Simulation of Secondary Dendritic Arm Spacing of Free Cutting Steel 38MnVS

The secondary dendritic arm spacing （SDAS） of free cutting steel 38MnVS during continuous casting process was simulated based on a Mixed Lagrangian and Eulerian Method （MILE Method） and SDAS model. The simulation results are basically in agreement with measured ones. The effect of composition, superheat and casting speed on SDAS are studied, and the relationship between SDAS and interdendritic segregation is discussed. The results show that SDAS increases with increasing carbon and silicon content, and decreases with increasing manganese and sulfur content. The increase of superheat and casting speed also makes SDAS increase. The permeability of co lumnar mushy zone which is parallel to the primary dendritic arms is calculated based on Carman-Kozeny relationship, and the increase of SDAS makes the permeability increase, which exacerbates interdendritic segregation of columnar crystal zone.

Influence of La-Ce Mischmetal on Dendritical Arm Space and Ultimate Tensile Strength in ZL105 Alloys

The influence of pure La, pure Ce, (La+Ce) mischmetal on the dendritical arm space(LDAS) of ZL105 alloy in cylinderical casting was studied. The effects of adding amount of (La+ Ce) mischmetal on LDAs and ultimate tensile strength(b) were investigated, and the relationship between b and LDAS was founded. (La+Ce) mischmetal has stronger ability to refine LDAs than pure La or pure Ce. The proper adding amounts of it is 0.15% (mass fraction). LDAs has a remarkable effect on ah of casting, which can be predicted by the regression equation obtained in this work.

Effect of melt convection on primary dendrite arm spacing in directionally solidified Pb-26%Bi hypo-peritectic alloys

Primary dendrite arm spacing（PDAS） of α phase in directionally solidified Pb-26%Bi（mass fraction） hypo-peritectic alloys was measured by considering the effect of melt convection in cylindrical samples with different diameters.The experimental results show the measured PDAS increases with increasing diameter of the sample.At the growth velocity of 5 μm/s,its value changes from 161.5 μm for the sample with 1.8 mm in diameter to 240.4 μm for the sample with 7 mm in diameter.The strong melt convection in large diameter samples causes a high bulk alloy composition and a high concentration gradient in peritectic β phase,resulting in a larger PDAS.Simultaneously,the high concentration gradient could effectively promote the peritectic transformation,enhancing the dissolution of the thin α dendrite.

Influence of directional solidification variables on primary dendrite arm spacing of Ni-based superalloy DZ125

The primary dendrite morphology and spacing of DZ125 superalloy have been observed during directional solidification under high thermal gradient about 500 K/cm. The results reveal that the primary dendrite arm spacing decreases from 94 μm to 35.8 μm with the increase of directional solidification cooling rate from 2.525 K/s to 36.4 K/s. The regression equation of the primary dendrite arm spacings A, versus cooling rate is λ1=0.013（GV）-0.32. The predictions of Kurz/Fisher model and Hunt/Lu model accord reasonably well with the experimental data. The influence of directional solidification rate under variable thermal gradient on the primary dendrite arm spacing has also been investigated.

Effect of sample diameter on primary and secondary dendrite arm spacings during directional solidification of Pb-26wt.%Bi hypo-peritectic alloy

The microstructure scales of dendrites, such as primary and secondary dendrite arm spacings, control the segregation profiles and the formation of secondary phases within interdendritic regions, which determine the properties of solidified structures. Investigations on primary and secondary dendrite arm spacings of primary a-phase during directionally solidified Pb-26wt%Bi hypo-peritectic alloy were carried out in this research, and systematic studies were conducted using cylindrical samples with different diameters （Ф = 1.8 and 7.0 mm） in order to analyze the effects of sample diameter on the primary and secondary dendrite arm spacings. In this work, the dependence of dendrite arm spacings on growth velocity was established. In addition, the experimental data concerning the primary and secondary dendrite ann spacings were compared with the main predictive dendritic models from the literatures. A comparison between experimental results for dendrite arm spacings of the 1.8-mm-diameter sample and 7.0-ram-diameter sample was also conducted.

Evaluation of the microstructure, secondary dendrite arm spacing, and mechanical properties of Al–Si alloy castings made in sand and Fe–Cr slag molds

The microstructure and mechanical properties of as-cast A356（Al–Si） alloy castings were investigated. A356 alloy was cast into three different molds composed of sand, ferrochrome（Fe–Cr） slag, and a mixture of sand and Fe–Cr. A sodium silicate–CO_2 process was used to make the necessary molds. Cylindrical-shaped castings were prepared. Cast products with no porosity and a good surface finish were achieved in all of the molds. These castings were evaluated for their metallography, secondary dendrite arm spacing（SDAS）, and mechanical properties, including hardness, compression, tensile, and impact properties. Furthermore, the tensile and impact samples were analyzed by fractography. The results show that faster heat transfer in the Fe–Cr slag molds than in either the silica sand or mixed molds led to lower SDAS values with a refined microstructure in the products cast in Fe–Cr slag molds. Consistent and enhanced mechanical properties were observed in the slag mold products than in the castings obtained from either sand or mixed molds. The fracture surface of the slag mold castings shows a dimple fracture morphology with a transgranular fracture nature. However, the fracture surfaces of the sand mold castings display brittle fracture. In conclusion, products cast in Fe–Cr slag molds exhibit an improved surface finish and enhanced mechanical properties compared to those of products cast in sand and mixed molds.

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%.

Microstructural evolution and microsegregation in directional solidification of hypoeutectic Al−Cu alloy:A comparison between experimental data and numerical results obtained via phase-field model

The objective of the work is focused on predictions of microsegregation,solidification speed,dendritic arm spacings and dendrite morphology by phase-field model.The numerical results were compared with experimental data.The experimental values for cooling rates and effective partition coefficient were adopted during calculations.The results of microsegregation through phase-field model show excellent agreement with the experimental data.Such excellent agreement is because cooling rates,effective partition coefficient and back-diffusion of solute are considered in the model.For solidification speed,the calculation results show good agreement with the experimental data.Tertiary dendritic arm spacing calculated with phase-field model is compared with experimental data.The results show good agreement between them.The dendrite arm spacing varies with position because high cooling rates are responsible for the refinement effect on microstructure.Finally,two-dimensional simulation produced a dendrite that is similar to that found in the experiment.

Effect of Sr content on microstructure and mechanical properties of Mg-Li-Al-Mn alloy

The as-cast Mg-8Li-3Al-0.5Mn-xSr（LAM830-xSr, x=0-1.0） alloys were designed and prepared in a vacuum induction furnace under controlled argon atmosphere. The alloys were then processed by hot extrusion, and their microstructural evolution and mechanical properties were analyzed. Results indicate that the LAM830 alloy mainly consists of α-Mg, β-Li, Al2Mn3, and LiMgAl2 phases. Sr addition results in the precipitation of Al-Sr. Moreover, Sr addition results in a fact that the secondary dendrite arm spacing（DAS） of the primary α-Mg phase is obvious refined. Microstructure of the investigated alloys is further refined as a result of the hot extrusion treatment. The content and morphology of the secondary phases have important effects on the mechanical properties of the alloys. The as-extruded LAM830-0.5Sr alloy exhibits an optimal elongation of 22.43% and as-extruded LAM830-0.75 Sr alloy shows an optimal tensile strength of 265.46 MPa.

Effect of M-EMS on the solidification structure of a steel billet

Effects of mold electromagnetic stirring （M-EMS） on the solidification structure of 45# steel billet were investigated by examination of interdendritic corrosion. The results show that the primary and secondary dendrite arm spacings increase from the edge of the billet to the center and decrease obviously with increasing electromagnetic torque, which will be beneficial to refine the solidification structure and enlarge the equiaxed crystal zone. The ratio of equiaxed crystal increases by 15.9% with the electromagnetic torque increasing from 230 to 400 cN·cm. The increase of stirring intensity can improve the cooling rate and the impact of M-EMS on it reduces from the edge of the billet to the central area, where the cooling rates are similar at different torques. The closer to the central area, the less the influence of M-EMS on the cooling rate is. The ratio of the primary to secondary dendrite arm spacing is approximately 2.0, namely, λ1≈2λ2, and is constant irrespective of the stirring intensity and position of the billet. Original position analysis （OPA） results indicate that the center segregation of the billet is greatly improved, and the more uniform and compact solidification structure will be obtained with the increase of stirring intensity.

Effect of cooling rates on dendrite spacings of directionally solidified DZ125 alloy under high thermal gradient

The dendrite morphologies and spacings of directionally solidified DZ125 superalloy were investigated under high thermal gradient about 500 K/cm. The results reveal that, with increasing cooling rate, both the spacings of primary and secondary dendrite arms decrease, and the dendrite morphologies transit from coarse to superfme dendrite. The secondary dendrite arms trend to be refined and be well developed, and the tertiary dendrite will occur. The predictions of the Kurz/Fisher model and the Hunt/Lu model accord basically with the experimental data for primary dendrite arm spacing. The regression equation of the primary dendrite arm spacings 21 and the cooling rate Vc is λ1 = 0.013 Vc^-0.32. The regression equation of the secondary dendrite arm spacing λ2 and the cooling rate Vc is λ2 = 0.00258 Vc^-0.31, which gives good agreement with the Feurer/Wunderlin model.

Grain and dendrite refinement of A356 alloy with Al-Ti-C-RE master alloy

Commercial A356 alloy was refined with a homemade A1-5Ti-0.25C-2RE master alloy, and the microstructure and macrostructure of the refined alloy were investigated. The results show that the grain refining effect of A356 is poor by the addition level of 0.5 wt% master alloy, but when the level reaches 3.0 wt% the grain can get a satisfactory refining effect. Dendrite of A356 can be effectively refined by addition of 0.5 wt% master alloy; however, the refining effect is not significantly improved by further increasing the addition of master alloy. Grain and dendrite refining effects are compared in this article, and the results show that the grain and dendrite exhibit different refining effects with the same addition level of master alloy. Dendrite is easier to reach the optimal refining effect than grain.

Solidification structure simulation and casting process optimization of GCr15 bloom alloy

Based on the solidification heat transfer model and CAFÉmodel,the solidification structure of GCr15 bloom alloy was studied.Using nail shooting and acid etching experiments,the solidification models were verified.The secondary dendrite arm spacing(SDAS)model of GCr15 was obtained by simulation calculation and metallographic observation.With the increase of casting speed,the SDAS,equiaxed crystal ratio(ECR)and average grain size increase.With the rise of superheat,the SDAS increases in the 20-70 mm of thickness and decreases in the 80-160 mm of thickness.The ECR decreases and the average grain size increases with the increase of superheat.With the increase of specific water flow,both the SDAS and ECR decrease.The minimum average grain size is obtained when the specific water flow is 0.20 L·kg^(-1).The central carbon segregation index is reduced from 1.11 to 1.075.

DENDRITE REFINING AND EUTECTIC TRANSFORMATION BEHAVIOR OF NICKEL-BASE SINGLE CRYSTAL (NBSC) SUPERALLOY

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Effect of solidification process parameters on dry sliding wear behavior of AlNiBi alloy

As-cast samples of the Al-3wt.%Ni-lwt.%Bi alloy resulting from the horizontal directional solidification process were subjected to the micro-abrasive wear test.The effects of the solidification thermal and microstructural parameters,such as the growth and cooling rates and the cellular and primary dendritic spacings(VL and TR;λ1 and λc;respectively),were evaluated in the wear resistance of the investigated alloy.The tribological parameters analyzed were the wear volume and rate(Vw and Rw).The solidification experiments and the wear tests were carried out by means of a water-cooled horizontal directional solidification device and a rotary-fixed ball wear machine,respectively.The results show lower Vw and Rw values correspond to finer microstructures and the Vw dependence on λ1 is characterized by an experimental mathematical equation.A better distribution of Bi soft droplets and Al3Ni hard intermetallic particles is observed within the finer interdendritic region and,in consequence,the better wear resistance is achieved in as-cast samples with dendritic morphology rather than cellular morphology.A transition of wear mechanism from adhesive to abrasive is observed.

Characterization of cooling rate and microstructure of Cu Sn melt droplet in drop on demand process

Different sized single droplets of Cu-6%Sn alloy were prepared by drop on demand(DOD)technique.The secondarydendrite arm spacing was measured and correlated with the droplet cooling rate by a semi-empirical formula.The microstructure ofdroplets was observed by optical microscopy(OM)and electro backscatter diffraction(EBSD).The dendrite feature of singledroplets depends on solidification rate,cooling medium and flight distance.When droplets collide with each other at temperaturesbetween solidus and liquidus,the dendrites and grains are refined obviously possibly because the collision enhances the heat transfer.The cooling rate of colliding droplets is estimated to be more than4×104K/s based on a Newton’s cooling model.The dendritesgrow along the colliding direction because of the temperature gradient induced by the internal flow inside the droplets.

Characterization of microstructural length scales in directionally solidified Sn-36%Ni peritectic alloy

Sn-36%Ni peritectie alloys were directionally solidified at different growth rates under a constant temperature gradient （20 K/mm）, the dependences of microstructural characteristic length scales on the growth rate were investigated. Experimental results are presented, including primary and higher order dendrite arm spacings 21, 22, 23 and dendrite tip radius R of primary NisSn2 phase. Comparisons between the theoretical predictions and the experimental results show that, for the primary dendrites, 21=335.882v-0.21, which is in agreement with the Kurz-Fisher model; for the secondary dendrites, λ2=44.957v-0.277, which is consistent with the Bouchard-Kirkaldy model; for the tertiary dendrites, λ3=40.512v-0.274; for the dendrite tip radius, R=22.7v-0.36. The experimental results also show that the 21/22 changes greatly with increasing growth rate while the 21/23 has no significant change, indicating that tertiary dendrite arms have a more similar growth characteristics to primary dendrites compared with secondary dendrites. The λ1/R ranges from 2 to 2.3 with the increase of growth rate. Key words： Sn-Ni alloy; directional solidification; dendrite arm spacing; dendrite tip radius

Microstructural evolution during unsteady-state horizontal solidification of Al-Si-Mg(356) alloy

The increasing demand for reducing vehicle weight in the automotive and aerospace industries has raised the need to develop improved structural aluminum-based alloys. Thus, horizontal solidification experiment with the Al-7%Si-0.3%Mg（mass fraction） alloy was carried out. A water-cooled horizontal directional solidification device was developed and used. Microstructural characterization was carried out using traditional techniques of metallography, optical microscopy and SEM microscopy. The Thermo-Calc software was used to generate the solidification path of the investigated alloy with addition of 0.17% Fe（mass fraction）. The effects of the thermal parameters such as the growth rate（VL）, cooling rate（TC） and solidification local time（tSL） on the formation of the macrostructure and on the dendritic microstructure evolution were evaluated. A columnar to equiaxed transition（CET） was found for VL and TC values from 0.82 to 0.98 mm/s and from 1.71 to 2.55 ℃/s, respectively. The microstructure was characterized by the measurement of the primary and secondary dendrite arm spacings（λ1 and λ2, respectively）. Experimental laws of λ1 =f（VL, TC） and λ2 =f（tSL） were proposed. It is observed that the interdendritic region is composed of the following eutectic mixture： a（Al）＋Si＋p-Al8 Mg3 Fe Si6＋q-Mg2 Si.

Effects of solidification parameters on microstructure and mechanical property of a Ni-based superalloy K35 blade

A gas turbine blade of Ni-based superalloy K35 was chosen as the test casting and the effects of solidification parameters on microstructure and mechanical property of the blade were investigated.A software package was used to numerically simulate the mold filling and solidification process of the blade casting in order to obtain the solidification parameters in the casting.The secondary dendrite arm spacing and grain size at different positions of the blade casting were measured.The relationships of secondary dendrite arm spacing and grain size versus cooling rate and solidification time were quantitatively studied.The relationships of Vickers-hardness versus solidification structures are also studied.The results show that Vickers-hardness decreases with the increase of both grain size and secondary dendrite arm spacing.This offers a good basis to predict the microstructure and mechanical property of a gas turbine blade casting through numerical simulation in order to obtain a high-quality gas turbine blade casting.

Effect of Ta on solidification characteristics and mechanical properties of DZ411 Ni-based superalloy

The effects of Ta content(2.72wt.%,3.10wt.%and 4.00wt.%)on the solidification characteristics and mechanical properties of directionally solidified DZ411 Ni-based superalloys were investigated.It is found that the content of Mo decreases with the increase of Ta in liquid phase after directional solidification,indicating the addition of Ta can reduce the element segregation in alloys.The primary and secondary dendrite arm spacings(PDAS and SDAS)of the DZ411 alloy increase with the addition of Ta,which are consistent with the models by Hunt and Wagner.The increase of PDAS and SDAS can provide enough space for the growth of tertiary dendrite arms,which hinders the growth of unfavorably oriented primary dendrites.As a result,the addition of Ta facilitates the growth of favorably oriented dendrites.More MC carbides andγ-γ'eutectics are formed in the interdendritic regions,which is attributed to the segregation of Ta in the liquid phase.Furthermore,the degree of supersaturation of W,Mo inγmatrix increases with the increase of Ta,thus,the addition of Ta promotes the formation of TCP phase.The addition of Ta also increases the microhardness in both the primary dendrite and interdendritic regions of the alloy,and the microhardness of the primary dendrite is closer to that in interdendritic regions with the increase of Ta.