A high-Nb TiAl alloy with highly refined microstructure and excellent mechanical properties fabricated by electromagnetic continuous casting

In the present research, microstructure refinement of a high-Nb TiAl alloy(Ti-48Al-8Nb-0.15B) was realized by means of the electromagnetic continuous casting(EMCC) technique. The microstructure of an ingot obtained by EMCC was analyzed using scanning electron microscopy(SEM). As compared with the raw as-cast al oy, the obtained EMCC alloy presented a much finer microstructure with lamellar colonies with a mean size of about 50-70 μm because the electromagnetic stirring broke initial dendrites and enhanced the heterogeneous nucleation. As the grains were refined, the properties of the TiAl alloy were improved significantly. This implies that the EMCC technique could offer the possibility of application for high-Nb TiAl alloys with a refined microstructure and excel ent properties to be used as a structural material.

Inhomogeneity of microstructure and mechanical properties of a 500 mm diameter heavy section semi-continuous cast AZ61 magnesium alloy ingot

For the large magnesium alloy ingot, there is a considerable difference in cooling rate of different parts in the ingot, which leads to non-uniform distribution of the secondary phases, solute segregation and tensile properties. In the present research, an heavy AZ61 alloy ingot with a diameter of 500 mm was made by semi-continuous casting. The microstructure and mechanical properties at different positions along the radial direction of the large ingot were investigated by using an optical microscope(OM), a scanning electron microscope(SEM), an energy dispersive spectroscope(EDS), and a micro-hardness tester. The results indicate that the microstructure of the AZ61 ingot is non-uniform in different locations. It changes from equiaxed to columnar grains from the center to the edge; the average grain size gradually reduces from 1,005 μm to 763 μm, the secondary dendrite arm spacing reduces from 78 μm to 50 μm, and the Mg17(Al,Zn)12 phase is also refined. The micro-hardness value increases from 55.4 HV at the center to 72.5 HV at the edge of the ingot due to the microstructure differences, and the distribution of micro-hardness at the edge of the ingot is more uniform than that in the center. The tensile properties at room temperature show little difference from the center to the edge of the ingot except that the elongation at the edge is only 3.5%, much lower than that at other areas. The fracture mechanism is ductile fracture at the center and cleavage fracture at the edge of the ingot, and at the 1/2 radius of the ingot, a mixture of ductile and cleavage fracture is present.

Effect of Electromagnetic Frequency on Microstructures of Continuous Casting Aluminum Alloys

The relationship between electromagnetic frequency and microstructures of continuous casting aluminum alloys was studied. 7075 aluminum alloy ingot of 100 mm in diameter was produced by electromagnetic continuous casting process, the microstructures of as-cast ingot was examined by scanning electron microscopy (SEM) equipped with energy dispersive spectrometer (EDS). The results showed that electromagnetic frequency greatly influenced segregation and microstructures of as-cast ingot, and product quality can be guaranteed by the application of a proper frequency. Electromagnetic frequency plays a significant role in solute redistribution; low frequency is more efficient for promoting solution of alloying elements.

Effect of low-frequency electromagnetic field on the as-cast microstructure of a new super high strength aluminum alloy by horizontal continuous casting

The super high strength aluminum alloy ingots with 100 mm in diameter were cast by the process of low-frequency electromagnetic horizontal continuous casting (LFEHC) and the effect of electromagnetic field on the as-cast microstructure was studied. Results show that microstructure of the sample prepared by the LFEHC process was greatly refined. Microstructures at the border and the center of the ingots were fine, uniform and rosette-shaped. Electromagnetic frequency plays a key role in microstructure refining. Fine and uniform microstructures can be obtained with optimal electromagnetic frequency. In this experiment, under a frequency of 30 Hz the microstructure was the finest and the most uniform.

Structure and mechanical properties of AZ31 magnesium alloy billets by different hot-top semi-continuous casting technology

AZ31 alloy billets of 200 mm in diameter were produced by three different processes of conventional direct chill （DC） casting, low-frequency electromagnetic casting （LFEC） and low-frequency electromagnetic vibration casting （LFEVC）, respectively. The effect of LFEC and LFEVC on the microstructures, macmsegregation and mechanical properties of AZ31 alloy billets was investigated. In conventional DC casting, the AZ31 alloy billets exhibited coarse grains （about 370 μa） and severe segregation of A1 and Zn. In the presence of a solo low-frequency alternating magnetic field or a low-frequency electromagnetic vibration field applied during DC casting of Ф200 mm AZ31 billets, grains in the AZ31 alloy billets were effectively reffmed （about 210 μa） and the macrosegregation of A1 and Zn in the billets was greatly decreased. Furthermore, the tensile strength, fracture elongation and hardness of the as-cast AZ31 alloy billets were improved by the processes of LFEC and LFEVC relative to that cast by the process of conventional DC casting.

Effect of high-intensity ultrasonic field on process of semi-continuous casting for AZ80 magnesium alloy billets

Under the high-intensity ultrasonic field,AZ80 magnesium alloy was semi-continuously cast.The effects of ultrasonic intensity on the as-cast microstructures and mechanical properties were investigated.The results show that the microstructures of the alloy cast under high-intensity ultrasonic field are fine and uniform,and the grains are equiaxed,rose-shaped or globular with an average size of 257μm.High-intensity field significantly decreases the grain size,changes the morphologies of theβ-Mg17Al12 phases and reduces their area fraction.It is also shown that a proper increase in ultrasonic intensity is helpful to obtain fine,uniform and equiaxed as-cast microstructures.The optimum ultrasonic parameters are that frequency is 20 kHz and ultrasonic intensity is 1 368 W.The mechanical tests show that the mechanical properties of the as-cast AZ80 magnesium alloy billets cast under ultrasonic field are greatly improved,and with increasing the ultrasonic intensity,the mechanical properties of the entire alloy billets are much higher and more uniform than those of the alloy without ultrasonic field.

Microstructures of electromagnetic casting and direct chill casting LY12 aluminum alloys

LY12 aluminum alloys made by electromagnetic casting (EMC) and direct chill casting (DCC), were analyzed by optical microscope, differential scanning calorimetry, transmission electron microscope and X ray diffraction. It is found that the surface and subsurface quality of the ingot is improved largely due to the absence of an ingot mold, which is impossible to achieve with conventional DCC. It is also found that the intense forced convection can promote the fast superheat evacuation and break the dendrite arms, leading to the grain multiplication and the appearance of a fine equiaxed grains over the whole cross section. As a result, the hardness of EMC specimens increases one time than that from DCC in the as cast state. Even though after the solid solution treatment and the artificial aging, the DCC ingot still can not get the same hardness as EMC ones.

Effect of electromagnetic and ultrasonic cast rolling on microstructure and properties of 1050 aluminum substrate for presensitized plate

The 1050 aluminum alloy strip was prepared by means of electromagnetic and ultrasonic cast rolling on the modified asymmetric twin roll caster, and then the aluminum substrate for presensitized plate was prepared through cold rolling and annealing.The effects of electromagnetic and ultrasonic cast rolling on microstructure, mechanical properties, surface roughness and electrolytic corrosion properties of 1050 aluminum substrate were studied. The results show that electromagnetic and ultrasonic cast rolling can decrease the average crystallite size of aluminum substrate by 5 μm, increase the crystal boundaries with uniform distribution, and make the second-phase particles with smaller size distributed dispersively in the substrate, meanwhile, it can increase the tensile strength, elongation and micro-hardness by 4.58%, 9.85% and HV 2, respectively, reduce the surface roughness, make the surface appearance more even, electrolytic corrosion polarization curve of aluminum substrate more smooth and the surface corrosion pits with regular shape more dispersive.

A Review on Casting Magnesium Alloys： Modification of Commercial Alloys and Development of New Alloys

The research and development status of casting magnesium alloys including the commercial casting alloys and the new types casting alloys are reviewed,with more attention to microstructure and mechanical properties of modified-AZ91,AM60 and WE43 alloys with various additions,and new types of low cost casting alloys and high strength casting alloys.The modification and/or refinement of Mg2 Si phase in Mg-Al-Si based casting alloys by various additions are discussed and new purifying technologies for casting magnesium alloys are introduced to improve the performance.The modified AZ81 alloy with reduced impurities is found to have the tensile strength of 280 ± 6 MPa and elongation of 16% ± 0.7%.The fatigue strength of AZ91 D alloy could be obviously improved by addition of Ce and Nd.The Mg-16Gd-2Ag-0.3Zr alloy exhibits very high tensile and yield strengths（UTS：423 MPa and YS：328 MPa）;however,its elongation still needs to be improved.

连铸结晶器镍−钴−氧化铈复合镀液优化及镀层性能

为改善连铸结晶器铜板表面镀层的性能,提高其使用寿命,向Ni-Co合金电镀液中添加平均粒径为20μm的CeO_(2)颗粒进行Ni-Co-CeO_(2)复合电镀。以镀层的显微硬度为指标,通过正交试验得到的较优配方为:NiSO_(4)·6H_(2)O 90 g/L,CoSO_(4)·7H_(2)O 18 g/L,C6H8O7·H_(2)O 110 g/L,CeO_(2)3 g/L。通过场发射扫描电镜(FE-SEM)、能谱仪(EDS)和X射线衍射仪(XRD)对比了Ni-Co合金镀层和Ni-Co-CeO_(2)复合镀层的表面和截面形貌、成分及相结构,并通过电化学分析和摩擦磨损试验对比了它们的耐蚀性和耐磨性。结果表明,Ni-Co-CeO_(2)复合镀层的显微硬度为663 HV,微观表面呈粗糙的胞状结构,整体致密、无微裂纹,耐蚀性和耐磨性远优于Ni-Co合金镀层。

AZ61镁合金软接触电磁连铸的研究

采用软接触电磁连铸法制备了AZ61镁合金铸锭,对其晶体结构、金相组织、力学性能及抗腐蚀性能进行了研究,并与金属模铸法制备的铸锭作了比较。实验发现:两种方法制备的铸锭相结构相同;软接触电磁连铸铸锭晶粒细小,第二相弥散分布,促使其力学性能有很大提高,常温抗拉强度和延伸率分别提高了约30%和27%,其断口形貌具有更多韧性断裂的特征;在3.5%NaCl溶液中的动电位极化测试表明,软接触电磁连铸可以使镁合金的自腐蚀电压升高,腐蚀电流密度降低,从而提高镁合金的耐腐蚀性能。

等径角挤压对AZ31镁合金组织及力学性能的影响

研究了电磁连铸AZ31镁合金沿A路径经常规等径角挤压(ECAE)和两步ECAE变形后的微观组织与力学性能。结果表明:与预挤压态相比,常规ECAE态合金随着挤压道次的增加,晶粒不断细化,伸长率不断提高,但屈服强度与抗拉强度逐渐降低;两步ECAE可以使晶粒进一步细化,伸长率、屈服强度与抗拉强度均提高。伸长率、屈服强度与抗拉强度的改变与AZ31镁合金经两步ECAE变形后位错密度增加有关。

半固态AlSi7Mg铝合金的连续制备实验与研究

研究了采用电磁搅拌法的连续制备工艺对半固态ＡｌＳｉＭｇ合金棒坯表面质量和微观组织的影响；通过优化实验工艺参数，制备出具有触变性组织的半固态铝合金圆棒，其直径６０－１１０ｍｍ，长１．３－１．６ｍ。

铝合金的软接触电磁连铸研究

采用软接触电磁连铸技术和普通连铸技术铸造了Al 4 5%Si合金,用光学显微镜分析了显微组织。结果表明:软接触连铸的内部组织细小、均匀;由于感应热的作用,频率选择不宜过高,本试验条件下1kHz为佳。

电磁铸造对2024铝合金力学性能和组织的影响

通过光学显微镜、差热分析仪和透射电子显微镜，对比分析了电磁铸造和连续铸造２０２４铝合金铸态及热处理态的显微组织和力学性能．电磁铸造铝锭的硬度较连续铸造铸锭提高１倍，疲劳性能提高２倍．差热分析曲线显示，电磁铸造试样具有比连续铸造高的热焓，说明其在加热过程中沉淀强化物析出较多。

消失模铸造AZ91镁合金组织及耐蚀性研究

通过采用金相分析、能谱分析、电子万能材料试验机、腐蚀失重法、极化测试及交流阻抗分析等手段,研究了消失模铸造AZ91镁合金的组织、力学性能及腐蚀行为,并与普通砂型铸造及金属型铸造方法进行了比较。研究结果表明,消失模铸造镁合金组织除了粗大的α相与β相外,还出现了球状的Al-Mn-Fe三元相,造成消失铸造镁合金的力学性能及耐蚀性能低于砂型铸造及金属型铸造。本试验条件下,消失模铸造AZ91合金的抗拉强度及伸长率分别为135.6MPa与1.4%。失重法测得的消失模铸造AZ91镁合金的腐蚀速率为0.64mg/(cm2·d),为金属型铸造的2.2倍。极化曲线及交流阻抗等电化学研究表明,铸造工艺对镁合金的腐蚀行为有明显影响,消失模铸造镁合金的自腐蚀电位较低,但自腐蚀电流密度较大,分别为-1.577V与1.39×10-5Amp/cm2。

电磁连铸过程中电磁场对变形镁合金凝固组织的影响

采用软接触电磁连铸和普通连铸的方法分别制备了AZ61镁合金铸锭,结果表明软接触电磁连铸铸锭的组织均匀,晶粒细化,晶界上二次相析出减少,第二相呈断续状弥散分布,Al元素含量在晶内增加,而在晶界处降低。针对上述现象探讨了连铸过程中电磁场作用下AZ61镁合金的组织凝固机理,提出第二相"磁致弥散"的思想,并推导了软接触电磁连铸的热力学关系。

电磁连铸对镁合金显微组织及腐蚀性能的影响

对电磁连铸生产的AZ31镁合金铸坯的晶体结构、金相组织和材料耐腐蚀性能进行了研究。结果表明,电磁连铸未改变镁合金铸坯相的组成,电磁连铸坯晶粒细小,树枝晶破碎,分布在块状α-Mg相周边的β-Mg17Al12相均匀连续。质量分数为5%的NaCl盐雾腐蚀试验结果表明,电磁连铸生产的AZ31镁合金铸坯的腐蚀速率比普通连铸下同牌号铸坯下降29.4%,其主要原因是连续分布的网状β-Mg17Al12相有效阻碍了镁合金的腐蚀。

Zr对2E12铝合金显微组织和力学性能的影响

研究Zr元素对2E12铝合金T4态显微组织及力学性能的影响。结果表明:添加质量分数0.3%的Zr元素可以细化合金的铸态组织,使晶粒平均尺寸从42μm降低至30μm左右,并促使晶粒等轴化;锻造过程中Zr可以抑制合金的再结晶,防止晶粒长大,改善2E12-T4态的显微组织,提高合金的力学性能,其抗拉强度、屈服强度、伸长率和断面收缩率分别提高5.4%、11.3%、9.7%和12.6%;合金的强化机理主要包括晶粒细化、颗粒弥散强化及形变强化。

AZ61镁合金电磁连铸工艺与性能研究

研究了AZ61变形镁合金的熔炼过程,通过工艺试验和磁场强度测量,确定了水流量、拉速和浇注高度等电磁连铸工艺参数;并对AZ61变形镁合金电磁连铸铸坯进行微观组织及力学性能分析。结果表明:电磁连铸和普通连铸法制备的铸坯凝固组织和微观相结构相同,但电磁连铸锭的晶粒细小,第二相呈弥散分布;常温抗拉强度和伸长率分别较普通连铸变形镁合金提高了15%和50%左右,断口形貌显示其具有韧性断裂的倾向。