Formation and evolution of Al/steel interface structure in composite casting

Al/steel composite materials were prepared using liquid-solid composite casting method,with aluminum as the liquid and 45 steel rods as the solid.The key factors affecting the formation and evolution of intermetallic compounds at the Al/steel reaction interface were studied.Results show that the defects present in the intermetallic compounds prepared at a liquid temperature of 900℃and a holding time of 20 s are the least.The average hardness of Fe_(2)Al_(5)phase is 3 times higher than that of 45 steel and more than 7 times higher than that of pure aluminum.The average shear strength of the sample obtained through air cooling is higher than that of water cooling,and Fe_(2)Al_(5)phase is the main reason for the brittle fracture of the sample.The activation energy calculation of intermetallic compounds reveals that Fe_(2)Al_(5)is easy to grow up than FeAl_(3)phase under air cooling conditions,and FeAl_(3)is easy to grow up than Fe_(2)Al_(5)phase under water cooling conditions.This work offers assistance in studying the formation of intermetallic compounds during composite casting processes.

As-cast structure of DC casting 7075 aluminum alloy obtained under dual-frequency electromagnetic field

We have experimentally determined the as-cast structures of semi-continuous casting 7075 aluminum alloy obtained in the pres-ence of dual-frequency electromagnetic field. Results suggest that the use of dual-frequency electromagnetic field during the semi-continuous casting process of 7075 aluminum alloy ingots reduces the thickness of the surface segregation layer, increases the height of the melt menis-cus, enhances the surface quality of the ingot, and changes the surface morphology of the melt pool. Moreover, low-frequency electromag-netic field was found to show the most obvious influence on improving the as-cast structure because of its high permeability in conductors.

Electron theory study on the effect of Mn on as-cast structure of Fe-C-Cr-Mn cast irons

The valence electron structure of alloying austenite of 3C-15Cr high chromium white cast iron with different Mn contents from 1% to 6% is analyzed by BLD method and EET. Results show that the addition of Mn has major influence on the valence electron structure of the alloying austenite, especially on that of Fe-C, Fe-C-Cr and Fe-C-Cr-Mn unit cells of it. The effect becomes weak when Mn content is over 4%. Based on the effect of n~, F~~, the weighting of each unit cell and the degree of undercooling on phase transition of the aus- tenite, we can calculate the retained austenite content of as-cast structure of the high chromium white cast iron. The calculation results coincide well with those of the experiment. The phase transition characters of the austenite in high chromium white cast iron can be forecasted through valence electron structure analysis of alloying austenite by BLD method and EET on the basis of Fe-C-Cr equilibrium phase diagram.

AS-CAST STRUCTURE OF Fe-Mo-C ALLOY

The structure and morphology of as-cast Fe-13wt-% Mo-0.8wt-% C alloy have been ob- served under SEM and TEM.Few δ-eutectoid but certain minor eutectics appear in the core of dendrites of the alloy.The eutectic carbide is found as skeleton M_6C while the eutectoid carbide as rodlet M_6C.

Simulation of microstructures in solidification of aluminum twin-roll casting

Based on the research on the solidification of twin-roll continuous casting aluminum thin strip, the analytical model of heterogeneous nucleation, the growth kinetics of tip （KGT） and columnar dendrite transformation to equiaxed dendrite （CET） of twin-roll continuous casting aluminum thin strip solidification was established by means of the principle of metal solidification and modem computer emulational technology. Meantime, based on the cellular automaton, the emulational model of twin-roll continuous casting aluminum thin strip, solidification was established. The foundation for the emulational simulation of twin-roll casting thin strip solidification structure was laid. Meanwhile, the mathematical simulation feasibility was confirmed by using the solidification process of twin-roll continuous casting aluminum thin strip.

EFFECTS OF MISCHMETAL ADDITION ON THE CAST MICROSTRUCTURE OF 6063 ALLOYS

Effect of mischmetal addition on the cast microstructure of 6063 alloys has been investigated by means of optical microscopy, TEM and anode filming etc. The results show that there is a critical content of fining dendrite structure by adding mischmetal to 6063 alloys. This critical mischmetal content is about 0.15%. Only when the mischmetal content is above 0.15%, the secondary dendrite arm spacing decreased and eutectic structure fined. The cast grain is obviously refined when the content of mischmetal is lower. Consideration from the cast structure, the suitable mischmetal content in 6063 alloys is 0.20%.

REHEATING TEMPERATURE CONTRAST AND MICROSTRUCTURES OF 7075 Al ALLOY CAST BY LIQUIDUS SEMI-CONTINUOUS CASTING

In this study, reheating of liquidus semi-continuous cast billets of 7075 Al alloy was carried out in a resistance furnace, and the temperature contrast of the outer and the center of the reheated billets was investigated, then the reheating microstructures were investigated. Results show that: the difference of temperature between the outer and center is small and the difference of their microstructures are also small. During reheating at 576℃ the spheroidization of grains is significant after 5min and no rosettes are visible after 20min by optical microscopy. Similar observations were madeon materials reheated at 596℃, but the ripening process is faster. The grains growup to 30-60μm, fine enough for thixoforming.

Effect of ultrasonic power and casting speed on solidification structure of 7050 aluminum alloy ingot in ultrasonic field

With the experiment and finite element simulation, the influences of power ultrasonic on the solidification structure of 7050 aluminum alloy ingot in semi-continuous casting were researched, and the effects of casting speed on solidification structure in ultrasonic field were also analyzed. The experiment and simulation results show that the solidification structure of the ingot is homogeneously distributed, and its grain size is obviously refined at ultrasonic power of 240 W. The average grain sizes, which can be seen from the Leica microscope, are less than 100 μm. When the casting speed is 45-50 mm/min, the best grain refinement is obtained.

Solidification Structure of Low Carbon Steel Strips with Different Phosphorus Contents Produced by Strip Casting

In the present paper, low carbon steel strips with different phosphorus contents were produced using a twin roll strip casting process. The solidification structure was studied and its features were analyzed in detail. It was found that the strips possessed a fine microstructure compared with the mould cast steels. With increasing phosphorus content more ferrite has been formed with finer grains.

A CELLULAR AUTOMATON-APPROACH TO SIMULATION OFGRAIN STRUCTURE DEVELOPMENT INELECTROSLAG CASTING

A 3-D cellular automaton model of thermal transfer and solidification has been developed, aiming at a simulational study of the grain structure development in electroslag casting. The program we developed for simulation of the model allows the effects of both metallurgical factors, including solidification point, supercooling required for nucleation and its scattering, and liquid/solid interface energy, and thermophysical factors, including heat conduction coeffcients, heat transfer coefficients and latent heat, to be investigated. The effect of process control can be indirectly inspected with the simulation by varying the melting rate. A box counting algorithm was employed to estimate the local curvature of liquid/solid interface. A series of simulated experiments of electroslag casting processes have been carried out. The simulation started from the beginning of the electroslag casting and proceeds by iteration of certain rules, during which a uniform constant slag temperature and a constant melting rate were assumed. It has been observed that a pool of molten metal forms and deepens gradually under constant melting rate. The deepening of the pool slows down with the simulated electroslag casting process, and the depth and shape of the pool tends to be steady after certain height of cast is formed. A finger-like grain structure with the fingers approximately normal to the bottom of the molten metal pool was generally observed. Higher latent heat was found to enhance dendritic growth. The results agree well with general observation of the grain structures in electroslag castings and demonstrate the applicability of cellular automaton modeling to structural development in casting.

Casting structure of pure aluminum by electric pulse modification at different superheated temperatures

Electric pulse modification （EPM） is a novel technique that reduces grain size by altering the structure of a melt. It was investigated that the response of the casting structure of high pure aluminum to EPM in different superheated melts. The results indicate that the grain refining effect of a given pulse electric field holds an optimal temperature range, moreover, a lower or higher superheated temperature will both disadvantage the improvements of casting structure. It essentially lies in the cooperative action between the distorted absorption of clusters and the activated capability of atoms in the aluminum melt.

Effect of RE on Cast Structure and Properties of High Manganese Aluminium Bronze

The effects of various amount of Y and La on the cast structure.the fluidity,the wearability and corrosion resistance of the high manganese aluminium bronze have been investigated.The results have shown that a proper content of rare earth elements is able to refine the cast structure of the alloy,and furthermore to enhance its wearability and corrosion resistance.The reasons for these phenomena have also been discussed.

Effects of ultrasonic treatment on structure of roll casting aluminum strip

The experiment of ultrasonic treatment of roll casting aluminum strip on plane twin-roll cast-roller with double-heads ultrasonic tools was carried out, and the metallographic structure of the roll casting aluminum strip treated by ultrasonic was studied. The results show that ultrasonic treatment can refine the grain of the roll casting aluminum strips and make the structure of the strips more homogeneous. The effect is the best when the power of ultrasonic is 300 W and the incident angle of the guide rod is 45、. The mechanism of acoustic cavitations and acoustic flow on grain refinement was also discussed. The heat effect of intensity ultrasonic was studied. The present problems during ultrasonic roll casting process, such as the imperfect cooling system, the inaccurate calculation of ultrasonic energy, and the shape and position of the guide rod to be improved were pointed out.

Microstructure and Mechanical Properties of Electromagnetic Centrifugal Cast 1Cr25Ni20Si2 Tube Blank

1Cr25Ni20Si2 tube blank centrifugally cast in a steady magnetic field was investigated. The results indicated that the solidification structure and the mechanical properties of the blank can be improved remarkably by electromagnetic stirring, and seamless tube can be manufactured from such blanks.

Microstructure and mechanical properties of a new type of austempered boron alloyed high silicon cast steel

In the present paper, a new type of austempered boron alloyed high silicon cast steel has been developed, and its microstructures and mechanical properties at different temperatures were investigated. The experimental results indicate that the boron alloyed high silicon cast steel comprises a dendritic matrix and interdendritic eutectic borides in as-cast condition. The dendritic matrix is made up of pearlite, ferrite, and the interdendritic eutectic boride is with a chemical formula of M2B （M represents Fe, Cr, Mn or Mo） which is much like that of carbide in high chromium white cast iron. Pure ausferrite structure that consists of bainitic ferrite and retained austenite can be obtained in the matrix by austempering treatment to the cast steel. No carbides precipitate in the ausferrite structure and the morphology of borides remains almost unchanged after austempering treatments. Secondary boride particles precipitate during the course of austenitizing. The hardness and tensile strength of the austempered cast steel decrease with the increase of the austempering temperature, from 250℃ to 400 ℃. The impact toughness is 4-11 J.cm^-2 at room temperature and the impact fracture fractogragh indicates that the fracture is caused by the brittle fracture of the borides.

Solidified structure of thin-walled titanium parts by vertical centrifugal casting

The solidified structure of the thin-walled and complicated Ti-6AI-4V castings produced by the vertical centrifugal casting process was studied in the present work. The results show that the wall thickness of the section is featured with homogeneously distributed fine equiaxial grains, compared with the microstructure of the thick-walled section. The grain size of the castings has a tendency to decrease gradually with the increasing of the centrifugal radius. The inter-lamellar space in thick-walled casting parts is bigger than that of the thin-walled parts, and the profile of inter-lamellar space is not susceptible to the centrifugal radius.

SOLIDIFYING STRUCTURES OF Al_2O_3 SHORT FIBER／Al－Si ALLOY MATRIX COMPOSITE PREPARED BY SQUEEZE CASTING

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STUDY ON THE STRUCTURE AND PROPERTIES OF HIGH CHROMIUM WHITE CAST IRON AND ITS TEMPERING STANDARD

The structure and properties of high chromium white cast iron in different treatment states were studied. Using X ray diffraction method, observing their metallograph and measuring their microhardness, the phases involved in the iron were determined. The notch toughness, macrohardness and the fractograph of the samples are compared and their performance was determined, which mainly depends on the matrix structure. Relatively good comprehensive properties can be obtained in the tempering state. Improvements have been made on the commonly used tempering standard. Tempering for a short period at low temperature can improve the materials′ service performance obviously.

Effect of Austenitizing Treatment on Structure and Hardness of Bainite DuctileCast Iron

By continuous quenching process, the effect of austenitizing temperature and time on the structure and hardness of bainiteductile cast iron was studied. It was found that (l) low austenitizing temperature would result in scrap ferrite existing in matrix, whichreduces the macro-hardness of bainite ductile cast iron; (2) high austenitizing temperature would make carbide decomposed, which alsoinduces the macro-hardness of bainite cast iron, and (3) austenitizing time has little effect on the structure of bainite ductile cast iron, butas it increases, the macro-hardness ofbainite ductile cast iron and micro-hardness of bainite increases. To the ductile cast iron, as a result,the suitable austenitizing temperature and time are recommended as 880 and 120 min respectively.

Effect of cooling structure on thermal behavior of copper plates of slab continuous casting mold

A three-dimensional finite-element model of slab continuous casting mold was conducted to clarify the effect of cooling structure on thermal behavior of copper plates. The results show that temperature distribution of hot surface is mainly governed by cooling structure and heat-transfer conditions. For hot surface centricity, maximum surface temperature promotions are 30 ℃and 15 ℃ with thickness increments of copper plates of 5 mm and nickel layers of 1 ram, respectively. The surface temperature without nickel layers is depressed by 10 ℃ when the depth increment of water slots is 2 mm and that with nickel layers adjacent to and away from mold outlet is depressed by 7℃ and 5 ℃, respectively. The specific trend of temperature distribution of transverse sections of copper plates is nearly free of cooling structure, but temperature is changed and its law is similar to the corresponding surface temperature.