Effect of cold rolling deformation on microstructure evolution and mechanical properties of spray formed Al−Zn−Mg−Cu−Cr alloys

The impact of cold rolling deformation,which was introduced after solid solution and before aging treatment,on microstructure evolution and mechanical properties of the as-extruded spray formed Al−9.8Zn−2.3Mg−1.73Cu−0.13Cr(wt.%)alloy,was investigated.SEM,TEM,and EBSD were used to analyze the microstructures,and tensile tests were conducted to assess mechanical properties.The results indicate that the D1-T6 sample,subjected to 25%cold rolling deformation,exhibits finer grains(3.35μm)compared to the D0-T6 sample(grain size of 4.23μm)without cold rolling.Cold rolling refines the grains that grow in solution treatment.Due to the combined effects of finer and more dispersed precipitates,higher dislocation density and smaller grains,the yield strength and ultimate tensile strength of the D1-T6 sample can reach 663 and 737 MPa,respectively.In comparison to the as-extruded and D0-T6 samples,the yield strength of the D1-T6 sample increases by 415 and 92 MPa,respectively.

Microstructure of spray formed Al-Zn-Mg-Cu alloy with Mn addition

With the aim to improve the strength of Al-Zn-Mg-Cu alloy,the alloy billet containing Mn was produced by spray forming method,and the microstructural features were investigated using X-ray diffraction（XRD）,optical microscopy（OM）,scanning electron microscopy（SEM）,transmission electron microscopy（TEM） and differential scanning calorimetry（DSC）.The results show that the billet mainly consists of fine equiaxial grains of MgZn2 and Al6Mn with size ranging from 5 μm to 25 μm.Nano-scaled MgZn2 is dispersed in the as-sprayed alloy,primary Al6Mn particles are precipitated at grain boundaries with an average size of 5 μm.A few CuAl2,Al3Zr and eutectic are also found in as-sprayed Al alloy.The volume fraction of the porosity is about 12%.DSC result indicates that most of the solutes are precipitated during spray forming process,and no obviously thermal effects occur below 450 ℃.Both matrix grains and Al6Mn particles grow monotonously with the increase of annealing temperature,but the growth rate of Al6Mn particles is markedly lower than that of Al grains,and the matrix grains grow rapidly when the annealing temperature is above 375 ℃.

HEAT TRANSFER BEHAVIOR OF SUPERALLOY DROPLETS DURING SPRAY FORMING

Based on the Newtonian heat transfer formulation and classical heterogeneous nucleation theory, a mathematical model has been established to predict the profile of flight velocity, heat transfer coefficient, temperature, solid fraction and cooling rate of atomizing droplets for a superalloy. The results indicated that above parameters change with different droplet size and flight distance. The changing trend as well as the mechanism for the change are described and discussed.

Plasma Spray Forming of Nanostructured Composite Coatings

The nanostructure composite coating is obtained via plasma spraying of Al2O3-13 wt pct TiO2 powder. Brittle and hard lamella results from melted nanostructured powder. Ductile nanostructured matrix forms from unmelted nanostructured particles. Through the adjustment of constituent and nanostructure, hardness/strength and toughness/ductility are balanced and overall properties of the structure composite are achieved.

Fatigue strength and microstructure evaluation of Al 7050 alloy wires recycled by spray forming,extrusion and rotary swaging

Recycled high-strength aluminum alloys have limited use as structural materials due to poor mechanical properties. Spray forming remelting followed by hot extrusion is a promising route for reprocessing 7 xxx alloys. The 7050 alloy machining chips were spray formed, hot extruded, rotary swaged and heat-treated in order to improve mechanical properties. Microstructures, tensile properties and fatigue strength results for a 2.7 mm-diameter recycled wire are presented. Secondary phases and precipitates were investigated by XRD, SEM, EBSD, TEM and DSC. As-swaged and heat-treated(solution and aging) conditions were evaluated. Mechanical properties of both conditions outperformed AA7050 aerospace specification. Substantial grain refinement resulted from the extensive plastic deformation imposed by rotary swaging. Refined micrometric and sub-micrometric Al grains, as well as coarse and fine intermetallic precipitates were observed. Subsequent solution treatment resulted in a homogeneous, recrystallized and equiaxed microstructure with grain size of 9 μm. Nanoscale GP(I) zones and η′ phase precipitates formed after aging at 120 ℃, imparting higher tensile(586 MPa) and fatigue(198 MPa) strengths.

Production of high strength Al-Zn-Mg-Cu alloys by spray forming process

High strength Al Zn Mg Cu alloys were produced by spray forming process, and compacted by hot extrusion. The results show that the as deposited billets have fine grained microstructure and low porosity. After heat treatment, mechanical properties increase greatly: tensile strength up to 754 MPa, yield strength up to 722 MPa, fracture elongation up to 8%, and elastic modulus up to 72 GPa, respectively. [

MICROSTRUCTURAL CHARACTERISTICS AND MECHANICAL PROPERTIES OF SPRAY FORMED HIGH SPEED STEEL FOR WORK ROLL

The mechanical properties and microstructure characteristics of a high speed steel (HSS) for roll has been studied. As compared with the as-cast HSS, the spray-formed HSS have fine grain and segregation free microstructures. Carbides distribute uniformly. The morphology and types of the carbides in spray-formed HSS are different from those in as-cast HSS. The results of the high temperature tensile experiment show that, as to spray-formed HSS, there is a possibility of superplastic deformation in the range of 780-810℃.

Isothermal grain growth of reactive spray formed 7075 alloys in semi-solid state

The grain growth behavior in reactive spray formed 7075+2.91 vol percent TiCAl alloy was studied and compared with that of spray formed 7075 Al alloy at semi-solid state. Theeffects of in-situ TiC particles on the microstructure of spray formed 7075 Al alloy were alsoinvestigated. The specimens were heat-treated isothermally at various temperatures between thesolidus and liquidus of 7075 Al alloy for times in the range of 10-60 min, then quenched in water.The microstructure of reheated specimens was characterized using scanning electron microscopy andoptical microscopy. The grain size was measured using a mean linear intercept method. Results showthat the in-situ TiC particles can effectively retard grain growth and refine the grain at a limitedsize. The grain growth exponent in Arrhenius equation increases from 2 to 3, which indicates thatthe in-situ TiC particles have the significant pinning effect on grain coarsening in the semi-solidstate.

Microstructural Features and Mechanical Properties Induced by the Spray Forming and Cold Rolling of the Cu-13.5 wt pct Sn Alloy

Copper alloys with high strength and high conductivity are an important functional material with full of potential applications. In the present investigation, a bronze with higher tin content （Cu-13.5 wt pct Sn） was prepared successfully by spray forming, the feasibility of cold roiling this alloy was investigated, and the cold roiling characteristics of this alloy have also been discussed. The results indicate that the spray-formed Cu-13.5 wt pct Sn alloy, compared with the as-cast ingot, shows a quite fine and homogeneous single-phase structure, and, therefore shows an excellent workability. It can be cold-roiled with nearly 15% reduction in the thickness per pass and the total reduction can reach 80%. The classical border between the wrought and cast alloys is shifted to considerably higher tin contents by spray forming. After proper thermo-mechanical treatment, spray-formed Cu-13.5 wt pct Sn alloy exhibits excellent comprehensive mechanical properties. Particularly, it shows a low elastic modulus （-88 GPa） and a high flow stress （over 800 MPa） after cold forming. This combination of properties is unique in the domain of metallic materials and could open new possibilities in spring technology field.

Shape-predicted model of spray forming rod under scanning atomization

A model for simulating the spray forming process with scanning atomizer was developed.Models for the scanning atomization and the deposition processes were coupled together in order to obtain a new description of the spray forming process.The model,which is able to predict the shape of a spray-formed billet prepared with scanning atomizer,was established after analyzing the changes in droplet size and density distribution along the r-axis in the spray cone in scanning atomization.The effects of the two kinds of atomization were compared,showing that the scanning atomization is good for deposition.

Research on flow stress of spray formed 70Si30Al alloy under hot compression deformation

The flow stress of spray formed 70Si30Al alloy was studied by hot compression on a Gleeble- 1500 test machine. The experimental results indicated that the flow stress depends on the strain rate and the deformation temperature. The flow stress increases with an increase in strain rate at a given deformation temperature. The flow stress decreases with the deformation temperature increasing at a given strain rate. The relational expression among the flow stress, the swain rate, and the deformation temperature satisfies the Arrhenius equation. The deformation activation energy of 70Si30Al alloy during hot deformation is 866.27 kJ/mol from the Arrhenius equation.

Effect of P/M value on the preforms and microstructures of spray formed 70Si30Al alloy

A novel 70Si30Al alloy was prepared by the spray forming process for electronic packaging materials. The effect of the ratio of atomization pressure to metal melt mass flux rate （P/M） on the preforms and microstructures of the spray-deposited 70Si30Al alloy was studied. The results indicate that the PIM value has a considerable influence on the formation of the preforms and the optimal value is in the range of 0.209-0.231 MPa/（kg.min^-1）. The microstructure of the spray formed 70Si30AI alloy is fine and homogenous. The primary silicon phases distributing in the aluminum matrix evenly are fine and irregular. The aluminum matrix is divided into two groups： supersaturated α-Al phase or α-Al phase and Al-Si pseudoeutectic phase or Al-Si eutectic phase.

Modeling and Simulation of the Microstructure Evolution of the Gas-atomized Alloy Droplets during Spray Forming

In order to understand the solidification process of an atomized droplet and predict the fraction solidification of droplets with flight distance during spray forming, a numerical model based on the population dynamics approach is developed to describe the microstructure evolution under the common action of the nucleation and growth of grains. The model is coupled with droplets heat transfer controlling equations and solved for AI-4.5 wt pct Cu alloy. It is demonstrated that the numerical results describe the solidification process well.

Deformation mechanism of the spray formed 70Si30Al alloy during hot compression

The deformation mechanism of the spray formed 70Si30Al alloy was studied by hot compression on a Gleeble-1500 test machine. It is shown that hot deformation of the spray formed 70Si30Al alloy is achieved by liquid flow due to isostatic pressure and movement of solid particles due to shear force. Deformation condition depends on the nucleation rate and closure rate of the cavities. The flow stress slightly varies when the difference between the nucleation rate and closure rate of the cavities is small; however, it decreases when the nucleation rate of the cavities is greater than the closure rate of the cavities.

Experimental and mathematical modeling of metal spray forming process

The metal spray forming process was examined using mathematical simulation and verified through the prototyping evaluation at Baosteel＇ s test and development facilities. The mathematical model comprised of four sections, including jet gas flow in the deposition chamber;single droplet behavior along its trajectory path;probability and statistical analysis of droplet mass behavior, and forecast of the shape and temperature distribution of the billet during the spray forming process.

Microstructure of the spray formed Vanadis4 cold work die steel and its evolution during hot rolling and heat treatment

A high alloyed Vanadis4 （V4） steel was produced by spray forming process in Baosteel, and the microstructure of the as-sprayed steel and its evolution during hot rolling and annealing processes were characterized. It was found that the as-sprayed V4 steel has a homogeneous and fine scale rrficrostructure with uniform dispersion of carbides. The hot rolling temperature is the key factor in controlling the evolution of type, morphology and distribution of carbides, as well as the matrix microstructure of the as-rolled steels. The optimized processing parameters for the as-sprayed V4 steel are rolling at 1050℃ and then annealing at 900℃. The microstructural evolution mechanisms during hot rolling and annealing are determined according to the microstructural analyasis of the material at different stages.

Effect of Retrogression and Reaging on Stress Corrosion Cracking of Spray Formed Al Alloy

Stress corrosion cracking (SCC) resistance of a spray formed Al-Zn-Mg-Cu alloy underwent retrogression and reaging (RRA) was studied by slow strain rate tests in dry air and 3.5 wt% NaCl solution. The results showed that after RRA treatment, interrupted η phases at grain boundaries and slightly wide precipitate free zones could decrease SCC susceptibility of the alloy. Lots of reticular dislocations appeared in deformation process could prevent hydrogen induced cracking, and then SCC. Abundance transgranular dispersive η' phases separated out again promoted tensile strength to 759.4 MPa. The fracture ways of the specimens were dimple fracture in dry air and sub-cleavage fracture in 3.5% NaCl solution.

Strength and elongation of spray formed Al–Si–Pb alloys

The strength and elongation to fracture of spray deposited Al-Si-Pb alloys were studied as a function of lead content, silicon content, and distance from the centre to periphery of the deposit. It is found that the ultimate tensile strength, proof stress and elongation to fracture decrease, linearly and exponentially, with the increase in lead content and porosity of the deposit, respectively. Both the strengths and elongation to fracture linearly increase with increasing distance from the centre to periphery of the deposit. The ultimate tensile strength and proof stress are higher at a higher silicon content and they have a linear relationship with the hardness of the deposit.

Plasma Spray Forming

In the course of plasma spray, the plasma jet is comprehensively functioned by such effects as thermal pinch, magnetic pinch and mechanical compression and the flow is jetting at a high speed, the energy is concentrated and its center temperature is so high as to reach upwards of 15 000 ℃ which is capable of melting various kinds of materials inclusive of ceramic, it has a broad applied prospects in the fields of automobile, electronics, telecommunications, medical treatment, air navigation & space navigation and light industries etc because of being able to rapid fabricate thin-walled metals, ceramics and alloy parts thereof, metal moulds, functionally gradient material moulds and so on, and it has become a research spotlight for the scholars. The technology of plasma spray forming (PSF) is introduced, and the two different kinds of technique presented in this paper are studied. Some typical links in the course of technical process is also analyzed, including original prototype fabrication and surface treatment, post-treatment of formed workpiece and demoulding methods. When spraying, it should select the appropriate making methods of prototype according to the dimensions, shapes and forming accuracy as required by the formed parts. At the same time, it should be paid to the characteristic of the material for the prototype. The main purpose of surface treatment of the prototype is to raise the quality of formed parts and ensure the integrity demoulding of the coating. The method of the prototype’s surface treatment is closely related to the demoulding method, which is mainly comprised of destructive demoulding, non-destructive demoulding and composite demoulding, and is key technology in PSF. In order to eliminate these intrinsic defects and improve its performance, the fabricated parts can be given the necessary post-treatment so as to further raise the mechanical strength and surface quality. There are many methods for the post-treatment such as chemical reinforcment, metal melt-infiltration, laser-melting and self-propagating high-temperature synthesis, etc., all these methods can decrease the porosity and raise the quality of coating and service performance; whereas the finishing machining can improve the surface roughness of spray formed parts. In the course of spray forming, affected by such complex and complicated factors as electric field, the entangled ambient gas and introduced powder, as a result, it shall induce the instability of the spray condition and affect the forming quality. This paper has, on the basis of large quantity of experiments, analyzed every links in the course of PSF, summarized and evaluated the main factors affecting on the quality of formed parts, such as prototype characteristic, characteristic of plasma jet, powder characteristic, spray gun and spray parameters. The experiments prove that the process of PSF is simple and the cost is lower in rapid tooling with complex and complicated fine patterns, and PSF is apt to form special-shape and thin-walled parts made of some protective materials so as to protect those fragile workpieces. Therefore PSF is a new technology with broad and brilliant prospects of development.

Spray forming and mechanical properties of a new type powder metallurgy superalloy

The deposited billet of a new type powder metallurgy （PM） superalloy FGH4095M for use in turbine disk manufac- turing has been fabricated using spray forming technology. The metallurgical quality of the deposited billet was analyzed in terms of density, texture, and grain size. Comparative research was done on the microstructure and mechanical properties between the flat disk preform prepared with hot isostatic pressing （HIP） and the same alloy forgings prepared with HIP followed by isothermal forging （IF）. The results show that the density of the spray-formed and nitrogen-atomized deposit billet is above 99% of the theoretical density, indicating a compact structure. The grains are uniform and fine. The billet has weak texture with a random distribution in the spray deposition direction and perpendicular to the direction of deposition. A part of atomizing nitrogen exists in the preform in the form of carbonitride. Nitrogen-induced microporosity causes the density reduction of the preform. Compared with the process of HIP＋IF, the superalloy FGH4095M after HIP has better mechanical properties at both room temperature and high temperature. The sizes of the 7~ phase are finer in microstructure of the preform after HIP in comparison with the forgings after HIP＋IE This work shows that SF＋HIP is a viable processing route for FGH4095M as a turbine-disk material.