Effect of Co on Solidification Characteristics and Microstructural Transformation of Non-equilibrium Solidified Cu-Ni Alloys

Non-equilibrium solidification structures of Cu55Ni45 and Cu55Ni43Co2 alloys were prepared by the molten glass purification cycle superheating method.The variation of the recalescence phenomenon with the degree of undercooling in the rapid solidification process was investigated using an infrared thermometer.The addition of the Co element affected the evolution of the recalescence phenomenon in Cu-Ni alloys.The images of the solid-liquid interface migration during the rapid solidification of supercooled melts were captured by using a high-speed camera.The solidification rate of Cu-Ni alloys,with the addition of Co elements,was explored.Finally,the grain refinement structure with low supercooling was characterised using electron backscatter diffraction(EBSD).The effect of Co on the microstructural evolution during nonequilibrium solidification of Cu-Ni alloys under conditions of small supercooling is investigated by comparing the microstructures of Cu55Ni45 and Cu55Ni43Co2 alloys.The experimental results show that the addition of a small amount of Co weakens the recalescence behaviour of the Cu55Ni45 alloy and significantly reduces the thermal strain in the rapid solidification phase.In the rapid solidification phase,the thermal strain is greatly reduced,and there is a significant increase in the characteristic undercooling degree.Furthermore,the addition of Co and the reduction of Cu not only result in a lower solidification rate of the alloy,but also contribute to the homogenisation of the grain size.

Preparation of Laser Cladding Coating Undercooling Cu-based Alloy and Co on Non-equilibrium Solidification Structure

The effect of the gradient content of Co element on the solidification process of Cu-based alloy under deep under cooling conditions was explored.The non-equilibrium solidification structure of the under cooled alloy samples were analyzed.It is found that the rapidly solidified alloy has undergone twice grain refinement during the undercooling process.Characterization and significance of the maximum undercooling refinement structure of Cu60Ni35Co5 at T=253 K were analyzed.High-density defects were observed,such as dislocations,stacking faults networks,and twinning structures.The standard FCC diffraction pattern represents that it is still a single-phase structure.Based on the metallographic diagram,EBSD and TEM data analysis,it is illustrated that the occurrence of grain refinement under high undercooling is due to stress induced recrystallization.In addition,the laser cladding technology is used to coat Co-based alloy(Stellite12) coating on 304 stainless steel substrate;the microstructure of the coating cross-section was analyzed.It was found that the microstructure of the cross-section is presented as columnar crystals,planar crystals,and disordered growth direction,so that the coating has better hardness and wear resistance.By electrochemical corrosion of the substrate and coating,it can be seen that the Co and Cr elements present in the coating are more likely to form a dense passivation film,which improved the corrosion resistance of the coating.

Effect of solidification cooling rate on microstructure and tribology characteristics of Zn-4Si alloy

The main objective of this work was to modify the microstructure and enhance the tribological properties of a new Zn-4Si al-loy through a high solidification cooling rate(SCR).According to the results,by increasing the SCR from 2.0 to 59.5℃/s the average size of primary Si particles and that of the grains reduced from 76.1 and 3780μm to less than about 14.6 and 460μm,respectively.Augment-ing the SCR also enhanced the microstructural homogeneity,decreased the porosity content(by 50%),and increased the matrix hardness(by 36%).These microstructural changes enhanced the tribological behavior.For instance,under the applied pressure of 0.5 MPa,an in-crease in the SCR from 2.0 to 59.5℃/s decreased the wear rate and the average friction coefficient of the alloy by 57%and 23%,respect-ively.The wear mechanism was also changed from the severe delamination,adhesion,and abrasion in the slowly-cooled alloy to the mild tribolayer delamination/abrasion in the high-cooling-rate-solidified sample.

Effects of mechanical vibration on filling and solidification behavior, microstructure and performance of Al/Mg bimetal by lost foam compound casting

Al/Mg bimetal was prepared by lost foam solid-liquid compound casting,and the effects of mechanical vibration on the filling and solidification behavior,microstructure and performance of the bimetal were investigated.Results show that the mechanical vibration has a remarkable influence on the filling and solidification processes.It is found that after mechanical vibration,the filling rate increases and the filling rate at different times is more uniform than that without vibration.In addition,the mechanical vibration also increases the wettability between liquid AZ91D and A356 inlays.The mechanical vibration reduces the horizontal and vertical temperature gradient of the casting and makes the temperature distribution of the whole casting more uniform.Compared to the Al/Mg bimetal without vibration,the shear strength is improved by 39.76%after the mechanical vibration is applied,due to the decrease of the inclusions and Al_(12)Mg_(17) dendrites,and the refinement and uniform distribution of the Mg_(2)Si particles in the interface of the Al/Mg bimetal.

Effect of Cooling Rates on Solidification Microstructures and Tensile Property of a Novel Wrought Superalloy

The effects of cooling rates on solidification behaviors,segregation characteristics and tensile property of GH4151 alloy were investigated using microstructure characterization and tensile test.Firstly,a relationship between the secondary dendrite arm spacing and cooling rate was determined and it was confirmed to be valid.Secondly,it can be found from microstructure observations that the morphology of(Nb,Ti)C carbides transits from blocky and script type to fine script type and spotty type,and the refinedγ'phase was observed due to decrease of segregation with increasing cooling rates.Thirdly,the solidification microstructures of the industrial-scale samples were analyzed.The morphology ofηphase changes from indistinguishable shape,fine needle-like shape to large block-like shape with increasing ingot diameter.As a result,the mechanical properties of alloy decrease due to increase of brittle precipitations.The experimental results show that the precipitation behavior of GH4151 is affected by segregation degree of elements,and the segregation degree is determined by solute distribution process and solid back-diffusion process.

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.

Simulation and Optimization of the Fluid Solidification Process in Brazed Plate Heat Exchangers

When a brazed plate heat exchanger is used as an evaporator,the working mass in the channel may undergo soli-dification,thereby hindering the refrigeration cycle.In this study the liquid solidification process and its optimi-zation in a brazed plate heat exchanger are investigated numerically for different inlet velocities;moreover,different levels of corrugation are considered.The results indicate that solidificationfirst occurs around the con-tacts,followed by the area behind the contacts.It is also shown that deadflow zones exist in the sharp areas and such areas are prone to liquid solidification.After optimization,the solidification area attains its smallest value when a corrugation spacingλ=4.2 mm is considered.

Comparative analysis of isothermal and non-isothermal solidification of binary alloys using phase-field model

Based on the entropy function, a two-dimensional phase field model of binary alloys was established. Meanwhile, an explicit difference method with uniform grid was adopted to solve the phase field and solute field controlled equations. And the alternating direction implicit(ADI) algorithm for solving temperature field controlled equation was also employed to avoid the restriction of time step. Some characteristics of the Ni-Cu alloy were captured in the process of non-isothermal solidification, and the comparative analysis of the isothermal and the non-isothermal solidification was investigated. The simulation results indicate that the non-isothermal model is favorable to simulate the real solidification process of binary alloys, and when the thermal diffusivity decreases, the non-isothermal phase-field model is gradually consistent with the isothermal phase-field model.

Development of Low-carbon and Sustainable Magnesium-bearing Cementitious Materials-based Solidification Approaches for Management of Problematic Soils

The production of traditional cementitious binders such as calcium-based Portland cement poses a serious challenge to the environment and society.Therefore,low-carbon,green and sustainable magnesium-based cementitious materials are developed to replace fully or partly Portland cement and reduce the consumption of natural resources and CO_(2)emissions.Three interesting techniques,including reactive MgO-activated industrial solid wastes,MgO-based cement and carbonation of magnesium-bearing materials,are elucidated to point to the necessity for developing novel magnesium-based cementitious materials.In the coming future,the carbonation of magnesium-rich industrial solid wastes or its combination with reactive MgO for application in various construction sectors such as soft ground improvement and concrete fabrication would be a promising approach to generate high-value products based on industrial solid wastes.

Solidification/Stabilization of Chromium in Red Mud-based Geopolymer

Up to 1.5wt%of Cr(Ⅲ)salts(CrCl_(3),and Cr_(2)O_(3))and Cr(Ⅵ)salts(Na_(2)CrO_(4),and CaCr_(2)O_(7))were incorporated into red mud-based geopolymers,respectively.The solidification/stabilization,compressive strength,and durability of the Cr-containing geopolymers were investigated.The experimental results indicate that the red mud-based geopolymer could effectively solidify/stabilize different types of Cr salts with solidification/stabilization rates of above 99.61%.Geopolymers are environmentally safe when the dosage of CaCr_(2)O_(7)is≤1.0wt%,or the dosage of CrCl_(3),Cr_(2)O_(3),and Na_(2)CrO_(4)is≤1.5wt%,respectively.The effects of Cr salts on the compressive strength varies with the type and content of Cr salts.The freeze-thaw cycle is more destructive to geopolymer properties than sulfate attack or acid rain erosion.The solidification/stabilization of Cr is mainly attributed to the following reasons:a)The chemical binding of Cr is related to the formation of Cr-containing hydrates(eg,magnesiochromite((Mg,Fe)(Cr,Al)_(2)O_(4)))and doping into N-A-S-H gel and C-A-S-H gel framework;b)The physical effect is related to the encapsulation by the hydration products(e g,N-A-S-H gel and C-A-S-H gel).This study provides a reference for the treatment of hazardous Cr-containing wastes by solid waste-based geopolymers.

Irregular initial solidification by mold thermal monitoring in the continuous casting of steels:A review

Occasional irregular initial solidification phenomena,including stickers,deep oscillation marks,depressions,and surface cracks of strand shells in continuous casting molds,are important limitations for developing the high-efficiency continuous casting of steels.The application of mold thermal monitoring(MTM) systems,which use thermocouples to detect and respond to temperature variations in molds,has become an effective method to address irregular initial solidification phenomena.Such systems are widely applied in numerous steel companies for sticker breakout prediction.However,monitoring the surface defects of strands remains immature.Hence,indepth research is necessary to utilize the potential advantages and comprehensive monitoring of MTM systems.This paper summarizes what is included in the irregular initial solidification phenomena and systematically reviews the current state of research on these phenomena by the MTM systems.Furthermore,the influences of mold slag behavior on monitoring these phenomena are analyzed.Finally,the remaining problems of the formation mechanisms and investigations of irregular initial solidification phenomena are discussed,and future research directions are proposed.

Volume-averaged modeling of multiphase solidification with equiaxed crystal sedimentation in a steel ingot

Macrosegregation is a critical factor that limits the mechanical properties of materials.The impact of equiaxed crystal sedimentation on macrosegregation has been extensively studied,as it plays a significant role in determining the distribution of alloying elements and impurities within a material.To improve macrosegregation in steel connecting shafts,a multiphase solidification model that couples melt flow,heat transfer,microstructure evolution,and solute transport was established based on the volume-averaged Eulerian-Eulerian approach.In this model,the effects of liquid phase,equiaxed crystals,columnar dendrites,and columnar-to-equiaxed transition(CET)during solidification and evolution of microstructure can be considered simultaneously.The sedimentation of equiaxed crystals contributes to negative macrosegregation,where regions between columnar dendrites and equiaxed crystals undergo significant A-type positive macrosegregation due to the CET.Additionally,noticeable positive macrosegregation occurs in the area of final solidification in the ingot.The improvement in macrosegregation is beneficial for enhancing the mechanical properties of connecting shafts.To mitigate the thermal convection of molten steel resulting from excessive superheating,reducing the superheating during casting without employing external fields or altering the design of the ingot mold is indeed an effective approach to control macrosegregation.

Exploration of the coupled lattice Boltzmann model based on a multiphase field model:A study of the solid-liquid-gas interaction mechanism in the solidification process

A multiphase field model coupled with a lattice Boltzmann(PF-LBM)model is proposed to simulate the distribution mechanism of bubbles and solutes at the solid-liquid interface,the interaction between dendrites and bubbles,and the effects of different temperatures,anisotropic strengths and tilting angles on the solidified organization of the SCN-0.24wt.%butanedinitrile alloy during the solidification process.The model adopts a multiphase field model to simulate the growth of dendrites,calculates the growth motions of dendrites based on the interfacial solute equilibrium;and adopts a lattice Boltzmann model(LBM)based on the Shan-Chen multiphase flow to simulate the growth and motions of bubbles in the liquid phase,which includes the interaction between solid-liquid-gas phases.The simulation results show that during the directional growth of columnar dendrites,bubbles first precipitate out slowly at the very bottom of the dendrites,and then rise up due to the different solid-liquid densities and pressure differences.The bubbles will interact with the dendrite in the process of flow migration,such as extrusion,overflow,fusion and disappearance.In the case of wide gaps in the dendrite channels,bubbles will fuse to form larger irregular bubbles,and in the case of dense channels,bubbles will deform due to the extrusion of dendrites.In the simulated region,as the dendrites converge and diverge,the bubbles precipitate out of the dendrites by compression and diffusion,which also causes physical phenomena such as fusion and spillage of the bubbles.These results reveal the physical mechanisms of bubble nucleation,growth and kinematic evolution during solidification and interaction with dendrite growth.

Lunar In Situ Large-Scale Construction:Quantitative Evaluation of Regolith Solidification Techniques

Lunar habitat construction is crucial for successful lunar exploration missions.Due to the limitations of transportation conditions,extensive global research has been conducted on lunar in situ material processing techniques in recent years.The aim of this paper is to provide a comprehensive review,precise classification,and quantitative evaluation of these approaches,focusing specifically on four main approaches:reaction solidification(RS),sintering/melting(SM),bonding solidification(BS),and confinement formation(CF).Eight key indicators have been identified for the construction of low-cost and highperformance systems to assess the feasibility of these methods:in situ material ratio,curing temperature,curing time,implementation conditions,compressive strength,tensile strength,curing dimensions,and environmental adaptability.The scoring thresholds are determined by comparing the construction requirements with the actual capabilities.Among the evaluated methods,regolith bagging has emerged as a promising option due to its high in situ material ratio,low time requirement,lack of hightemperature requirements,and minimal shortcomings,with only the compressive strength falling below the neutral score.The compressive strength still maintains a value of 2–3 MPa.The proposed construction scheme utilizing regolith bags offers numerous advantages,including rapid and large-scale construction,ensured tensile strength,and reduced reliance on equipment and energy.In this study,guidelines for evaluating regolith solidification techniques are provided,and directions for improvement are offered.The proposed lunar habitat design based on regolith bags is a practical reference for future research.

Effect of cooling rate on solidification parameters and microstructure of A1-7Si-0.3Mg-0.15Fe alloy

The effects of cooling rate on the solidification parameters and microstructure of Al-7Si-0.3Mg-0.15 Fe alloy during solidification process were studied.To obtain different cooling rates,the step casting with five different thicknesses was used and the cooling rates and solidification parameters were determined by computer-aided thermal analysis method.The results show that at higher cooling rates,the primary α（Al） dendrite nucleation temperature,eutectic reaction temperature and solidus temperature shift to lower temperatures.Besides,with increasing cooling rate from 0.19 ℃/s up to 6.25 ℃/s,the secondary dendritic arm spacing decreases from 68 μm to 20 μm,and the primary dendritic volume fraction declines by approximately 5%.In addition,it reduces the length of Fe-bearing phase from 28 μm to 18 μm with a better uniform distribution.It is also found that high cooling rates make for modifying eutectic silicon into fibrous branched morphology,and decreasing block or lamella shape eutectic silicon.

Influence of pouring temperature on solidification behavior, microstructure and mechanical properties of sand-cast Mg-10Gd-3Y-0.4Zr alloy

Influence of the pouring temperature ranging from 680 to 780 ℃ on the solidification behavior, the microstructure and mechanical properties of the sand-cast Mg-10Gd-3Y-0.4Zr alloy was investigated. It was found that the nucleation undercooling of the a-Mg phase increased from 2.3 to 6.3 ℃. The average a-Mg grain size increased from 44 to 71 μm, but then decreased to 46 μm. The morphology of the eutectic compound transformed from a continuous network into a discontinuous state and then subsequently into an island-like block. The volume fraction of β-Mg_24RE_5 phase increased and its morphology transformed from particle into rod-like. The increase in pouring temperature increased the solute concentration. YS increased from 138 to 151 MPa, and UTS increased from 186 to 197 MPa. The alloy poured at 750 ℃ had optimal combining strength and ductility. The fracture surface mode transformed from quasi-cleavage crack into transgranular fracture, all plus the dimple-like fracture, with the micro-porosity and the re-oxidation inclusion as major defects. The average a-Mg grain size played a main role in the YS of sand-cast Mg-10Gd-3Y-0.4Zr alloy, besides other factors, i.e. micro-porosity, morphology of eutectic compounds, re-oxidation inclusion and solute concentration.

Preparation, microstructure and dislocation of solar-grade multicrystalline silicon by directional solidification from metallurgical-grade silicon

A vacuum directional solidification with high temperature gradient was performed to prepare low cost solar-grade multicrystalline silicon （mc-Si） directly from metallurgical-grade mc-Si. The microstructure characteristic, grain size, boundary, solid-liquid growth interface, and dislocation structure under different growth conditions were studied. The results show that directionally solidified multicrystalline silicon rods with high density and orientation can be obtained when the solidification rate is below 60 μm/s. The grain size gradually decreases with increasing the solidification rate. The control of obtaining planar solid-liquid interface at high temperature gradient is effective to produce well-aligned columnar grains along the solidification direction. The growth step and twin boundaries are preferred to form in the microstructure due to the faceted growth characteristic of mc-Si. The dislocation distribution is inhomogeneous within crystals and the dislocation density increases with the increase of solidification rate. Furthermore, the crystal growth behavior and dislocation formation mechanism of mc-Si were discussed.

Solidification process and microstructure evolution of bulk undercooled Co-Sn alloys

A series of Co-Sn alloys with Sn content ranging from 12% to 32%（mole fraction） were undercooled to different degrees below the equilibrium liquidus temperature and the solidification behaviors were investigated by monitoring the temperature recalescence and examing the solidification microstructures.A boundary clearly exists,which separates the coupled growth zone from the decoupled growth zone of eutectic phases for the alloys with Sn content ranging from 14% to 31%（mole fraction）.The other Co-Sn alloys out of this content range are hard to be undercooled into the coupled growth zone in the experiment.It is found that the so-called non-reciprocal nucleation phenomenon does not happen in the solidification of undercooled Co-Sn off-eutectic alloys.

Solidification characteristics and hot tearing susceptibility of Ni-based superalloys for turbocharger turbine wheel

The solidification characteristics and the hot tearing susceptibility were investigated on two Ni-based superalloys for turbocharger turbine wheel, K418 and K419. The segregation behaviors of the alloying elements and the precipitation phases were also studied. The results show that the solidification behavior of K419 alloy is complicated when compared with K418 due to the interdendritic segregation of many kinds of strong interdendritic partitioning elements in the remaining liquid at the final stage of solidification. The segregation of multiple elements in interdendritic liquid results in an extremely low solidus in K419. A long residual liquid stage is found during the solidification of K419, giving rise to reduced cohesion strength of dendrites and increased sensitivity to hot tearing. A hot tearing susceptibility coefficient（HTS） criterion is proposed based on a hot tearing sensitive model. The HTS value of K419 alloy is larger than that of K418 alloy.

Effect of configuration on magnetic field in cold crucible using for continuous melting and directional solidification

To improve the power efficiency and optimize the configuration of cold crucible using for continuous melting and directional solidification （DS）, based on experimental verification, 3D finite element （FE） models with various configuration-elements were developed to investigate the magnetic field in cold crucible. Magnetic flux density （B） was measured and calculated under different configuration parameters. These parameters include the inner diameter （D2）, the slit width （d）, the thickness of crucible wall, the section shape of the slit and the shield ring. The results show that the magnetic flux density in z direction （Bz） both at the slit and at the midpoint of segment will increase with the decrease of D2 or with the increase of the width of the slit and the section area of wedge slit or removing the shield ring. In addition, there is a worst wall thickness that can induce the minimum Bz for a cold crucible with a certain outer diameter.