Influence of introducing Zr,Ti,Nb and Ce elements on externally solidified crystals and mechanical properties of high-pressure die-casting Al–Si alloy

High pressure die casting(HPDC)AlSi10Mn Mg alloy castings are widely used in the automobile industry.Mg can optimize the mechanical properties of castings through heat treatment,while the release of thermal stress arouses the deformation of large integrated die-castings.Herein,the development of non-heat treatment Al alloys is becoming the hot topic.In addition,HPDC contains externally solidified crystals(ESCs),which are detrimental to the mechanical properties of castings.To achieve high strength and toughness of non-heat treatment die-casting Al-Si alloy,we used AlSi9Mn alloy as matrix with the introduction of Zr,Ti,Nb,and Ce.Their influences on ESCs and mechanical properties were systematically investigated through three-dimensional reconstruction and thermodynamic simulation.Our results reveal that the addition of Ti increased ESCs'size and porosity,while the introduction of Nb refined ESCs and decreased porosity.Meanwhile,large-sized Al_3(Zr,Ti)phases formed and degraded the mechanical properties.Subsequent introduction of Ce resulted in the poisoning effect and reduced mechanical properties.

Effects of shot speed and biscuit thickness on externaly solidified crystals of high-pressure diet cast AM60B magnesium alloy

Standard mechanical test bars with a diameter of 6.4 mm and a gauge length of 50 mm were processed, and the microstructures of die cast AM60B alloy under different die casting process parameters were observed. The influences of the slow shot speed, the fast shot speed and the biscuit thickness on the externally solidified crystals （ESCs） were investigated. With the increase of the biscuit thickness, the number of the ESCs in the cast samples decreases. Under a low slow shot speed, larg ESCs are found in the cast structure and a high fast shot speed results in more spherical ESCs. The relationships between ESCs and process parameters were also discussed.

Effects of high-pressure heat treatment on the solid-state phase transformation and microstructures of Cu_(61.13)Zn_(33.94)Al_(4.93) alloys

The phase transformation activation energy of the Cu61.13Zn33.94A14.93 alloys, which were treated at 4 GPa and 700 ℃ for 15 minutes, was calculated by means of differential scanning calorimetry curves obtained at various heating and cooling rates. Then, the effects of high-pressure heat treatments on the solid-state phase transformation and the microstructures of Cu61.13Zn33.94A14.93 alloys were investigated. The results show that high-pressure heat treatments can refine the grains and can change the preferred orientation from （111） to （200） of α phase. Compared with the as-cast alloy, the sample with high-pressure heat treatment has finer grains, lower β＇→β and/β→β＇ transformation temperature and activation energy. Furthermore, we found that high cooling rate favours the formation of fine needle-like α phase in the range of 5-20℃/min.

Microstructure refinement of AZ31 alloy solidified with pulsed magnetic field

The effects of a pulsed magnetic field on the solidified microstructure of an AZ31 magnesium alloy were investigated.The experimental results show that the remarkable microstructural refinement is achieved when the pulsed magnetic field is applied to the solidification of the AZ31 alloy.The average grain size of the as-cast microstructure of the AZ31 alloy is refined to 107 μm.By quenching the AZ31 alloy, the different primary α-Mg microstructures are preserved during the course of solidification.The microstructure evolution reveals that the primary α-Mg generates and grows in globular shape with pulsed magnetic field, contrast with the dendritic shape without pulsed magnetic field.The pulsed magnetic field causes melt convection during solidification, which makes the temperature of the whole melt homogenized, and produces an undercooling zone in front of the liquid/solid interface, which makes the nucleation rate increased and big dendrites prohibited.In addition, the Joule heat effect induced in the melt also strengthens the grain refinement effect and spheroidization of dendrite arms.

Microstructure and thermal stability behavior of a rapidly solidified Al-Ti-Fe-Cr alloy

A rapidly solidified Al-2.5Ti-2.5Fe-2.5Cr (mass fraction in percent) alloywas prepared by melt spinning. As-quenched and as-annealed microstructures were studied by X-raydiffractometry (XRD), transmission electron microscopy (TEM), high-resolution transmission electronmicroscopy (HREM) and energy dispersive spectrum (EDS) analysis. The microhardness of the alloy atdifferent annealing temperatures was measured. The results obtained indicate that the microhardnessof the rapidly solidified Al-2.5Ti-2.5Fe-2.5Cr alloy does not vary with different annealingtemperatures. The as-quenched microstructure of the alloy includes two kinds of dispersed primaryphases: Al_3Ti and Al_(13)(Cr, Fe)_2. After annealing at 400 deg C for 10 h, the stable phaseAl_(13)Fe_4 appears in the microstructure.

Microstructures of FeSi_2 based thermoelectric materials prepared by rapid solidification and hot pressing

FeSi_2 based thermoelectric materials have heen prepared by melt spinning andvacuum hot pressing. Most of the rapidly solidified (melt spinning) powders are thin flakes with athickness less than 0.1 mm. Scanning electron microscope (SEM) surface profiles show there arefurther finer grain structures with the characteristic size of about 100 nm in a flake. The samplesobtained by hot uniaxial pressing (HUP) in vacuum have densities higher than 90% the theoreticaldensity of the materials. It was found by SEM observations that the microstructures are verydifferent for vertical and parallel sections of the HUP samples. X-ray diffraction (XRD) analysesshow there are some texture features in the samples. It is considered that the textures of thesamples are originated from the orientation of the flakes that tended to align perpendicular to thehot press axis. WSi_2 was introduced into the powders unexpectedly during melting process before therapid solidification, but it makes the microstructures more easily to be explained.

Microstructure and hardness of W-25Re alloy processed by high-pressure torsion

The evolution of microstructure and microhardness was studied in a commercial tungsten-25%rhenium(mass fraction)(W-25Re)alloy processed by the high pressure torsion(HPT)procedure under a pressure of7.7GPa up to10revolutions at different temperatures.The results show that the samples processed by10revolutions at room temperature could have the smallest grain size at around0.209μm.High saturation hardness(HV^1200)could be achieved after the rapid strengthening stage for samples processed by10revolutions both at room temperature and at573K.Microstructural observation and analysis from Hall-Patch relationship could reveal that grain refinement and grain boundaries strengthening are the main factors of hardening mechanism in W-25Re alloy.It is also demonstrated that sintered W-25Re sample may have brittle phase separation phenomenon after HPT processing.

Microstructure refinement of AZ91D alloy solidified with pulsed magnetic field

The effects of pulsed magnetic field on the solidified microstructure of an AZ91D magnesium alloy were investigated. The experimental results show that the remarkable microstructural refinement is achieved when the pulsed magnetic field is applied in the solidification of AZ91D alloy. The average grain size of the as-cast microstructure of AZ91D alloy is refined to 104 μm. Besides the grain refinement, the morphology of the primary α-Mg is changed from dendritic to rosette, then to globular shape with changing the parameters of the pulsed magnetic field. The pulsed magnetic field causes melt convection during solidification, which makes the temperature of the whole melt homogenized, and produces an undercooling zone in front of the liquid/solid interface by the magnetic pressure, which makes the nucleation rate increased and big dendrites prohibited. In addition, primary α-Mg dendrites break into fine crystals, resulting in a refined solidification structure of the AZ91D alloy. The Joule heat effect induced in the melt also strengthens the grain refinement effect and spheroidization of dendrite arms.

Effects of Additional Elements on Microstructure and Precipitation Behaviour in Rapidly Solidified Al-Ti Base Alloys

Rapidly solidified Al-Ti base alloys were prepared by melt spinning at the cooling rate about 107 K/s. The melt-spun ribbons were used to observe the dricrostructures after heat treatment.In the supersaturated Al-Tl-Si alloy, age hardening occurred after 1 h anneal in the temperature range of 4000~500℃, which seems to be attributed to the precipitation of metastable Ll2- (Al,Si)3Ti phase. However. the microhardness was relatively low because of the low v/o and the insufflcient stability of precipitates. Thus. Cr was added to Al-Ti-Si alloys in order to stabilize the microstructures and to increase the v/o of precipitate5. As a result. the alIoys containing Cr were evaluated to possess the improved properties at the service temperature.

Effects of runner design and pressurization on the microstructure of a high-pressure die cast Mg-3.0Nd-0.3Zn-0.6Zr alloy

To clarify the relationship between externally solidified crystals(ESCs)and other defects,e.g.,defect bands and pores,two dimensional(2D)and three dimensional(3D)characterization methods were adopted to analyze castings produced using a modified ingate system equipped with and without an ESC collector.The reduction of ESCs strongly reduced defect band width and shrinkage pore quantity.By reducing the quantity and size of ESCs,net-shrinkage pores were transformed into isolated island-shrinkage pores.We determined via statistical analysis that the mechanical properties of high pressure die castings were strongly related to the size and fraction of the ESCs rather than porosity volume.The reduction of ESCs also caused tensile transgranular fracture modes to transform into intergranular fracture modes.Additionally,casting pressurization strongly reduced pore morphology,volume,and size.

Effects of process parameters on morphology and distribution of externally solidified crystals in microstructure of magnesium alloy die castings

During the cold-chamber high pressure die casting(HPDC) process, samples were produced to investigate the microstructure characteristics of AM60B magnesium alloy. Special attention was paid to the effects of process parameters on the morphology and distribution of externally solidified crystals(ESCs) in the microstructure of magnesium alloy die castings, such as slow shot phase plunger velocity, delay time of pouring and fast shot phase plunger velocity. On the basis of metallographic observation and quantitative statistics, it is concluded that a lower slow shot phase plunger velocity and a longer delay time of pouring both lead to an increment of the size and percentage of the ESCs, due to the fact that a longer holding time of the melt in the shot sleeve will cause a more severe loss of the superheat. The impingement of the melt flow on the ESCs is more intensive with a higher fast shot phase plunger velocity, in such case the ESCs reveal a more granular and roundish morphology and are dispersed throughout the cross section of the castings. Based on analysis of the filling and solidification processes of the melt during the HPDC process, reasonable explanations were proposed in terms of the nucleation, growth, remelting and fragmentation of the ESCs to interpret the effects of process parameters on the morphology and distribution of the ESCs in the microstructure of magnesium alloy die castings.

Positron Annihilation Study on the Microstructural Stability in Rapidly Solidified Al_(92.3)Fe_(4.3)V_(0.7)Si_(1.7)Mm_(1.0) Alloy

Rapidly solidified Al92.3Fe4.3V0.7Si1.7Mm1.0 alloy has been studied by positron lifetime spectroscopy and the variations on the intedecial defects with the annealing temperature were revealed by an analysis of the lifetime results. The intedece characteristics derived from the positron-lifetime results could be used to give a satisfactory interpretation of the dependence of mechanical properties on the annealing temperature

Microstructure Development of Directionally Solidified Nb-Ti-Si Based Ultrahigh Temperature Alloy

Integrally directional solidification of an Nb-Ti-Si based ultrahigh temperature alloy was performed in an ultrahigh temperature and high thermal gradient furnace with the use of ceramic crucibles. The microstructural evolution with the withdrawing rate increasing during directional solidification was revealed. The integrally directionally solidified microstructure was composed of couple grown lamellar (Nbss+(Nb,X)5Si3) eutectic colonies and a few hexagonally cross-sectioned (Nb,X)5Si3 columns (X represents Ti and Hf elements). All the directionally solidified microstructure was straightly aligned along the longitudinal axis of the specimens. With increasing of the withdrawing rate, the average diameter of the eutectic cells and inter lamella spacings in the eutectic cell decreased. The near-planar solid/liquid interface appeared when the withdrawing rate was 1μm/s, and the cellular solid/liquid interface formed when the withdrawing rate was 5 μm/s.

Research on the solidified microstructure and segregation behaviors of the UNS N10276 alloy produced by electroslag remelting

In this study,the solidified microstructure and segregation behaviors of the alloying elements and precipitate behaviors of the UNS N10276 alloy in a large-scale electroslag remelting(ESR)ingot were studied.Further,the formation of the solidified microstructure and segregation of ESR were systematically analyzed via thermodynamic calculations.The ESR ingot of the UNS N10276 alloy exhibits a typical dendritic structure.The secondary dendrite spacing at the head of the ingot is clearly larger than that at the bottom of the ingot.The alloying elements(e.g.,Mo,Mn,Si,and C),which are positive segregation elements,segregate to the interdendritic zones during the solidification process.However,Fe,W,and Cr segregate to the dendritic trunk zones,indicating that they are negative segregation elements.Among the alloying elements,Mo segregates the most,especially at the head of the ESR ingot.Majority of the precipitates that precipitate in the interdendritic zones and at grain boundaries belong to large-scale μ and M6C phases,respectively.Mo is the main element of the precipitates.The precipitates at the head of the ESR ingot are more abundant and larger than those at the bottom of the ingot.Hence,to improve the metallurgical quality and hot working properties of the UNS N10276 alloy,the segregation of the Mo element should be minimized,whereas the formation of the precipitates should be reduced as much as possible during the optimization of the composition and production processes.

Microstructure of Pd_(77.5)Au_6Si_(16.5) Alloy Droplet Solidified in a Drop Tube Process

The microstructure development of Pd77.5Au6Si16.5 alloy droplet solidified in a drop tube process was studied. It was found that two distinct microstructures, i.e. (Pd,Au)3Si primary phase and Pd+(Pd,Au)3Si eutectic can be obtained when the droplet diameter is within the range between 2.3~0.4 mm. The morpologies of the (Pd,Au)3Si developed from dendrite trunk-like with single branching only into dendrite cluster-like with ternary branching with the decrease of the droplet diameter. When the droplet diameter is about 0.25 mm, the primary phase (Pd,Au)3Si almost disappears and the microstructure mainly shows Pd+(Pd,Au)3Si eutectic. The morphology of the eutectic transforms from fiber-like to plate-like with the decrease of the droplet diameter in the range between 2.3-0.25 mm. When the droplet diameter is about 0.19 mm, the microstructure is only the single phase of Pd solid solution

Characteristics and formation mechanisms of defect bands in vacuum-assisted high-pressure die casting AE44 alloy

The microstructure in vacuum-assisted high-pressure die casting(HPDC) Mg-4Al-4RE(AE44) alloy was studied. Special attention was paid to the characteristics of defect bands and their formation mechanisms. Since double defect bands are commonly observed, the cross section of die cast samples is divided into five parts with different grain morphologies and size distributions. The inner defect band is much wider than the outer one. Both the defect bands are solute segregation bands, resulting in a higher area fraction of Al;RE;phase than that in the adjacent regions. No obvious aggregation of porosities is observed in the defect bands of AE44 alloy. This may be due to a narrow solidification temperature range of AE44 alloy and a large amount of latent heat released during the precipitation of intermetallic phases. The formation of the defect bands is related to the shear stress acting upon the partially solidified alloy, which can lead to collapse of the grain network. However, the generation mechanisms of shear stress in the outer and inner defect bands are quite different.

Energy-storage welding connection characteristics of rapidly solidified Cu-Co alloy foils

The connection characteristics of rapidly solidified Cu-40%Co alloy foils were studied using a self-developed micro-type energy-storage welding machine. The results show that the microstructure of the alloy foils is characterized by uni form and fine equiaxed grains,whose maximum grain size is 1.8 μm. Under the o ptimum energy,the regular flat nugget is formed,low voltage and high capacitan ce are favorable for obtaining the perfect connection joints,whereas high volta ge and low capacitance are likely to result in the surface burn of the alloy foi ls. With the increase of welding energy,the spot welding joint will be transfor med from regular flat nugget to nugget-free one,and the microstructure tends t o coarsen. The welding parameters recommended are: welding voltage 80100 V,(electric) capacitance 1 8002 500 μF,and welding force 48 N.

Investigation on Rapidly Solidified T15 High Speed Steel Powder and Its Bulk Microcrystalline Material

Authors produced rapidly solidified T15 high speed steel powders by high pressure(5~ 6MPa) N_a atomization and liquid N_2 cooling,observed and analyzed the morphology and structure of the powders;at the same time,prepared bulk microcrystalline T15 high speed steel materials by hot extruding or HIPing and hot rolling of the powders,observed and measured the microstructure and performance of the bulk materials.It was shown that rapid solidification may change the solidification characteristics and structure of T15 high speed steel powder and improve the qualities and properties of T15 high speed steel materials.

Effect of SiC particle addition on microstructure of Mg_2Si/Al composite

In the present study, by adding SiC particles into AI-Si-Mg melt, Mg2Si and SiC particles hybrid reinforced AI matrix composites were fabricated through the Mg2Si in situ synthesis in melt combined with the SiC ex situ stir casting. The as-cast microstructure containing primary Mg2Si and SiC particles that distribute homogenously in AI matrix was successfully achieved. The effects of SiC particle addition on the microstructure of Mg2Si/AI composites were investigated by using scanning electron microscopy （SEM） and XRD. The results show that, with increasing the fraction of the SiC particles from 5wt.% to 10wt.%, the morphologies of the primary Mg2Si particulates in the prepared samples remain polygonal, but the size of the primary phase decreases slightly. However, when the SiC particle addition reaches 15wt.%, the morphologies of the primary Mg2Si particulates change partially from polygonal to quadrangular with a decrease in size from 50 pm to 30 μm. The size of primary AI dendrites decreases with increasing fraction of the SiC particles from 0wt.% to 15wt.%. The morphology of the eutectic Mg2Si phase changes from a fiber-form to a short fiber-form and/or a dot-like shape with increasing fraction of the SiC particles. Furthermore, no significant change in dendrite arm spacing （DAS） was observed in the presence of SiC particles.

Enhanced mechanical and electrical properties of multi-walled carbon nanotubes reinforced Cu/Ti_(3)SiC_(2)/C nanocomposites via high-pressure torsion

In order to achieve combined mechanical and electrical properties,multi-walled carbon nanotubes(MWCNTs)reinforced Cu/Ti_(3)SiC_(2)/C nanocomposites were further processed by high-pressure torsion(HPT).The maximum microhardness values of central and edge from the composites with 1 wt.%MWCNTs reached HV 130.0 and HV 363.5,which were 43.9%and 39.5%higher than those of the original samples,respectively.With the same content of MWCNTs,its electrical conductivity achieved 3.42×10^(7) S/m,which was increased by 78.1%compared with that of original samples.The synergistic improvement of mechanical and electrical properties is attributed to the obtained microstructure with increased homogenization and refinement,as well as improved interfacial bonding and reduced porosity.The strengthening mechanisms include dispersion and refinement strengthening for mechanical properties,as well as reduced electron scattering for electrical properties.