Effect of melt holding on morphological evolution and sedimentation behavior of iron-rich intermetallic phases in Al-Si-Fe-Mn-Mg alloy

The effect of the melt holding temperature on the morphological evolution and sedimentation behavior of iron-rich intermetallics in Al-7.0 Si-1.0 Fe-1.2 Mn-0.25 Mg alloy was investigated using an optical microscope,scanning electron microscope and differential thermal analyzer.The results show that as the holding temperature decreases,the morphologies of the primary iron-rich phase in matrix change from star-like to polygonal,and the number of the primary phases gradually decreases and disappears at 615°C.Finally,the Chinese script phases with small size,high compact and uniform distribution are obtained.In contrast,the primary iron-rich phases in slag transform into a coarser polygonal shape with lower roundness,and some of them have hollow structures.Furthermore,the area fraction of intermetallics and Fe content in the matrix decrease gradually due to the formation and growth of sludge and subsequent natural sedimentation during melt holding.With the decrease of holding temperature,the main factors hindering the settlement of the primary phases are morphology,size,and density in turn.

Multiplex intermetallic phases in a gravity die-cast Mg-6.0Zn-1.5Nd-0.5Zr(wt%) alloy

Components and crystal structures of the intermetallic phases in a gravity die-cast Mg-6.0Zn-1.5Nd-0.5Zr(wt%)alloy were investigated using transmission electron microscopy.The results indicate that this alloy has multiple intermetallic phases and various inner faults.Totally,six eutectoid intermetallic phases,namely W(Mg Nd Zn_(3)),T(Mg_(39)Zn_(55)Nd_(6)),(Mg,Zr)Zn_(2),Z(Mg_(28)Zn_(65)Nd_(7)),H_(2)(Mg_(15)Zn_(70)Nd_(15)),and H1(Mg_(24)Zn_(64)Nd_(11)),were simultaneously observed at grain boundaries,and six precipitates(Z,Mg_(7)Zn_(3),T,Mg_(4)Zn_(7),β_(1)-Mg Zn_(2) and β_(2)-Mg Zn_(2))were found inα-Mg grains.Furthermore,faults like sub-grain boundaries,orientation domains(coherent with the same matching plane but with different orientations),stacking faults and twins were observed in the eutectoid intermetallic phases.Finally,some new orientation relationships between the known intermetallic phases were revealed.This paper can provide new insight into alloy design for Mg-Zn-RE(RE:rare earth)based alloys.

Study on the formation of intermetallic phases in the new type of Zn-Mg coatings on steel sheets

Zn-Mg alloy coatings were obtained by physical vapor deposition （PVD） on electroplated steel sheets. Study on the formation of intermetallic phases in the coatings was conducted through the use of X-ray diffraction （XRD） ,scanning electron microscope （SEM） and glow discharge optical emission spectrometry （GDOES）. It is found that MgZn2 is the main Zn-Mg alloy phase formed after heat treatment. The formation of Mg-Zn intermetallic phases is controlled not only by thermodynamics, but also by kinetics. MgZn2 has different morphologies, such as laminar structure,porous structure and floc-like structure,which are mainly determined by the annealing temperature. Obvious diffusion of Mg starts at 350 ℃, and the diffusion of iron increases significantly when the temperature is elevated to 380℃.

Formation of primary intermetallic phases in the interaction of Fe-containing melts of recycled Al-Si alloys with Al_(2)O_(3)and Al_(2)O_(3)-C filter materials:Aμ-CT study

Fe is the most detrimental impurity element in recycled Al-Si alloys due to the formation of brittle,primary,Fe-containing,intermetallic particles during solidification.Their removal from the Al-Si melts e.g.by filtration can reduce the Fe content.New active filter materials can facilitate the formation of these particles for their removal and contribute to the production of high-quality,recycled Al-Si alloys.The interaction of the alloy with the filter material can lead to modification of the thermodynamics of the alloy or of the kinetics of the particle formation.Time-resolved,three-dimensional microstructural inves-tigations have been carried out to study the formation of primary intermetallic particles in Al7.1Si1.5Fe and Al7.1Si0.75Fe0.75Mn alloy melts in contact with Al_(2)O_(3)and Al_(2)O_(3)-C filter substrate material during a melt conditioning treatment at 620℃.The microstructures,in particular the primary intermetallic particlesαc andαh,have been characterized by computed tomography(CT)and supplementary scanning electron microscopy(SEM).As expected by thermodynamics,the total volume fraction of primary par-ticles remains unchanged by the interaction with the substrate materials.However,kinetic advantages for Fe-removal efficiency can be achieved by an accelerated and preferred selective particle formation in contact with the Al_(2)O_(3)-C material.Furthermore,particle formation is discussed in view of its different stages:nucleation,growth,and ripening.

Effect of Intermetallic Phases on Corrosion Initiation of AZ91 Alloy With Rare Earth Y Addition

The effect of the rare earth（RE） element Y on the microstructure of AZ91 Mg alloy is investigated.A detailed description of the procedure of identifying the intermetallic phases containing Y in the AZ91 Mg alloy with 0.9 wt%Y addition is presented.The results shows that there are two different kinds of RE phases in scanning electron microscopy（SEM） images.Energy dispersive spectrum（EDS） analysis shows that one is rich in Y element and the other is rich in Mn element.According to the element mapping of electron probe microanalysis（EPMA）.the element Al can be found not only in the β-Mg17Al12phase but also in these two RE phases.X-ray diffraction（XRD） and transmission electron microscopy（TEM） results further confirm one of the two RE phases is AI2Y;the phase of Al10Mn2Y has just been determined by transmission electron microscopy（TEM） instead of XRD probably because it is scarce.The shapes of these two RE intermetallic phases are pretty similar.The 3D digital microscopy is employed to observe in-situ the effect of the(5 phase and the above two RE intermetallic phases on the corrosion initiation of the alloys.The results show that the corrosion attack of AZ91 Mg alloy without Y addition starts around the eutectic phase β-Mg17Al12.With the addition of 0.9 wt%Y,the two kinds of Y-rich intermetallic phases act as cathodic effect and a phase in the adjacent of them was activated and cathodic effect of the β-Mg17Al12phase was inhibited.

Morphologies of intermetallic compound phases in Sn-Cu and Sn-Co peritectic alloys during directional solidification

The morphologies of intermetallic phases(IMCs)during directional solidification of the Sn-Cu(L+Cu_(3)Sn→Cu_(6)Sn_(5))and Sn-Co(L+CoSn→CoSn_(2))peritectic systems were analyzed.The primary Cu_(3)Sn and peritectic Cu_(6)Sn_(5)phases in Sn-Cu alloy are IMCs whose solubility ranges are narrow,while both the primary CoSn and peritectic CoSn_(2)phases in Sn-Co alloy are IMCs whose solubility ranges are nil in equilibrium condition.The experimental results before acid corrosion shows that the dendritic morphology of both the Cu_(6)Sn_(5)and CoSn_(2)phases can be observed.The investigation on the local dendritic morphology after deep acid corrosion shows that these dendrites are composed of small sub-structures with faceted feature.Faceted growth of the primary Cu_(3)Sn and CoSn phases is also confirmed,and a faceted to non-faceted transition in their morphologies is observed with increasing growth velocities.Further analysis shows that the dendritic morphology is formed in the solidified phases whose solubility range is larger during peritectic solidification.

Formation of intermetallic phases in unrefined and refined AA6082 Al alloys investigated by using SEM-based ultramicrotomy tomography

The spatial arrangement,distribution and morphology of Fe-bearing intermetallics in AA6082 alloys depends on the manufacturing process of the alloy and thus influences the macroscopic properties.Here,the microstructure of a near industrial scale casting AA6082 Al alloy fabricated by:(a)direct chill casting,(b)Al-5 Ti-1 B grain refiner addition and(c)intensive melt shearing has been investigated by threedimensional visualization using SEM-based serial ultra microtomy tomography.The formation sequence of phases in AA6082 alloys is generally categorized into four stages:formation ofα-Al grains,Fe-bearing intermetallics,Mg_(2)Si phase,and eutectic rosettes.Results of three-dimensional visualization of the microstructure indicated that TiBparticles not only could nucleate Fe-bearingβ-intermetallics,but also could provide substrate for the formation of Fe-bearingα-intermetallics and Mg_(2)Si.A further deep analysis reveals that the essential condition for the formation of secondary phases such as Fe-bearing intermetallics and Mg_(2)Si phase is the build-up of a supersaturated solute front at theα-Al solid-liquid interface irrespective of the specific nucleation site.In addition,the results indicate that grain refinement processing causes the severe interconnectivity of Fe-bearingα-intermetallics.However,the intensive melt shearing is a better manufacturing process because the intermetallics are more evenly distributed and refined than with the addition of the grain refiner,thereby improving the properties of the alloy.

Intermetallic phase evolution of 5059 aluminum alloy during homogenization

Intermetallic phase evolution of 5059 aluminum alloy during homogenization was investigated by means of optical microscopy （OM）, scanning electron microscopy （SEM）, transmission electron microscopy （TEM）, energy dispersive spectrometry （EDS）, differential scanning calorimetry （DSC） and X-ray diffraction analysis （XRD）. The results show that severe dendritic segregation exists in as-cast alloy. The dissolvable intermetallic phases in as-cast alloy consist of Zn-and Cu-rich non-equilibriumβ（Al3Mg2） phase, Fe-rich eutectic Al6Mn phase and equilibrium Mg2Si phase. During the homogenization, Zn- and Cu-rich non-equilibrium β （Al3Mg2） phase, Fe-rich eutectic Al6Mn phase and equilibrium Mg2Si gradually dissolve into matrix. Fine dispersed β（Al3Mg2） particles and rod-shaped Al6Mn particles form in the Al matrix after homogenization. The proper homogenization processing is at 450 °C for 24 h, which is consistent with the results of homogenizing kinetic analysis.

Characterization of Phases in an As-cast Copper-Manganese-Aluminum Alloy

Copper-manganese-aluminum （CMA） alloys, containing small additions of Fe, Ni, and Si, exhibit good strength and remarkable corrosion resistance against sea water. The alloys are used in as-cast condition, and their microstructure can show wide variations. The morphology, crystallography and composition of the phases presented in an as-cast （CMA） alloy of nominal composition Cu-14%Mn-8%Al-3%Fe-2%Ni were investigated using optical, electron optical, and microprobe analytical techniques. The as-cast microstructure consisted of the grains of fcc α and bcc β-phases alongwith intermetallic precipitates of various morphologies. The room temperature microstructure exhibited four different types of precipitates inside the α-grains： the ＇large＇ dendritic-shaped particles and the cuboid-shaped precipitates, which were rich in Fe and Mn and had an fcc structure, while the ＇small＇ dendritic-shaped particles and the globular precipitates were based on FeaAI and had DO3 structure. These four different morphologies of intermetallic precipitates exhibited discrete orientation-relationships with the α-matrix. The β-grains only contained very small cuboid shaped precipitates, which could only be resolved through transmission electron microscopy. These precipitates were found to be based on Fe3Al and had the DO3 structure.

Intermetallic Getters Reactants for Vacuum Applications

The present work continues a series of publications devoted to the study of the sorption properties of reactive alloys based on IIA metals and the development of advanced getter materials for gas and vacuum technologies. This publication attempts to answer the current challenges in the field of gas sorption associated with the emergence of new vacuum products such as vacuum insulated glasses, electronic systems, cryogenic devices, etc. An analysis of the problems that arise here, as well as the results of sorption measurements, carried out with the participation of intermetallic phases of the composition CaLi2 and Ca0.33Li0.48Mg0.19, show that the best getter support for these new hermetically sealed products can be provided by intermetallic compounds formed in systems Li-IIA metals. Intermetallic phases of this family are easy to manufacture and demonstrate outstanding service characteristics: their specific sorption capacity is recorded high, exceeding traditional gas sorbents in this respect by at least an order of magnitude;the kinetics of gas capturing is set at the stage of alloy production, i.e., is adjustable;the temporary resistance of these phases to atmospheric gases allows to install the getter at its workplace in air, without further thermal activation. The sorption superiority of reactive intermetallics is explained by their special sorption mechanism: the gas/metal interaction is formed here as a combination of two processes, continuous growth of reaction products on a metallic surface and corrosion decay of brittle intermetallic phase under mechanical forces, which feeds the chemical reaction with a fresh surface. The advantages of sorption processes of this new type are undoubted and significant: compared with the conventional sorbents, an intermetallic getter reactant solves two important problems;it reduces production costs and increases the sorption yield.

Electrochemical extraction and the analysis of inter-metallic phases and nitrides in tempered duplex stainless steels

During aging at a temperature ranging from 650 -950 ℃,the ferric matrix in duplex stainless steels undergoes various decomposition processes which could form the precipitates of the Sigma （σ） and Chi （X） phases, as well as nitrides. It is well known that these precipitates lead to a reduction in creep ductility and adversely affect toughness and corrosion properties of steel. This experiment carded out qualitative and quantitative analyses of intermetallic phases and nitrides and established an analytical procedure, including specimen preparation, the choosing of the electrolyte and electrolytic systems,electrolytic isolation,wet chemical separation, and physical and chemical analysis, etc. The residues were collected by ultrasonic cleaning and filtration after galvanostatic electrolysis. Dynamic laser scattering sizer （DLS- sizer） ,scanning electron microscope （SEM） and transmission electron microscope （TEM） were used to examine their structure,modality and size. Qualitative and quantitative analyses were performed by using X-ray diffraction （XRD）, oxygen-nitrogen analyzer and wet chemical analysis. Furthermore, there is a discussion on the effect of isothermal treatment on precipitation that occurs at different temperatures for different periods of time.

Microstructure of the Ductile Phase in Intermetallic Compound Ni_(50)Al_(20)Fe_(30)

The microstructure of the single hot extruded and annealed Ni50Al20Fe30Y0.003 intermetallic compound alloys has been examined by means of high resolution electron microscopy (HREM). In these extruded and annealed alloys. the ductile phase is of a mixture of the disordered fcc γ matrix and or dered γ' precipitates. This fact well interprets the reason why the degree of annealing treatment can influence the strength and ductility of these alloys. The HREM observation revealed directly that there was some strain concentration at γ'-γ interfaces, due to the presence of more iron atoms in these two phases. The fixed orientation relationship between the γ phase and γ' precipitates was identified to be {001}γ||{00 }γ' and <100 >γ|| < 100 > γ'

Formation of microstructural features in hot-dip aluminized AISI 321 stainless steel

Hot-dip aluminizing（HDA） is a proven surface coating technique for improving the oxidation and corrosion resistance of ferrous substrates. Although extensive studies on the HDA of plain carbon steels have been reported, studies on the HDA of stainless steels are limited. Because of the technological importance of stainless steels in high-temperature applications, studies of their microstructural development during HDA are needed. In the present investigation, the HDA of AISI 321 stainless steel was carried out in a pure Al bath. The microstructural features of the coating were studied using scanning electron microscopy and transmission electron microscopy. These studies revealed that the coating consists of two regions： an Al top coat and an aluminide layer at the interface between the steel and Al. The Al top coat was found to consist of intermetallic phases such as Al_7Cr and Al_3Fe dispersed in an Al matrix. Twinning was observed in both the Al_7Cr and the Al_3Fe phases. Furthermore, the aluminide layer comprised a mixture of nanocrystalline Fe_2Al_5, Al_7Cr, and Al. Details of the microstructural features are presented, and their formation mechanisms are discussed.

Thermodynamic reassessment of Ga-Hg and Mg-Hg systems

The Ga-Hg binary system was thermodynamically assessed by the CALPHAD method, but only configuration contributions were considered to the entropy of the liquid. The Mg-Hg binary system has not been assessed yet. In the assessments of the Ga-Hg and Mg-Hg binary systems, solutions including liquid and hcp (Mg) were treated as substitution solutions, of which the excess Gibbs energies were formulated with the Relich-Kister polynomial. The intermetallic phases in the Mg-Hg binary system, Mg3Hg, Mg5Hg2, Mg2Hg, Mg5Hg3, MgHg, and MgHg2, were described as stoichiometric compounds. Based on the reported experimental data and thermodynamic properties of the phase diagram, sets of self-consistent parameters describing all phases in the Ga-Hg and the Mg-Hg binary systems were obtained.

Enhanced oxidation and overheating resistance of the extruded Mg–Zn–Al–Mn magnesium alloy by Calcium addition

The effects of Ca addition on the microstructure and oxidation properties of a new Mg alloy were studied.The oxidation behavior of the alloys was analyzed by thermal analysis and material characterization of the alloys exposed in flame environment;and both electrical and induction furnaces.Moreover,the surface layers were characterized using field emission scanning electron microscopy,and X-ray diffraction technique.It was found that increasing the Ca addition reduces the grain size and increases the fraction of the secondary phases,and enhances the mechanical properties.Moreover,increasing the Ca contents resulted in the formation of a dense CaO/MgO layer on the surface prohibited the oxygen diffusion and assisted in protection of the substrate against further oxidation.Therefore,ignition temperature was increased from 680℃ to 890℃ after addition of the Ca element.The mechanical properties and ignition behavior of the current materials was compared with the literature which it showed an excellent combination of the properties in the developed alloys.

Microstructural evolution during homogenization of DC cast 7085 aluminum alloy

The microstructural evolution of a DC cast 7085 alloy during homogenization treatment was investigated by optical microscopy, scanning electron microscopy, energy dispersive X-ray spectrometry (EDS), differential scanning calorimeter (DSC) and X-ray diffraction (XRD). The results showed that serious dendritic segregation existed in the as-cast 7085 alloy. Numerous eutectic microstructures and phases were observed at the grain boundary. During homogenization process, eutecticα(Al)+T(AlZnMgCu) microstructure gradually was dissolved into matrix. IntermetallicS(Al2CuMg) phase formed and grew along the eutectic microstructure and disappeared into the matrix completely when it was homogenized at 460 °C for 24 h. It could be found that the evolution of primary eutectic structure of 7085 alloy consisted of three processes, dissolution of eutecticα+T microstructure, phase transformation fromT phase toS phase and the dissolution ofS phase. The optimum homogenization parameter was at 470 °C for 24 h.

Effects of Ag contents in Sn-xAg lead-free solders on microstructure,corrosion behavior and interfacial reaction with Cu substrate

The effects of Ag on the microstructure and corrosion behavior of pre-soldering Sn-xAg lead-free solders,and on the formation of intermetallic layer of the solders with Cu substrate were investigated.The Ag contents(x)were 0,3.0,3.5,4.0,and5.0 wt.%.The Ag content played a role in the morphology of Ag3 Sn phase in the solders.The microstructure analysis showed that theβ-Sn phase was surrounded by eutectic networks in the 3.0 Ag and 3.5 Ag solders and large plate-like Ag3 Sn formed in the 4.0 Ag and5.0 Ag solders.Nonetheless,the Ag content slightly impacted the corrosion behavior of the as-cast solders as characterized using potentiodynamic polarization test.After soldering,only a single layer of a Cu6 Sn5 intermetallic compound formed at the Sn-xAg/Cu interface.By comparison,the Cu6 Sn5 intermetallic layer of the Ag-doped solders was thinner than that of the 0Ag solder.The fine Ag3 Sn particles in the eutectic networks precipitating in the 3.0 Ag and 3.5 Ag solders effectively hindered the growth of Cu6 Sn5 grains compared to large plate-like Ag3 Sn in the 4.0 and 5.0Ag solders.

Effect of yttrium modification on the corrosion behavior of AZ63 magnesium alloy in sodium chloride solution

The microstructures and corrosion behaviors of Mg-6%Al-3%Zn and Mg-6%Al-3%Zn-(0.251.0)%Y in 3.5 wt.%Na Cl solution are investigated via morphology observation,phase characterization,immersion and electrochemical methods.The experimental results suggest that yttrium alloying can improve the corrosion resistance of Mg-6%Al-3%Zn throughout the immersion.The initial enhanced corrosion resistance of magnesium alloy is attributed to the Y alloying,which gives rise to the increasing content of Al_(2)O_(3)in oxide layer.The promoted protectiveness of oxide layer on Mg-6%Al-3%Zn-1.0%Y alloy arouse a filiform corrosion as revealed by in-situ metallographic observation.Furthermore,the Y-containing magnesium alloys still perform higher corrosion resistance compared with that of Mg-6%Al-3%Zn alloy even if the oxide layer is exhausted.This phenomenon is owing to two factors,one is the gradual transformation of intermetallic phases from continuous Mg_(17)Al_(12)to discrete Al_(2)Y in matrix,by which the micro-galvanic corrosion betweenα-Mg grains and intermetallic phases is alleviated;the other is the morphology variation of corrosion products,the uniform and compact products layer on Y-containing alloys provide a barrier that effectively prevent the corrosive ions from penetrating into and reacting with Mg matrix.

Sacrificial Anode Stability and Polarization Potential Variation in a Ternary Al-xZn-xMg Alloy in a Seawater-Marine Environment

In this paper, the effects of zinc （Zn） and magnesium （Mg） addition on the performance of an aluminum-based sacrificial anode in seawater were investigated using a potential measurement method. Anodic efficiency, protection efficiency, and polarized potential were the parameters used. The percentages of Zn and Mg in the anodes were varied from 2% to 8% Zn and 1% to 4% Mg. The alloys produced were tested as sacrificial anodes for the protection of mild steel in seawater at room temperature. Current efficiency as high as 88.36% was obtained in alloys containing 6% Zn and 1% Mg. The polarization potentials obtained for the coupled （steel/Al-based alloys） are as given in the Pourbaix diagrams, with steel lying within the immunity region/cathodic region and the sacrificial anodes within the anodic region. The protection offered by the sacrificial anodes to the steel after the 7th and 8th week was measured and protection efficiency values as high as 99.66% and 99.47% were achieved for the A1-6%Zn-l%Mg cast anode. The microstructures of the cast anodes comprise of intermetallic structures of hexagonal Mg3Zn2 and body-centered cubic A12Mg3Zn3. These are probably responsible for the breakdown of the passive alumina film, thus enhancing the anode efficiency.

Microstructural features of Mg-8%Sn alloy and its correlation with mechanical properties

The aim of this investigation is to establish a structure-property correlation of Mg-8%Sn alloys aged at different time interval.The alloy under the present investigation was aged at elevated(200℃)temperature for various holding period.Differently aged alloys show retention of intermetallic phases after ageing,but in different area fraction of the same with ageing time.Mechanical properties evaluation and corresponding microstructural characterizations were performed to correlate their strength and ductility properties with their microstructural features(i.e.,grain size,grain connectivity and the area fraction of intermetallic phases).