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.

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.

Recalescence Behavior, Solidification Characteristics and Microstructure Transformation of Rapidly Solidified Undercooled Cu-based Alloys

The undercooled solidification microstructures of Cu55Ni45,Cu55Ni43Co2,and Cu60Ni38Co2 Cu-base alloys were obtained by fluxing method.Using infrared temperature measuring device,the law of the change of the recalescence degree with the increase of the undercooling during rapid solidification was studied.At the same time,high-speed camera was used to capture and photograph the images of solid/liquid interface migration during rapid solidification of undercooled melt,and the morphology evolution of solidification front was discussed.Finally,the microstructure morphology and transformation process of the Cubased alloys were systematically analyzed.It is found that the microstructure morphology of the alloys goes through the same evolution process and appeared two grain refinement phenomena,that is,“coarse dendrite-equiaxed grain-oriented fine dendrite-equiaxed grain”.But its characteristics undercoolingΔT_(1),ΔT_(2),and critical undercoolingΔT^(*)varies.Electron backscatter diffraction(EBSD)and transmission electron microscopy(TEM)were used to characterize the grain refinement structure with high undercooling.EBSD results show that the grain refinement structure with high undercooling presents a very high proportion of high angle grain boundaries,the grain orientation is random and there is no high strength texture,and a large number of annealing twins,which indicates that recrystallization occurs in the structure.TEM results show that dislocation network and stacking fault density are relatively low in most areas of grain refinement structure with high undercooling,which can confirm the theory that stress induces recrystallization of the structure.

Dislocation mechanism of Ni_(47)Co_(53) alloy during rapid solidification

Dislocations and other atomic-level defects play a crucial role in determining the macroscopic properties of crystalline materials,but it is extremely difficult to observe the evolution of dislocations due to the limitations of the most advanced experimental techniques.Therefore,in this work,the rapid solidification processes of Ni_(47)Co_(53) alloy at five cooling rates are studied by molecular dynamics simulation,and the evolutions of their microstructures and dislocations are investigated as well.The results show that face-centered cubic(FCC) structures are formed at the low cooling rate,and the crystalline and amorphous mixture appear at the critical cooling rate,and the amorphous are generated at the high cooling rate.The crystallization temperature and crystallinity decrease with cooling rate increasing.Dislocations are few at the cooling rates of 1×10^(11) K/s,5×10^(12) K/s,and 1×10^(13) K/s,and they are most abundant at the cooling rates of 5×10^(11) K/s and1 × 10^(12) K/s,in which their dislocation line lengths are both almost identical.There appear a large number of dislocation reactions at both cooling rates,in which the interconversion between perfect and partial dislocations is primary.The dislocation reactions are more intense at the cooling rate of 5×10^(11) K/s,and the slip of some dislocations leads to the interconversion between FCC structure and hexagonal close packed(HCP) structure,which causes the twin boundaries(TBs) to disappear.The FCC and HCP are in the same atomic layer,and dislocations are formed at the junction due to the existence of TBs at the cooling rate of 1 ×10^(12) K/s.The present research is important in understanding the dislocation mechanism and its influence on crystal structure at atomic scales.

Cooling rate dependence of polymorph selection during rapid solidification of liquid metal zinc

The polymorph selection during rapid solidification of zinc melt was investigated by molecular dynamics simulation. Several methods including g（r）, energy, CNS, basic cluster and visualization were used to analyze the results. The results reveal that the cooling rate has no observable effect on the microstructure as TTc（Tc is the onset temperature of crystallization）; and at the first stage of crystallization, although microstructures are different, the morphologies of nucleus are similar, which are composed of HCP and FCC layers; the polymorph selection of cooling rate finally takes place at the second stage of crystallization： at a high cooling rate, the rapid increase of FCC atoms leads to a FCC crystal mixed with less HCP structures; while at a low cooling rate, HCP atoms grow at the expense of FCC atoms, resulting in an almost perfect HCP phase. The results reveal that the cooling rate is one of the important factors for polymorph selection.

Influence of rapid solidification on Sn-8Zn-3Bi alloy characteristics and microstructural evolution of solder/Cu joints during elevated temperature aging

The effects of rapid solidification on the microstructure and melting behavior of the Sn-8Zn-3Bi alloy were studied. The evolution of the microstructuraI characteristics of the solder/Cu joint after an isothermal aging at 150 ℃ was also analyzed to evaluate the interconnect reliability. Results showed that the Bi in Sn-8Zn-3Bi solder alloy completely dissolved in the Sn matrix with a dendritic structure after rapid solidification. Compared with as-solidified Sn-8Zn-3Bi solder alloy, the melting temperature of the rapid solidified alloy rose to close to that of the Sn-Zn eutectic alloy due to the extreme dissolution of Bi in Sn matrix. Meanwhile, the adverse effect on melting behavior due to Bi addition was decreased significantly. The interfacial intermetallic compound （IMC） layer of the solder/Cu joint was more compact and uniform. Rapid solidification process obviously depressed the formation and growth of the interfacial IMC during the high-temperature aging and improved the high-temperature stability of the Sn-8Zn-3Bi solder/Cu joint.

Effect of cooling rates on clustering towards icosahedra in rapidly solidified Cu_(56)Zr_(44) alloy

The rapid solidification processes of liquid Cu56Zr44 alloys at different cooling rates （γ） were simulated by a molecular dynamics （MD） method. In order to assess the influence of cooling rate on the clustering tendency and degree towards icosahedrons, a ten-indices＇ cluster-type index method was suggested to characterize the local atomic structures in the super-cooled liquid and the rapidly solidified solid. And their clustering and ordering degrees as well as the packing density of ieosahedral clusters were also evaluated by an icosahedral clustering degree （fI）, the chemical order parameter （ηαβ） and densification coefficients （D0, DI and DIS）, respectively. Results show that the main local atomic configurations in Cu56Zr44 alloy system are Z12 clusters centered by Cu, and most of which are （12 0 12 0 0 0 0 0 0 0） standard icosahedra and （12 0 8 0 0 0 2 2 0 0） as well as （12 2 8 2 0 0 0 0 0 0） defective icosahedra. Below glass transition temperature （Tg）, these icosahedral clusters will be coalesced to various icosahedral medium-range orders （IMROs） by IS linkages, namely, icosahedral bond, and their number N, size n, order parameter ηαβ as well as spatial distributions vary with y. As the cooling rate exceeds the critical value （γc） at which a glassy transition can take place, a lower cooling rate, e.g., γ1=10^1K/ns, is demonstrated to be favorable to uplift the number of icosahedra and enlarge the size of IMROs compared with the higher cooling rates, e.g., γ5=10^5 K/ns, and their packing density and clustering degree towards icosahedra in the rapidly solidified solid can also benefit from the slow cooling process.

Simulation of formation and evolution of nano-clusters during rapid solidification of liquid Ca_(70)Mg_(30) alloy

A molecular dynamics simulation study was performed to investigate the formation and evolution mechanisms of nano-clusters during the rapid solidification of liquid CaToMg30 alloy. The cluster-type index method （CTIM） was adopted to describe microstructure evolutions of nano-clusters during solidification. Results indicate that amorphous structure is mainly formed with three bond-types of 1551, 1541 and 1431 at the cooling rate of 5~1011 K/S, and glass transition temperature Tg is about 530 K; the icosahedron cluster of （12 0 12 0） plays a key role in formation of amorphous structure, and smaller Mg atoms are much more probable to be central atoms of icosahedron clusters; and nano-clusters are mainly formed by combining medium-size clusters. Interestingly, it was also found that formation and evolution processes of the nano-cluster display a three-stage feature which is analogous to crystallization process of amorphous alloy.

Effect of back diffusion on overall solidification kinetics of undercooled single-phase solid-solution alloys

Departing from the volume-averaging method,an overall solidification kinetic model for undercooled single-phase solid-solution alloys was developed to study the effect of back diffusion on the solidification kinetics.Application to rapid solidification of undercooled Ni-15%Cu（mole fraction） alloy shows that back diffusion effect has significant influence on the solidification ending temperature but possesses almost no effect on the volume fraction solidified during recalescence.Inconsistent with the widely accepted viewpoint of Herlach,solidification ends at a temperature between the predictions of Lever rule and Scheil＇s equation,and the exact value is determined by the effect of back diffusion,the initial undercooling and the cooling rate.

Precipitation of multi-type nano-quasicrystals in a Mg-Zn-Y alloy

Mg-6Zn-1Y(at.%)ribbons with strengthening precipitates of multi-type nanoquasicrystals were prepared by melt-spinning followed by aging treatments.Microstructural evolution of the rapidly solidified ribbons during isothermal aging was comprehensively studied using various electron microscopy techniques.Two new kinds of decagonal quasicrystals were formed in aged ribbons,in addition to precipitation of nanometer icosahedral quasicrystals.Atomic-resolution observations reveal that both decagonal quasicrystals can be modeled by quasiperiodic tiling with decagonal clusters of 2.5 nm in diameter,but overlap of neighboring clusters in both decagonal quasicrystals is different from the Gummelt model observed in other quasicrystals.A shell composed of complex Laves Mg-Zn domains was formed surrounding each decagonal quasicrystal precipitate upon prolonged aging.In addition,all kinds of nanoprecipitates exhibit excellent structure and size stability at 573 K.Our findings may have implications for not only fundamental studies about quasicrystals,but also microstructural manipulation of high-performance Mg alloys.

TEM microstructure of rapidly solidified Mg-6Zn-1Y-1Ce alloy

Rapidly solidified（RS） Mg-6Zn-1Y-1Ce ribbons were prepared by single roller melt-spinning technique.Transmission electron microscopy and energy dispersive X-ray spectroscopy were employed to characterize the microstructure of RS ribbons.The results show that there is high density of particles distributed within grains and at grain boundaries in the region near wheel side.The particle density is decreased in the middle region and free surface region.The alloy is predominantly composed of supersaturated--Mg solid solution,T phase and W phase;meanwhile,a few icosahedral quasicrystalline and Mg4Zn7 particles are also observed.The T phase is confirmed having a body-centered orthorhombic structure that is transformed from the body-centered tetragonal structure Mg12Ce phase due to the partial substitution of Mg atoms by Zn.

Damping capacity of high strength-damping aluminum alloys prepared by rapid solidification and powder metallurgy process

Two kinds of high strength-damping aluminum alloys （LZ7） were fabricated by rapid solidification and powder metallurgy （RS-PM） process. One material was extruded to profile aluminum directly and the other was extruded to bar and then rolled to sheet. The damping capacity over a temperature range of 25-300 ℃was studied with damping mechanical thermal analyzer （DMTA） and the microstructures were investigated by optical microscopy （OM）, scanning electron microscopy （SEM） and transmission electron microscopy （TEM）. The experimental results show that the damping capacity increases with the test temperature elevating. Internal friction value of rolled sheet aluminum is up to 11.5×10^-2 and that of profile aluminum is as high as 6.0×10^-2 and 7.5×10^-2 at 300 ℃, respectively. Microstructure analysis shows the shape of precipitation phase of rolled alloy is more regular and the distribution is more homogeneous than that of profile alloy. Meanwhile, the interface between particulate and matrix of rolled sheet alloy is looser than that of profile alloy. Maybe the differences at interface can explain why damping capacity of rolled sheet alloy is higher than that of profile alloys at high temperature （above 120 ℃）.

Rapid solidification of Cu_(60)Co_(30)Cr_(10) alloy under different conditions

Metastable liquid phase separation and rapid solidification in a metastable miscibility gap were investigated on the Cu60Co30Cr10 alloy by using the electromagnetic levitation and splat-quenching.It is found that the alloy generally has a microstructure consisting of a（Co,Cr）-rich phase embedded in a Cu-rich matrix,and the morphology and size of the（Co,Cr）-rich phase vary drastically with cooling rate.During the electromagnetic levitation solidification processing the cooling rate is lower,resulting in an obvious coalescence tendency of the（Co,Cr）-rich spheroids.The（Co,Cr）-rich phase shows dendrites and coarse spheroids at lower cooling rates.In the splat quenched samples the（Co,Cr）-rich phase spheres were refined significantly and no dendrites were observed.This is probably due to the higher cooling rate,undercooling and interface tension.

Comparison of dendrite and dispersive structure in rapidly solidified Cu-Co immiscible alloy with different heat flow modes

Rapid solidification of Cu-Co immiscible alloy was investigated by glass-fluxing, spray casting and melt-spinning techniques. Both the transition from dendrite to dispersive structure and corresponding scale evolution were revealed and further elucidated in terms of the heat flow mode, nucleation and growth processes under different solidification conditions. With the increase of undercooling, columnar dendrite is replaced by dispersive structure due to the immiscible effect. In contrast, equiaxed dendrite forms in spray cast alloy due to multiple nucleation events and becomes thinner for the case of higher cooling rate. Ascribed to the enhanced non-equilibrium effect and insufficient period for collision and coagulation processes between separated droplets, fine globular dispersion appears upon the diameter of spray casting reaching 4 mm. As for the melt-spun ribbon with the highest cooling rate, a single-phase solid solution microstructure with refined grain of cellular morphology can be obtained, which is attributed to the suppression of liquid phase separation by instant solidification.

Energy-storage Welding Connection Characteristics of Rapid Solidification AZ91D Mg Alloy Ribbons

Energy-storage welding connection characteristics of rapidly solidified AZ91D Mg alloy ribbons with 40-70 μm thickness are investigated using a microtype energy-storage welding machine. The microstructure and performance of the connection joints are analyzed and studied. The research results indicate that energy-storage welding is able to realize the spot welding connection of AZ9ID Mg alloy ribbons. The welding nugget consists of developed α-Mg equiaxed grains with the sizes of 1.2-2.7 μm and intergranular distributed β-Mg17Al12 compounds. The thickness of bond zone is about 4 μm and the solidification microstructure is characterized by the fine equiaxed grains with the sizes of 0.8-1.2μm and grain boundary has become coarsening. The columnar crystal in HAZ also becomes slightly coarsening and the grain boundary has broadened, however, there is no obvious change in its primitive morphology and crystallographic direction. When welding energy is about 2.0 J, the welding joints with higher shear strength and smaller electrical resistivity are obtained.

INTERACTION OF PRECIPITATION AND RECRYSTALLIZATION IN RAPIDLY SOLIDIFIED Cu-Cr-Zr-Mg ALLOY

The recrystallization process of a rapidly solidified Cu-Cr-Zr-Mg alloy during its aging was investigate experimentally. It was found that (1) upon aging, the precipitation process takes place prior to recrystallization for the cold-deformed Cu-Cr-Zr-Mg alloy produced by rapid solidification, and the precipitates have a restrained effect on the following recrystallization process; (2) the hindrance of the dispersed fine precipitates to the common recrystallization leads to the simultaneous in situ and discontinuous recrystallization; (3) the resolution of the precipitates in the front of migrating grain boundaries takes place during the nucleation and growth of recrystallization, which results in a supersaturation in the recrystallized zones, while the re-precipitation of the supersaturated solute atoms in vacancies further increases the dispersion hardening effect.

MICROSTRUCTURE OF Mg-6.4Zn-1.1Y ALLOY FABRICATED BY RAPID SOLIDIFICATION AND RECIPROCATING EXTRUSION

In order to explore the methods to prepare high-strength quasicrystal-reinforced magnesium alloys, the flakes of rapidly solidified Mg-6.4Zn-1.1 Y magnesium alloy with a thickness of 50-60μm were obtained by a melt spinning single-roller device, and the flakes were then processed into rods by reciprocating extrusion and direct extrusion. The microstructure of the alloy was analyzed by optical microscope and SEM, and the constituent phases were identified by XRD. Phase transformation and its onset temperature were determined by differential thermal analyzer （DTA）. The analysis result shows that rapid solidification for Mg-6.4Zn-I.IY alloy can inhibit the eutectic reactions, broaden the solid solubility of Zn in α-Mg solute solution, and impede the formation of Mg3 Y2Zn3 and MgZn2 compounds, and thus help the icosahedral Mg3 YZn6 quasicrystal formed directly from the melt. The microstructure of the flakes consists of the α-Mg solid solution and icosahedral Mg3 YZn6 quasicrystal. Dense rods can be made from the flakes by two-pass reciprocating extrusion and direct extrusion. The interfaces between flakes in the rods can be welded and jointed perfectly. During the reciprocating extrusion and direct extrusion process, more Mg3 YZn6 compounds are precipitated and distributed uniformly, whereas the rods possess fine microstructures inherited from rapidly solidified flakes. The rods contain only two phases： α- magnesium solid solution as matrix and fine icosahedral Mg3 YZn6 quasicrystal which disperses uniformly in the matrix.

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.

Effects of directional solidification parameters and crystal selector on microstructure of single crystal of Ni-base superalloys

The single crystal of nickel-base super alloy is widely used for making turbine blades.The microstructure of the alloy,especially the deviation of preferred orientation of single crystal,possesses the most important effects on the mechanical properties of the blades.In this study,the single crystal ingot and blade of DZ417G alloy are prepared by means of the spiral crystal selector as well as the directional solidification method,and the effect of the parameters(i.e.,the shape of samples,the withdrawal rate)and the structure of the spiral crystal selector on the formation of single crystal and the crystal orientation are investigated.This method can prepare not only the single crystal ingot with simple shape but also the single crystal blades with the complex shape,the simple with rod-shape can form the single crystal easily with a relatively fast withdrawal rate,but the blade with complex shape requires much slower withdrawal rate to form single crystal.The length of the crystal selector almost has no effect on the crystal orientation.However,the angle of selector plays an obvious role on the orientation;the selector with a smaller angle can effectively reduce the deviation of preferred orientation;the appropriate angle of selector to obtain optimal orientation is found to be around30°and the deviation of preferred orientation is about30°for this selector.

Liquid phase separation and subsequent dendritic solidification of ternary Fe_(35)Cu_(35)Si_(30) alloy

Liquid Fe35Cu35Si30alloy has achievedthemaximum undercooling of 328 K （0.24TL） with glass fluxing method, and it displayed triple solidification mechanisms. A critical undercooling of 24 K was determined for metastable liquid phase separation. At lower undercoolings,α-Fe phase was the primary phase and the solidification microstructure appeared as homogeneous well-defined dendrites. When the undercooling exceeded 24 K, the sample segregated into Fe-rich and Cu-rich zones. In the Fe-rich zone, FeSi intermetallic compound was the primary phase within the undercooling regime below 230 K, while Fe5Si3intermetallic compound replaced FeSi phase as the primary phase at larger undercoolings. The growth velocity of FeSi phase increased whereas that ofFe5Si3 phase decreased with increasing undercooling. For the Cu-rich zone, FeSi intermetallic compound was always the primary phase. Energy-dispersive spectrometry analyses showed that the average compositions of separated zones have deviated substantially from the original alloycomposition.