Effect of melt superheat on structural uniformity of lotus-type porous metals prepared by unidirectional solidification

Structural uniformity is an important parameter influencing physical and mechanical properties of lotus-type porous metals prepared by directional solidification of metal-gas eutectic (Gasar). The effect of superheat on structural uniformity as well as average porosity, pore morphology of porous metals was studied. The experimental results show that, when the superheat is higher than a critical value (ΔTc), the bubbling or boiling phenomenon will occur and the gas bubbles will form in the melt and float out of the melt. As a result, the final porosity will decrease. In addition, a higher superheat will simultaneously cause a non-uniform porous structure due to the pores coalescence and bubbling phenomenon. Finally, a theoretical model was developed to predict the critical superheat for the hydrogen to escape from the melt and the corresponding escapement ratio of hydrogen content. Considering the escapement of hydrogen, the predicted porosities are in good agreement with the experimental results.

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.

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.

An extended social force model on unidirectional flow considering psychological and behavioral impacts of hazard source

An accurate assessment of the evacuation efficiency in case of disasters is of vital importance to the safety design of buildings and street blocks.Hazard sources not only physically but psychologically affect the pedestrians,which may further alter their behavioral patterns.This effect is especially significant in narrow spaces,such as corridors and alleys.This study aims to integrate a non-spreading hazard source into the social force model following the results from a previous experiment and simulation,and to simulate unidirectional pedestrian flows over various crowd densities and clarity–intensity properties of the hazard source.The integration include a virtual repulsion force from the hazard source and a decay on the social force term.The simulations reveal(i)that the hazard source creates virtual bottlenecks that suppress the flow,(ii)that the inter-pedestrian push forms a stabilisation phase on the flow-density curve within medium-to-high densities,and(iii)that the pedestrians are prone to a less orderly and stable pattern of movement in low clarity–intensity scenarios,possibly with lateral collisions passing the hazard source.

Tailoring the texture and mechanical properties of 3%Y_(2)O_(3)p/ZGK200 composites fabricated by unidirectional and cross rolling followed by annealing

3%Y_(2)O_(3)p/ZGK200 composites were subjected to unidirectional rolling(UR)and cross rolling(CR)at 400℃and 350℃followed by annealing at 300℃for 1 h.The microstructure,texture and mechanical properties of rolled and annealed composites were systematically studied.The rolled composites exhibited a heterogeneous microstructure,consisting of deformed grains elongated along rolling direction(RD)and Y_(2)O_(3)particles bands distributed along RD.After annealing,static recrystallization(SRX)occurred and most deformed grains transformed into equiaxed grains.A non-basal texture with two strong T-texture components was obtained after UR while a non-basal elliptical/circle texture with circle multi-peaks was obtained after CR,indicating that rolling path had great influences on texture of the composites.After annealing process,R-texture component disappeared or weakened,as results,a non-basal texture with double peaks tilting from normal direction(ND)to transverse direction(TD)and a more random non-basal texture with circle multi-peaks were obtained for UR and CR composites,respectively.The yield strength of rolled composites after UR showed obvious anisotropy along RD and TD while a low anisotropic yield strength was obtained after CR.Some Y_(2)O_(3)particles broke during rolling.The fracture of the composites was attributed to the existence of Y_(2)O_(3)clusters and interfacial debonding between particles and matrix during tension,as a result,the ductility was not as superior as matrix alloy.

Frost deformation and microstructure evolution of porous rock under uniform and unidirectional freeze-thaw conditions

The frost deterioration and deformation of porous rock are commonly investigated under uniform freeze-thaw(FT)conditions.However,the unidirectional FT condition,which is also prevalent in engineering practice,has received limited attention.Therefore,a comparative study on frost deformation and microstructure evolution of porous rock under both uniform and unidirectional FT conditions was performed.Firstly,frost deformation experiments of rock were conducted under cyclic uniform and unidirectional FT action,respectively.Results illustrate that frost deformation of saturated rock exhibits isotropic characteristics under uniform FT cycles,while it shows anisotropic characteristics under unidirectional FT condition with both the frost heaving strain and residual strain along FT direction much higher than those perpendicular to FT direction.Moreover,the peak value and residual value of cumulative frost strain vary as logarithmic functions with cycle number under both uniform and unidirectional FT conditions.Subsequently,the microstructure evolution of rock suffered cyclic uniform and unidirectional FT action were measured.Under uniform FT cycles,newly generated pores uniformly distribute in rock and pore structure of rock remains isotropic in micro scale,and thus the frost deformation shows isotropic characteristics in macro scale.Under unidirectional FT cycles,micro-cracks or pore belts generate with their orientation nearly perpendicular to the FT direction,and rock structure gradually becomes anisotropic in micro scale,resulting in the anisotropic characteristics of frost deformation in macro scale.

Advantages of rapid solidification over casting of Mg-0.4Zn-1Y alloy

The Mg-Y-Zn magnesium alloy system is commonly recognized for its remarkable combination of high strength and ductility,achieved even with minimal amounts of alloying elements.This exceptional performance is attributed to its unique microstructure,which includes Long-Period Stacking Ordered(LPSO)phases or the distinctive microstructure derived from the LPSO phase,referred to as the Mille-Feuille structure(MFS).This study systematically compares the traditional ingot metallurgy method with the rapid solidification technique,coupled with diverse heat treatments and extrusion processes.Microscopic analyses reveal variations in the presence of LPSO phases,Mille-Feuille structure,and grain size,leading to divergent mechanical and corrosion properties.The rapid solidification approach stands out,ensuring superior mechanical properties alongside a reasonable corrosion rate.

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.

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.

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.

Numerical simulation on directional solidification and heat treatment processes of turbine blades

Study on turbine blades is crucial due to their critical role in ensuring the efficient and reliable operation of aircraft engines.Nickel-based single crystal superalloys are extensively used in the hot manufacturing of turbine blades due to their exceptional high-temperature mechanical properties.The hot manufacturing of single crystal blades involves directional solidification and heat treatment.Experimental manufacturing of these blades is time-consuming,capital-intensive,and often insufficient to meet industrial demands.Numerical simulation techniques have gained widespread acceptance in blade manufacturing research due to their low energy consumption,high efficiency,and rapid turnaround time.This article introduces the modeling and simulation of hot manufacturing in single crystal blades.The discussion outlines the prevalent mathematical models employed in numerical simulations related to blade hot manufacturing.It encapsulates the advancements in research concerning macro to micro-level numerical simulation techniques for directional solidification and heat treatment processes.Furthermore,potential future trajectories for the numerical simulation of single crystal blade hot manufacturing are also discussed.

Effect of TiB_(2)Nanoparticles on Microstructure and Mechanical Properties of Ni_(60)Cr_(21)Fe_(19)Alloy in Rapid Directional Solidification Process:Molecular Dynamics Study

Molecular dynamics(MD)simulations are employed to delve into the multifaceted effects of TiB2 nanoparticles on the intricate grain refinement mechanism,microstructural evolution,and tensile performance of Inconel 718 superalloys during the rapid directional solidification.Specifically,the study focuses on elucidating the role of TiB2 nanoparticles in augmenting the nucleation rate during the rapid directional solidification process of Ni60Cr21Fe19 alloy system.Furthermore,subsequent tensile simulations are conducted to comprehensively evaluate the anisotropic behavior of tensile properties within the solidified microstructures.The MD results reveal that the incorporation of TiB₂nanoparticles during the rapid directional solidification of the Ni_(60)Cr_(21)Fe_(19)significantly enhances the average nucleation rate,escalating it from 1.27×10^(34)m^(-3)·s^(-1)to 2.55×10^(34)m^(-3)·s^(-1).Notably,within the face centered cube(FCC)structure,Ni atoms exhibit pronounced compositional segregation,and the solidified alloy maintains an exceptionally high dislocation density reaching up to 10^(16)m^(-2).Crucially,the rapid directional solidification process imparts a distinct microstructural anisotropy,leading to a notable disparity in tensile strength.Specifically,the tensile strength along the solidification direction is markedly superior to that perpendicular to it.This disparity arises from different deformation mechanisms under varying loading orientations.Tensile stress perpendicular to the solidification direction encourages the formation of smooth and organized mechanical twins.These twins act as slip planes,enhancing dislocation mobility and thereby improving stress relaxation and dispersion.Moreover,the results underscore the profound strengthening effect of TiB2 nanoparticles,particularly in enhancing the tensile strength along the rapid directional solidification direction.

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.

Hydrogen diffusion coefficient in liquid metals evaluated by solid-gas eutectic unidirectional solidification

Based on the solid-gas eutectic unidirectional solidification technique and the principle of unidirectional solidification of single-phase alloy, a new method for evaluating the diffusion coefficient of hydrogen in liquid metals was proposed. Taking Cu-H2 system for example, the influences of argon partial pressure and superheat degree of melt on the diffusion coefficient of hydrogen in liquid metal were studied and the predicted values were similar to each other. The obtained temperature-dependent equation for diffusion coefficient of hydrogen in liquid copper is comparable with experimental data in literature, which validates the effectiveness of this method. The temperature-dependent equations for diffusion coefficient of hydrogen in liquid Mg, Si and Cu-34.6%Mn alloy were also evaluated by this method, along with the values at the melting point of each metal and alloy.

Fabrication of pure copper rods containing continuous columnar crystals by continuous unidirectional solidification technology

Pure copper rods containing continuous columnar crystals were fabricatedusing the downward CUS (Continuous Unidirectional Solidification) equipment. When the technologicalparameters were set as the ranges of mould temperature 1100-1300℃, cooling distance (the distancefrom the exit of the cast mould to the start point of cooling) 10-20 mm, casting speed 0.2-2.5 mm/s,cooling water (20-25℃) volume 1000-1320 L/h, and when these parameters matched reasonably, the CUSprocess was performed stably, and pure copper rods containing continuous columnar crystals withbright and smooth surface were produced. The dendritic arm spacing of the crystals in copper rodsdecreased with increasing the casting speed. The results of the texture by X-ray diffractionanalysis showed that the rods has strong <100> fiber texture.

Formation of twinned dendrites during unidirectional solidification of Al-32%Zn alloy

The present study focused on the formation and crystallographic orientation of twinned dendrites coexisting with equiaxed grains in unidirectional solidification of Al-32%Zn(mass fraction)alloy.The morphology was investigated by optical metallograph and electron back-scattered diffraction technique.Results showed that the macrostructure of the alloy exhibited a typical feathery and fan-like structure while the microstructures were elongated lamellas,which were separated by coherent and incoherent twin boundaries.Both the primary trunk and all lateral arms of twinned dendrites grew along〈110〉directions,unlike regular〈100〉α(Al)dendrites.The facet growth of crystals at solid/liquid interface was responsible for the origin of twinned dendrites during the weak local convection,and high thermal gradient and medium solidification velocity had significant contribution to the formation of twinned dendrites.The formation mechanism of twinned dendrites which consisted of three multiplication ways of new twin boundaries formation and one way of dendrite evolution in twin plane was shown schematically.

Continuous unidirectional solidification of QAl9-4 Cu-Al alloy

A continuous unidirectional solidification equipment with the advantages of electric slag remelting, induction heating, continuous casting and unidirectional solidification was built to study the QAl9 4 Cu Al alloy. The results show that the electro slag induction continuous unidirectional solidification process can be used for the steady continuous unidirectional solidification of QAl9 4, and revitalizes the down pulling continuous unidirectional solidification process; that the temperature distribution in the mold wall reflects that of the molten metal in the mold, thus the temperature distribution in the mold wall can be used to control the electric slag induction continuous unidirectional solidification process; and that the mutual matching of the technological parameters is the key to stabilize the solidification process.

Macrostructure and properties of thin walled copper tubes prepared by the downward continuous unidirectional solidification method

The macrostructure and properties of the thin walled copper tube prepared by the downward continuous unidirectional solidification （DCUS） method were studied. The result shows that the macrostructure is closely related to the solid-liquid interface profile, which is influenced by the distance between the cooling water location and the solidification front. The mechanical properties of the thin walled copper tube prepared by the DCUS method are near those of the normal cast copper, and it has good relative density, electrical conductivity, and elongation, which are not greatly affected by casting speed. The thin walled copper tube prepared by the DCUS method also has good processing properties that can be taken to further drawing procedures directly without an intermediate process, and obtains good mechanical properties with the total processing rate of 89.8%.