Calculation of thermophysical properties of iron casting alloys

Abstract

A simple and easy calculation tool to determine thermophysical properties, such as density, heat capacity, liquidus and solidus temperature, thermal conductivity, latent heat, and volume contraction, of iron casting alloys based on equilibrium phase diagrams is introduced. It is well known that accurate thermophysical properties of iron casting alloys are necessary for a valid simulation of the casting process. While there are a number of thermophysical calculation programs, a specific knowledge of thermodynamics is required to operate them. The calculation method proposed in the present study does not require any special knowledge of thermodynamics, only information regarding the composition of the alloy. The proposed calculation tool is based on the CALPHAD approach for the modelling of multicomponent alloys using experimental published data. Comparison of calculated thermophysical properties for several conventional iron casting alloys with experimental results showed good agreement.     

The influence of copper on microstructure and mechanical properties of compacted graphite iron

Abstract

The influence of copper content (0·26 to 1·31 wt-%) on microstructure formation and mechanical properties of compacted graphite iron (CGI) has been evaluated through standard metallographic analysis, colour etching techniques and tensile testing of machined test bars. The properties investigated are yield strength, tensile strength and elongation. The castings were made in an industrial environment from a combination of CGI returns, pig iron, cast iron- and steel scrap. A total of four heats were cast in specially designed sampling cups (3 different cooling rates), chill wedges as well as tensile test bars machined from sand moulded cylinders (20, 45 and 85 mm in diameter). The results clearly illustrate the combined effect of copper and cooling rate on nodularity, chilling tendency as well as pearlite content. A discussion concerning the effect of graphite morphology on the ferrite growth is also included.     

Fabrication of dc–dc converter using nanocrystalline Mn–Zn ferrites

Abstract

The microwave–hydrothermal method has been successfully used for synthesis of nanocrystalline Mn–Zn ferrites which are used for high frequency applications. The nanopowders were characterised using X-ray diffraction and TEM. The nanopowders were annealed using microwaves at 600°C/10 min. The frequency dependence of dielectric constant ?′ was measured in the range from 10 Hz to 1·3 GHz, and initial permeability μ _i was measured in the range from 10 Hz to 1 MHz. The total power loss was measured at 100 kHz and 200 mT on the annealed samples. Conductor embedded ferrite transformers were fabricated, and output power P _o, efficiency η and temperature increase ΔT were measured at sinusoidal voltage of 25 V with frequency 1 MHz. The transformer efficiency η was found to be high, and surface rise of temperature ΔT is very low.     

Phase transformation during aging and resulting mechanical properties of two Ti–Nb–Ta–Zr alloys

Abstract

Phase transformations and mechanical properties of both Ti–29Nb–13Ta–4·6Zr and Ti–39Nb–13Ta–4·6Zr (wt–%) alloys were investigated. The microstructure of the 29Nb alloy is sensitive to solution and aging treatment. Ice water quenching from the solution treatment temperature resulted in (β+α") microstructure but air or furnace cooling led to a mixture of (β+ω). The formation of the orthorhombic α" martensite thus suppresses ω formation in the ice water quenched 29Nb alloy. Cooling rate from the solution treatment temperature also has a significant effect on the formation of α and ω phases during subsequent isothermal aging below the ω start temperature: slow cooling enhances ω but depresses α formation. This cooling rate dependence of aged microstructure was attributed to α" martensite acting as precursor of the α phase, thus providing a low energy path to the precipitation of a at the expense of ω. Phase transformation in the 39Nb alloy is more sluggish than that in the 29Nb alloy, owing to the presence of the higher content of β stabiliser Nb. For the 29Nb alloy, Young's modulus and mechanical properties are sensitive to the fraction of phases, and change significantly during aging, in contrast with the 39Nb alloy.     

Investigation of microstructure and mechanical properties of steel fibre–cast iron composites

Abstract

The aim of the present experimental study was to investigate improvement of the toughness and strength of grey cast iron by reinforcing with steel fibres. The carbon content of the steel fibres was chosen to be sufficiently low that graphite flakes behaving as cracks were removed by carbon diffusion from the cast iron to the steel fibres during the solidification and cooling stages. To produce a graphite free matrix, steel fibres with optimum carbon content were used and the reinforced composite structure was cast under controlled casting conditions and fibre orientation. Three point bend test specimens were manufactured from steel fibre reinforced and unreinforced flake graphite cast iron and then normalising heat treatments were applied to the specimens at temperatures of 800 and 850°C. The fracture toughness and strength properties of the steel fibre reinforced material were found to be much better than those of unreinforced cast iron. The microstructures of the composite at the fibre–matrix transition zone were examined.     

Investigation of thermal properties of Al–Si matrix reinforced fine SiCp composites

Abstract

The characterisation of thermal expansion coefficient and thermal conductivity of Al–Si matrix alloy and Al–Si alloy reinforced with fine SiC_p (5 and 20 wt-%) composites fabricated by stir casting process are investigated. The results show that with increasing temperature up to 350°C, thermal expansion of composites increases and slowly reduces when the temperature reaches to 500°C. The values of both thermal expansion and conductivity of composites are less than those for Al–Si matrix. Microstructure and particles/matrix interface properties play an important role in the thermal properties of composites. Thermal properties of composites are strongly dependent on the weight percentage of SiC_p.     

Microstructure and compressive properties of NiAl–Cr(Mo)–Dy near eutectic alloy prepared by suction casting

Abstract

The NiAl–Cr(Mo) eutectic alloy doped with Dy was prepared by suction casting technique and its microstructure and mechanical properties were investigated. It is found that with the addition of Dy, the Ni₅Dy phase is formed along the NiAl/Cr(Mo) phase boundary in the intercellular region. By the suction casting method, the microstructure of the alloy get well optimisation which can be characterised by the fine interlamellar spacing, high proportion of eutectic cell area and fine homogeneous distributed Ni₅Dy phase. The compression test results reveal that the room temperature and high temperature mechanical properties of the suction cast alloy improve significantly, compared with the conventionally cast alloy.     

Development of microstructure and mechanical properties of as cast Al–Mg–Mn alloy during high temperature ECAP

Abstract

A large scale billet with diameter of 58·5 mm of an as cast Al–Mg–Mn alloy was processed by equal channel angular pressing (ECAP) at 350°C up to six passes. A significant refinement of the grains was observed after six pressings to ～2 μm. And the selected area electron diffraction (SAED) pattern showed that almost all of the grains were separated by boundaries with high angles of misorientation. A banded substructure was not observed during the hot ECAP, and a reasonably equiaxed structure was obtained just after one single pressing. Both the strength and the elongation increased abruptly in a single passage through the die, but thereafter, the increase was more gradual and exhibited a saturation effect after the fourth pressing. The good combination of strength and ductility of the Al–Mg–Mn alloy attained by the hot ECAP appeared to be attractive properties for industrial applications. Moreover, hot ECAP could possibly be used as an alternative step to hot extrusion or hot rolling in industrial processing, to break down an initial coarse as cast structure in a quite large scale billet.     

High strength Al2O3p/6061 Al composites: effect of particles,subgrains and precipitates

Abstract

Composites of 6061 Al reinforced by Al₂O₃ particles have been produced by squeeze casting followed by hot extrusion and a T4 precipitation hardening treatment. The tensile properties at room temperature have been determined and analysed based on microstructural parameters. The strength contributions from the matrix, particles, subgrains and precipitates have been estimated individually, and then based on an assumption of linear additivity, the yield stress values of the composites under the extruded and heat treated conditions have been calculated. Good agreement between the calculated and experimental values has been found, illustrating the suitability of the process for the manufacture of strong composites, with a maximum yield stress of 524 MPa obtained for a composite containing 60 vol.-%Al₂O₃.     

Preparation of zirconium pyrophosphate bonded silicon nitride porous ceramics

Abstract

A new method for preparing high bending strength porous silicon nitride ceramics with controlled porosity was developed using a pressureless sintering technique, using zirconium pyrophosphate as a binder. The fabrication process was described in detail and the sintering mechanism of porous ceramics was analysed by an X-ray diffraction method. The microstructure and mechanical properties of the porous Si₃N₄ ceramics were investigated, as a function of the content of ZrP₂O₇. The resultant porous silicon nitride ceramics sintered at low temperature (1000 and 1100°C) showed fine micropore structure and a high bending strength. Porous silicon nitride ceramics with porosity of 34–47%, a bending strength of 40–114 MPa and a Young's modulus of 20–50 GPa were obtained.