly compressible (SC) were investigated. These specimens were compacted with a pressure of 300, 400, 500, 600, and 700 MPa, before sintering in a production belt-type furnace. Steam treatment of the specimens was at 570 °C for 30 min. The sintered density and as-sintered hardness increase with increasing compaction pressure, and are significantly influenced by the powder structural characteristics. During steam treatment the type of powder and compaction pressure have an important influence on the extent of pore closure and weight gain. The maximum hardness was obtained for the components compacted at a pressure of 500 MPa for both groups of iron powders. Surface pore closure and oxidation resistance of the steam-treated components are improved with increasing compaction pressure.     

Process for dense 2D SiC fiber-SiC matrix composites

A new process using SiC fiber fabrics and SiC tapes to produce dense 2D SiC fiber-SiC (SiC/SiC) composites is demonstrated. The strategy for fabricating the SiC/SiC composites involves: (i) alternately stacking the SiC fiber fabrics and SiC tapes at room temperature, (ii) pyrolyzing of the stacked composites, and (iii) hot-pressing the pyrolyzed composites. By controlling the hot-pressing temperature, it is possible to obtain dense 2D SiC/SiC composites with relative densities of >98%. The 2D SiC/SiC composites show no degradation of the SiC fibers and a higher mechanical strength.     

Opportunities in the electrowinning of molten titanium from titanium dioxide

The value chain of titanium products shows that the difference between the cost of titanium ingot and titanium dioxide is about $9/kg titanium. In contrast, the price of aluminum, which is produced in a similar way, is only about $1.7/kg. Electrowinning of molten titanium from titanium dioxide is therefore believed to have significant potential to reduce the cost of titanium products. The process is hampered by the high operating temperatures and sophisticated materials of construction required; the high affinity of titanium for carbon, oxygen, and nitrogen; and physical and chemical properties of the different titanium oxide species when reducing titanium from Ti₄₊ to metallic titanium. For more information, contact D.S. van Vuuren, CSIR, Materials and Manufacturing Technology Department, Meiring Naude Road, Pretoria, Gauteng 0181, South Africa; +27 12-841 2375; fax +27 841 2135; e-mail dvvuuren@csir.co.za.