Effect of Process Factors on Microstructure of Semisolid Continuous Casting Billets

Semisolid continuous casting (SSCC) is a new technology to produce billets for semisolid metal forming (SSMF). The effect of process factors, such as pouring temperature, stirring rate, preheating temperature and thermal conductivity of stirring chamber, on the microstructure of SSCC billets was studied by means of the factorial experimental method. The results show that the microstructure of SSCC billets can be controlled by the above-mentioned four process factors. In order to obtain fine and rounded granular grains in an SSCC billet, the pouring temperature, preheating temperature and stirring rate should be kept in a moderate range, and the thermal conductivity of stirring chamber should be high. The regression equations with the process factors connecting the microstructure was also set up based on experimental data.

Microstructure Evolution during Solidification of AZ91D Magnesium Alloy in Semisolid

The liquid quenching method was adopted to study the solidification morphology and microstructure of AZglD Mg alloy in semisolid. The results indicate that cooling rate has important effects upon the solidification structures. Under the cooling rate of liquid quenching, primary α-phase grows first by attaching on the original α grains, or independent nucleation and growth. The high cooling rate makes primary α-phase grow in ＂rags＂ or dendrite shape. Eutectic solidification is carried out in terms of both dissociated growth and symbiotic growth. The dissociated growth forms rough and large β-phase at grain boundaries, while symbiotic growth forms eutectic of laminar structure. The small liquid pool inside the original α-phase solidifies basically in the same way as that of intergranular liquid, but owing to less amount of liquid phase, the eutectic solidification is mainly carried out in the dissociated pattern.

Controlled Nucleation Method:A New Process for Semisolid Metal Forming

Semisolid metal forming requires special feedstock material with a fine-grained and globular structure to achieve thixotropic properties. A number of methods have been developed to produce such feedstock materials. Controlled Nucleation Method (CNM) is a new and simple, cost effective method that has been developed by the University of Queensland. The CNM process does not use the conventional stirring process, instead, it uses solidification conditions to control nucleation, nuclei survival and grain growth, thereby produce fine and globular structures suitable for semisolid forming. No specialised equipment is required. The method can produce both semisolid slurry for rheocasting and semisolid billet for thixocasting. It can be applied to a wide range of alloys and can easily be incorporated into existing metal forming installation. Semisolid slurries/billets of hypoeutectic and hypereutectic aluminium-silicon casting alloys, aluminium wrought alloys and a magnesium alloys have been successfully produced.

Effect of directional solidification process on microstructure and stress rupture property of a hot corrosion resistant single crystal superalloy

The influences of different directional solidification processes, i.e., the high rate solidification(HRS) and liquid metal cooling(LMC), on microstructure and stress rupture property of DD488 alloy were investigated. The DD488 alloy was directional solidified by both HRS and LMC processes. The microstructure and stress rupture properties at 980 ℃/250 MPa were investigated by using optical microscopy(OM), scanning electron microscopy(SEM), electron microprobe analyzer(EPMA), transmission electron microscopy(TEM) and stress rupture testing. The results indicated that the LMC process refined the primary dendrite arm and decreased the microporosity volume fraction and solidification segregations of Cr and Co in as-cast DD488 alloy. After standard heat treatment of 1,260 ℃/4 h, AC(air cooling) + 1,080 ℃/4 h, AC + 870 ℃/24 h, AC, the γ′ morphology in LMC alloy was more cuboidal than that in HRS alloy, and the γ′ volume fraction of LMC alloy was higher than that of HRS alloy. The stress rupture life at 980 ℃/250 MPa of HRS alloy was 76.8 h, and it increased to 110.0 h in LMC al oy. The LMC process increased the stress rupture life due to the higher γ′ volume fraction, more perfect rafting structure and finer interfacial dislocation networks.

Solidification Behavior of Laser Melting Layer of Nd_(15)Fe_(77)B_8 Sintered Magnets and Its Microstructures Evolution

To research the solidification behavior and microstructures of a laser remelting/solidification layer on anisotropic Nd_(15)Fe_(77)B_(8 )sintered magnets with their magnetization direction parallel to X, Y, Z-axis respectively, their surfaces (parallel to XOY plane) were scanned by 5 kW Roffin-Sinar 850 type of CO_(2) laser along Y axis. The rapid solidification of the molten alloy in the layer results in three distinct zones. The transition zone close to the unmolten portion of a magnet (substrate), consists of the columnar Nd_(2)Fe_(14)B phase (matrix), the 10.0%~15.1% dendrite primary iron phase dispersing in the matrix, and the Nd-rich phase along Nd_(2)Fe_(14)B grain boundaries. The columnar crystal zone in the middle of the layer consists of the long columnar Nd_(2)Fe_(14)B grains and their grain boundary Nd-rich phase. And the dendrite crystal zone near the free surface of the layer consists of dendrite Nd_(2)Fe_(14)B grains and their grain boundary Nd-rich phase. When the laser scanning velocity is lower, the growing direction of the microstructures in the layer tends to the laser scanning direction step by step. When the velocity is not lower than 25 mm·s^(-1), the laser remelting/solidification layer thins and the columnar crystal zone comprises almost the whole layer. Under this condition, on the substrate with its magnetization direction along X or Y-axis respectively, the columnar Nd_(2)Fe_(14)B grains in the layer grow in the direction of Z-axis (that is their long-axis along Z-axis), their alignment of the easy magnetization axis [001] is parallel to the magnetization direction of the substrate correspondingly; but on the substrate with its magnetization direction along Z-axis, the columnar Nd_(2)Fe_(14)B grains in the transition zone grow at an angle of 30°~50° between Z-axis and their long-axis. And the columnar Nd_(2)Fe_(14)B grains in the columnar crystal zone gradually tend to the Z-axis,and their easy magnetization axis [001] arrange in the range of 0°~360° of the plane perpendicular to their long-axis.

Solidification, microstructure, and mechanical properties of the as-cast ZRE1 magnesium alloy with different praseodymium contents

The influence of praseodymium(Pr) content on the solidification characteristics, microstructure, and mechanical properties of ZRE1 magnesium(Mg) cast alloy was investigated. The obtained solidification parameters showed that Pr strongly affected the solidification time, leading to refinement of the microstructure of the alloys. When the freezing time was reduced to approximately 52 s, the grain size decreased by 12%. Mg_(12)Zn(Ce,Pr) was formed as a new phase upon the addition of Pr and was detected via X-ray diffraction analysis. The addition of Pr led to a substantial improvement in mechanical properties, which was attributed to the formation of intermetallic compounds; the ultimate tensile strength and yield strength increased by approximately 10% and 13%, respectively. Pr addition also refined the microstructure, and the hardness was recovered. The results herein demonstrate that the mechanical properties of Mg alloys are strongly influenced by their microstructure characteristics, including the grain size, volume fraction, and distribution of intermetallic phases.

Compositional design and microstructure analysis of Zr-based bulk metallic glasses

The systematical studies of Zr-based BMGs were summarized in terms of their compositional design and their structural characterization. In particular, several key issues of BMG materials were focused, including initial alloy design and subsequent composition optimization, solidification microstructure characterization and crystallization process specification. The results show that a compositional designing approach is successfully developed and, through extensive microstructure characterization using transmission electron microscopy, several new crystalline phases are discovered in these newly developed Zr-based BMG alloys. Crystallization behavior of Zr-based BMG is also determined based on the microstructure analysis.

Effect of alumina short fiber and air-cooling processing on solidification microstructure and tensile properties of Al_2O_3/Al-15Si composites

The effect of microstructure variation by addition of alumina short fiber and optimization of tensile properties by air cooling processing in Al 2O 3/Al 15Si composites were studied. The results show that in Al 15Si alloy matrix composites with 14% and 30%(volume fraction) fiber, the primary silicon is hardly refined, but the eutectic silicon is effectively refined and granulated. Granulation of some eutectic silicon mainly happens in fiber segregation areas. Refining and granulation of the eutectic silicon are related to the physical constraint arising from the fiber. After the 30%Al 2O 3/Al 15Si composite was remelted and air cooled, the number of the eutectic silicon on the surface of the fiber increases, which results in the improvement of fiber/matrix interface and tensile properties for the as cast composite. Air cooling processing may be reliable for the optimization of the microstructure and properties of fiber reinforced hypereutectic Al 15Si alloy composites.

Influence of solidification rate on the microstructure of (Nd,Dy)_(12.8)(Fe,Co)_(80.7)B_(6.5) cast strips

The influence of solidification rate on the microstructure of (Nd,Dy)(12.8)(Fe,Co)(80.7)B-6.5 cast strips was reported in this paper. The strips prepared at different wheel speeds were analyzed by X-ray diffraction (XRD). The microstructure of the strips was investigated by backscattered scanning microscope (BSM). The XRD results show that the strips are mainly composed of the main phase (T-1) existing apparent alignment along [00L]. The thickness of T-1 columnar grains is larger when the solidification rate is lower and the over-small isotropic microcrystalline appear on the cooling surface of the strips when the solidification rate is too high. The adequate wheel speed for obtaining the optimum microstructure of the strips is about V = 2.0 m/s. The strip prepared at V = 2.0 m/s possesses suitable thickness and the highest alignment degree of T-1 columnar grains, uniformly distributed Nd-rich phase, and no existence of alpha-Fe phase. This kind of cast strip is an ideal starting material for preparing sintered magnets with high magnetic properties.

Laser Multi-layer Cladding Experiment on the DD3 Single Crystal Using FGH95 Powder:Investigation on the Microstructure of Single Crystal Cladding Layer

Laser multi\|layer cladding experiments were performed on the substrate of DD3 single crystal with FGH95 powder as cladding material.The solidification microstructure in the sample was investigated.It was found that the solidification microstructure was greatly influenced by the crystallography orientation of the substrate and the local solidification conditions.When the angle between the preferred orientation of the single crystal and the direction of heat flow in the cladding layer is less than 30°,single crystal cladding layers were acquired.Otherwise the crystallography orientation of the cladding layer will deviate from the orientation of the substrate and the microstructure with polycrystalline appears.Meanwhile,even when the experiments were performed on the same preferred crystal surface,the solidification microstructures will be different distinctly resulting from the variation of the local solidification conditions.The secondary arms were degenerated and the primary arm spacing was about 10\|20μm.Further investigation shows that the phases of the cladding layer are mainly made up ofγ,γ′,the flower\|likeγ/γ′eutectic and carbide.The morphology ofγ′was cubical and the size is less than 0.1μm.

Influence of Microstructure Refinement on Strain Strengthening Effect of Cu-Ag Alloy in situ Filamentary Composites

The Cu-10Ag and Cu-10Ag-RE （RE=Ce, Y） alloys in situ filamentary composites were prepared. The relationships of the ultimate tensile strengths （UTS） and microstructure changes of the composites were studied. With increasing of the true strain η, the sizes of the Ag filaments in the composites reduce according to a negative exponential function of η:d=d0·exp（-0.228η）, and the UTS of the composites increase also according to a exponential function of η, σ Cu/Ag=σ 0（Cu）+[k Cu/Agd0 -1/2]exp（η/3）, here d0 is a coefficient related to the original size of Ag phase. The strain strengthening follows a two-stage strengthening effect. The strengthening mechanisms are related to changes of microstructure in the deformation process. At the low true strain stage, the strengthening is mainly caused by the working hardening controlled by dislocation increasing; at the high true strain stage, the strengthening is mainly caused by the super-fine Ag filaments and the large coherent interfaces between the Ag filaments and Cu matrix. The trace RE additions and the rapid solidification obviously refine scales of the Ag filament of the composites, and therefore obviously increased the strain strengthening rate. The microstructure refinement of the composites, especially the refinement of Ag filament, is the main reason of the high strain strengthening effect in Cu-Ag alloy in situ filamentary composites.

Morphology and microstructure of rapidly solidified tin-lead alloy powders

Sn60Pb40 al oy powders were fabricated using the planar flow casting （PFC） atomization process. By using OM, SEM and EPMA, the characteristics of the morphologies and microstructures of the powders have been investigated. It is observed that the environment of ambient gas in the atomization box has great effects on the morphology of the al oy powders. The microstructures of Sn60Pb40 al oy powders produced by the PFC atomization process are completely composed of eutectic, which is made up of both oversaturated αsolid solution and β solid solution. The microstructures of smal size powders are extraordinarily undeveloped dendritic eutectic, in which the large majority of the α phase appears nearly spherical, evidently since the cooling rate is higher and the under-cooling is larger. As for the large size powders, since the cooling rate and undercooling are relatively low, lamel ar α phase apparently increases in the eutectic microstructures of these powders, and there is even typical lamellar eutectic structure clearly observed in some micro-areas. After remelting tests by DTA, the microstructures of smal size powders are transformed, which become composed of large crumby α phase and eutectic （α＋β）, while those of large size powders change into classical tin-lead structures of primary α phase plus lamellar eutectic （α＋β）. By studying the microstructures of tin-lead alloy powders, a model has been proposed to predict the microstructure formation of Sn60Pb40 al oy powders.

Microstructure evolution and solidification behaviors of A2017 alloy during cooling/stirring and rolling process

A novel semisolid rheo-rolling process of A2017 alloy was achieved by combining the shape rolling mill with the vibrating sloping plate device. The microstructure evolution and solidification behaviors during the process were investigated. The high cooling rate caused by the sloping plate and stirring action caused by the vibration and metal flow lead to a high nucleation rate as well as two primary grain growth patterns, direct globular growth as well as dendrite growth and subsequent breakage, which causes the formation of fine spherical or rosette primary grains. During the rolling process, the grains of the strip were elongated. The primary grain size of A2017 alloy strip increases with the increment of casting temperature. When the casting temperature was between 650 °C and 660 °C, A2017 alloy strip with good quality was produced by the proposed process. The microstructures of the strip are mainly composed of spherical or rosette grains.

Directional Solidification Assisted by Liquid Metal Cooling

An overview of the development and current status of the directional solidification process assisted by liquid metal cooling （LMC） has been presented in this paper. The driving force of the rapid development of the LMC process has been analyzed by considering the demands of （1） newer technologies that can provide higher thermal gradients for alleviated segregation in advanced alloy systems, and （2） better production yield of the large directionally solidified superalloy components. The brief history of the industrialization of the LMC process has been reviewed, followed by the discussion on the LMC parameters including selection of the cooling media, using of the dynamic baffle, and the influence of withdrawal rates and so on. The microstructure and mechanical properties of the traditional superalloys processed by LMC, as well as the new alloys particularly developed for LMC process were then described. Finally, future aspects concerning the LMC process have been summarized.

Directional solidification casting technology of heavy-duty gas turbine blade with liquid metal cooling(LMC) process

In this work, some important factors such as ceramic shell strength, heat preservation temperature, standing time and withdrawal rate, which influence the formability of directionally solidified large-size blades of heavy-duty gas turbine with the liquid metal cooling(LMC) process, were studied through the method of microstructure analysis combining. The results show that the ceramic shell with medium strength(the high temperature flexural strength is 8 MPa, the flexural strength after thermal shock resistance is 12 MPa and the residual flexural strength is 20 MPa) can prevent the rupture and runout of the blade. The appropriate temperature(1,520 ℃ for upper region and 1,500 ℃ for lower region) of the heating furnace can eliminate the wide-angle grain boundary, the deviation of grain and the run-out caused by the shell crack. The holding time after pouring(3-5 min) can promote the growth of competitive grains and avoid a great deviation of columnar grains along the crystal orientation <001>, resulting in a straight and uniform grain structure. In addition, to avoid the formation of wrinkles and to ensure a smooth blade surface, the withdrawal rate should be no greater than the growth rate of grain. It is also found that the dendritic space of the blade decreases with the rise of solidification rate, and increases with the enlarging distance between the solidification position and the chill plate.

Solidification pattern and microstructures of AZ91D magnesium alloy through rheoforming

The optical microscope, SEM and EDS were adopted to analyze the rheoforming solidification morpholo-gies and microstructures of deformed AZ91D magnesium alloy after isothermal treatment in semisolid state. The re-sults show that primary α phase can be formed through attachment growth, when the liquid fraction is small; and primary α phase will grow in dendrites, when the liquid fraction is high. Eutectic solidification is carried out in the ways of both dissociated growth and symbiotic growth, de-pending on the morphology of primary α phase. Liquid with eutectic concentration solidifies into lamina eutectic. During solidification of the liquid pools inside grains, α phase can be formed through attachment growth. The eutectic solidifica-tion was mainly carried out in the dissociated pattern.

Effect of laser power and deposition environment on the microstructure and properties of direct laser metal-deposited 12CrNi2 steel

Direct laser metal deposition was used for preparing blocks of steel 12CrNi2 using four different laser powers under two different deposition environments including atmospheric environment and Ar-protected chamber.The results showed that microstructures and mechanical properties were significantly affected by different laser powers.Increasing laser power and deposition in Ar chamber will lead to a decrease in the quantity and size of the voids,which brings more elongation to the samples.Bainitic microstructure was replaced by Widmanstatten ferrite and pearlite,and the amount of proeutectoid ferrite increased with increasing laser power.Moreover,microstructures of previous layers were completely altered in high laser power.Excessive heat accumulation by using high heat input can produce equiaxed ferritic grains with the pearlites in previously deposited layers.Hardness of deposited samples increased from the bottom layer toward the top layer.By using a diode laser with a spot diameter size of 2 mm,the 900-W laser power is suitable for producing crack-and void-free samples.However,post-deposition heat treatment is necessary for obtaining homogeneous desired microstructure and grain size in the manufactured samples.

Microstructural evolution of directionally solidified DZ125 superalloy castings with different solidification methods

The properties of Ni-base superalloy castings microstructure, and different solidification methods have are closely related to the uniformity of their as-cast serious effect on microstructural uniformity. In this paper, the influences of high rate solidification （HRS） process （with or without superheating） and liquid metal cooling （LMC） process on the microstructure of DZ125 superalloy were investigated. Blade-shape castings were solidified at rates of 40 pm.s-1 to 110 tJm.s1 using HRS process and a comparative experiment was carried out at a rate of 70 IJm.s1 by LMC process. The optical microscope （OM）, scanning electron microscope （SEM） were used to observe the microstructure and the grain size was analyzed using electron back scattered diffraction （EBSD） technique. Results show that for the castings by either HRS or LMC process, the primary dendrite arm spacing and size of 7＇ precipitates decrease with increasing the withdrawal rate; the dendrites and 7＇ precipitates at the upper section of the blade are coarser than those in the middle, especially for the HRS castings without high superheating technique. When the withdrawal rate is 70 iJm.s1, the castings by HRS with high superheating technique have the smallest PDAS with fine 7＇ precipitates; while the size distribution of 7＇ precipitates is more homogenous in LMC castings, and the number of larger grains in LMC castings is smaller than that in the HRS castings. Moreover, high superheating technique yields smaller grains in the castings. Both the LMC method and HRS with high superheating technique can be used to prepare castings with reduced maximum grain size.

MICROSTRUCTURE AND DECOMPOSITION OF RS Al-Fe-Cr-Zr ALLOY

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高压下金属钽液体中拓扑密堆团簇对凝固路径的影响规律

金属液体(或过冷液体)中的主要微观结构对最终的凝固路径(晶化或非晶化)起着决定性作用,何种微观结构将扮演关键性角色一直处在不断的被探索和研究中.本文采用分子动力学方法模拟研究金属钽(tantalum,Ta)液体在不同压强下的快速凝固过程,通过原子平均能量、双体分布函数和最大标准团簇分析方法,对凝固过程中的微观结构演变进行量化分析.研究结果表明,相比于低含量的二十面体,拓扑密堆(topologically close-packed,TCP)团簇在金属Ta液体中扮演着关键角色,它不仅含量更高,而且更能对凝固路径起决定性作用.当压强P∈[0,8.75]GPa时,金属Ta液体中的TCP团簇不仅处于能量低且稳定性好的状态,同时TCP团簇相互连结程度高而不容易被分解,从而促进金属Ta液体发生非晶转变;当压强P∈[9.375,50]GPa时,金属Ta液体中TCP团簇处于亚稳定状态,且很多高能量的TCP团簇在液固转变过程中容易转变成其他团簇,此时体心立方(body-centered cubic,BCC)晶胚容易在TCP团簇堆积稀疏区域形核和长大,最终金属Ta液体转变成比较完美的BCC晶体.