Computational Modeling of Columnar to Equiaxed Transition in Alloy Solidification

The columnar to equiaxed transition (CET) provides a challenging simulation goal for computational models of alloy solidification, in addition to being an important technological feature of many casting processes. CET thus provides an industrially relevant test‐case for those developing numerical models across a range of scales. Whether or not CET occurs depends on numerous experimental parameters such as cooling rate, speed of columnar growth, thermal gradient in the liquid, and level of grain refiner in the alloy. Information on columnar and equiaxed grain structure, and the transition between the two, is very useful for foundry engineers, at the macroscopic scale of the casting. The detailed microstructure within each grain is determined by typically dendritic growth and local transport of solute and heat. This paper presents a review of recent progress on modeling CET at multiple length scales. It is evident that, whilst micro‐models can provide simulations of physical phenomena, such as the evolution of dendrite morphology, at scales 10^?3 to 10^?5 m, finite computational resources preclude this resolution over the length scale of castings which is in the 10^?2–10⁰ m range. Instead, reasonably accurate models of CET formation in castings can be achieved by meso‐scale modeling featuring 10^?3–10^?2 m phenomena. Such meso‐scale models make use of analytical expressions to simulate dendrite growth in undercooled melts. Recent progress in modeling of CET, at both macro/meso‐ and micro‐scales is reviewed, and computational challenges yet to be met are summarized.     

Combined in situ X-ray radiographic observations and post-solidification metallographic characterisation of eutectic transformations in Al–Cu alloy systems

In this study thin Al–Cu hypoeutectic alloys were mounted in a Bridgman furnace and solidified near isothermally from above the liquidus to below the eutectic temperature. The eutectic transformation is easily identified from the X-ray absorption contrast difference between the semi-solid mush and the fully solid phase in the field of view (FOV). By virtue of real time in situ X-radiography, and subsequent image analysis techniques, it was possible to directly observe and accurately measure eutectic nucleation, as well as transformation rate across the FOV. Post-solidified samples were then subjected to further microstructural analysis, whereby the lamellar eutectic spacings were measured at random locations across the FOV region. The lamellar spacings were correlated with the eutectic transformation rate and showed reasonable agreement with theoretical predictions. Some interesting observations, such as, for example, in situ observations of solidification shrinkage and the effect of liquid feeding through the semi-solid mush, are also discussed.     

Structural Evolution of PCL during Melt Extrusion 3D Printing

Screw‐assisted material extrusion technique is developed for tissue engineering applications to produce scaffolds with well‐defined multiscale microstructural features and tailorable mechanical properties. In this study, in situ time‐resolved synchrotron diffraction is employed to probe extrusion‐based 3D printing of polycaprolactone (PCL) filaments. Time‐resolved X‐ray diffraction measurements reveals the progress of overall crystalline structural evolution of PCL during 3D printing. Particularly, in situ experimental observations provide strong evidence for the development of strong directionality of PCL crystals during the extrusion driven process. Results also show the evidence for the realization of anisotropic structural features through the melt extrusion‐based 3D printing, which is a key development toward mimicking the anisotropic properties and hierarchical structures of biological materials in nature, such as human tissues.     

Process‐Driven Microstructure Control in Melt‐Extrusion‐Based 3D Printing for Tailorable Mechanical Properties in a Polycaprolactone Filament

3D printing techniques are utilized to produce biomaterial scaffolds with porous architectures that enable cell attachment, biological factors, and appropriate mechanical strength. As the basic building block of a scaffold, the individual filaments should have sufficient mechanical properties, comprising high compressive loading, and fracture resistance to mimic the natural tissue organisation. In this contribution, process–structure–property relationships in melt extruded polycaprolactone filaments are investigated by considering crystalline features, tensile properties, and an array of processing parameters. The tensile properties of the filaments are improved significantly with relatively higher screw rotational speed and relatively lower processing temperature resulting in considerable increase in Young's modulus. The favorable properties are attributed to the increased crystal volume fraction and anisotropy. Thus, this study provides initial pathways for the potential control of mechanical properties of bioscaffolds via engineering crystalline structural features in printed filaments.     

Simulation of international space station microgravity directional solidification experiments on columnar-to-equiaxed transition

It is well known that gravity affects solidification of alloys due to the convective effects it induces. As a result, different outcomes are expected if solidification experiments are carried out in near-zero gravity conditions achievable in space. Directional solidification experiments were conducted on board the Material Science Lab (MSL) in the International Space Station (ISS). The experiments, on Al–7 wt.% Si alloys, were carried out with a low gradient furnace (LGF). The LGF is a Bridgman-type furnace insert for the MSL. Numerical simulations for two such microgravity directional solidification experiments are presented and compared with experimental results. A front tracking algorithm to follow the growing columnar dendritic front, and a volume averaging model to simulate equiaxed solidification, were employed simultaneously in a common thermal simulation framework. The thermal boundary conditions for the simulation domain were computed via the temperature readings which were recorded during the experiments. The simulation results include the prediction of columnar-to-equiaxed transition (CET) and average as-cast equiaxed grain diameters, and agreed with the experimental results reasonably. The simulations predict that although an undercooled zone forms ahead of the growing columnar front, thermal conditions in the diffusion-controlled experiments were inadequate to trigger an entirely equiaxed zone without grain refiners.     

A plasma-assisted bioextrusion system for tissue engineering

A challenge for tissue engineering is to produce synthetic scaffolds of adequate chemical, physical and biological cues effectively. This paper describes a plasma-assisted bio-extrusion system to produce functional-gradient scaffolds; it comprises pressure-assisted and screw-assisted extruders, and plasma jets. This paper also describes how the system conducts plasma surface modification during the polycaprolactone scaffold fabrication process. Water contact angle and in vitro biological tests confirm that the plasma modification alters the hydrophilicity properties of synthetic polymers and promotes proliferation of cells, leading to homogeneous cell colonization. The results suggest this system is promising for producing functional gradient scaffolds of biomaterials.     

Phase transition of cross-linked and hydroxypropylated corn (Zea mays L.) starches

The thermal behaviors of three chemically modified starches (cross-linked waxy corn, hydroxypropylated regular corn, and hydroxypropylated and oxidized waxy corn) were studied using light microscopy, SEM, DSC, XRD, and HPSEC. During the gelatinization process, molecular and crystalline order losses occurred independently from each other. Oxidation treatment altered the effects of hydroxypropylation on starch gelatinization. Both cross-linking and hydroxypropylation tended to preserve granular crystalline order during initial stages of gelatinization. The crystallinities and X-ray patterns of each starch remained essentially unchanged prior to phase transition.     

Plastics from an Improved Canola Protein Isolate: Preparation and Properties

Canola meal proteins were solubilized from canola flour at pH 12 using sodium hydroxide solution. Proteins were then precipitated sequentially at pH values ranging from 11 to 3 in decrements of 1 pH unit. The weight distribution and the properties of these fractions were analyzed. The majority (>76%) of the recovered proteins were precipitated at pH values at or below 7. Another substantial fraction was precipitated at pH 11. The functional and thermal property (differential scanning calorimetry) analyses showed that this protein fraction exhibits the highest water holding capacity and lowest melting point. The plastics prepared with refined protein isolates (with pH 11 fraction removed) showed higher water resistance, tensile, and flexural strength, toughness, and elongation values compared to those prepared with standard canola protein isolates. This shows that mechanical and water resistance properties of protein-based plastics can be enhanced using improved protein isolates.