Effect of Rare Earth on Microstructure of Vacuum Melting Ni-Based Self-Fluxing Alloy Coatings

The Ni-based self-fluxing alloy coating containing RE was acquired by the technique of vacuum melting on the hypoeutectoid steel (Fe-0.45%C) matrix. By X-ray diffraction, SEM and EDX, the microstructure and phase structure of section of coating and the microstructure near the interface between coating and matrix were investigated, and the effect of RE on microstructure of coating was also discussed. The results show that the microstructure of the NiCrBSi alloy coating is composed of Ni-based solid solution and a lot of massive, globular and needle secondary phases CrB, Ni_3B, Cr_7C_3, Cr_(23)C_6 among the solid solution. The metallurgical binding between steel matrix and coating is realized. RE makes needle phase of alloy coating vanish. New phases of NiB and Cr_(6.5)Ni_(2.5)Si are precipitated from alloy coating, and secondary phases of alloy coating are sphericized. Consequently, RE also hinders the diffusion of Ni, Cr and Si atoms from coating to matrix and Fe atoms from matrix to coating, holds back the dilution of Fe for NiCrBSi alloy coating, and assures the chemical composition of the alloy coating.

Study of ultrahigh-purity copper billets refined by vacuum melting and directional solidification

The purpose of this paper is to study large-sized copper billets refined with 5N ultrahigh purity after vacuum melting and directional solidifi-cation （VMDS）. The precise impurity analysis of copper billets was carried out with a glow discharge mass spectrometer （GDMS）. The re-sults demonstrate that the total concentration of twenty-two impurities is decreased by 63.1wt.%-66.5 wt.%. Ag, P, S, Na, Mg, Se, Zn, In and Bi are easy to be removed due to lgPimp - lgPCu 1.5, and they can be removed effectively under the vacuum condition of 1650-1700 K for 30 min. The electrical conductivity of 5N copper is higher than that of the raw material as the impurity concentrations decrease. The segrega-tion effect in directional solidification can be remarkable when the equilibrium distribution coefficient （k0） value is less than 0.65 due to the strong affinity of Cu for some metallic and non-metallic impurities.

Preparation and Arc Erosion Resistance of C_f/Cu Composite by Vacuum Melting Infiltration

Cf/Cu composite was prepared by vacuum melting infiltration. Ti and Cr were doped to the Cu alloy to improve the wettability between Cu and carbon. The microstrueture was investigated by XRD, SEM and EDS. The arc erosion rate of Cf/Cu composite was investigated in vacuum. The results showed that the Ti and Cr could improve the wettability between Cu and C/C preform and the infiltration ability of Cu into C/ C preform greatly. A TiC interface formed between the fibers and matrix. The good bonding between the fiber and matrix guaranteed that part of the Cu matrix can still be bonded on the fibers even when the material was exposed to the plasma. Consequently, the carbon fibers were protected from the erosion. In comparison, Cu was completely consumed by the arc erosion. Hence, the graphite was eroded and presented a cauliflower-like morphology. Therefore, the prepared C/Cu bad better ability to resist the arc erosion, compared with common Cu-C material.

Effect of interaction of refractories with Ni-based superalloy on inclusions during vacuum induction melting

This study documents laboratory-scale observation of the interactions between the Ni-based superalloy FGH4096 and refractories.Three different crucibles were tested—MgO,Al2O3,and MgO–spinel.We studied the variations in the compositions of the inclusions and the alloy–crucible interface with the reaction time using scanning electron microscopy equipped with energy dispersive X-ray spectroscopy and Xray diffraction.The results showed that the MgO and MgO–spinel crucibles form MgO-containing inclusions(Al–Mg oxides and Al–Mg–Ti oxides),whereas the inclusions formed when using the Al2O3 crucible are Al2O3 and Al–Ti oxides.We observed a new MgAl2O4 phase at the inner wall of the MgO crucible,with the alloy melted in the MgO crucible exhibiting fewer inclusions.No new phase occurred at the inner wall of the Al2O3 crucible.We discuss the mechanism of interaction between the refractories and the Ni-based superalloy.Physical erosion was found to predominate in the Al2O3 crucible,whereas dissolution and chemical reactions dominated in the MgO crucible.No reaction was observed between three crucibles and the Ti of the melt although the Ti content(3.8wt%)was higher than that of Al(2.1wt%).

Mechanisms of reactive element Y on the purification of K4169 superalloy during vacuum induction melting

The effects of rare earth element Y on the purification of K4169 superalloy during vacuum induction melting were investigated at different superheating temperatures. The corresponding interaction mechanisms were also clarified. Results showed that the addition of Y remarkably promoted the purification effect on the K4169 melt. The contents of O and S in the K4169 as-cast alloy ingots after purification were 3–4 and 8–10 ppm, respectively. The degrees of deoxidation and desulfurization increased to 50% and 57%, respectively, upon the addition of 0.1 wt% Y. The yttrium-rich phase that precipitated at the grain boundary blocked the diffusion of C and the accumulation of S, thereby contributing to the purification of the alloy.

Evolution of inclusions in vacuum induction melting of superalloys containing 70%return material

The variation law of inclusions type and size in the vacuum induction melting process and ingot of Ni-based superalloy containing 70%return material was studied by industrial test sampling,and the mechanism of inclusions formation was analyzed with thermodynamic calculations.The results show that there are mainly two types of composite inclusions in the vacuum induction melting of Ni-based superalloys,which are nitride-and oxide-based composite inclusions,like Al_(2)O_(3)-SiO_(2)-Cr_(2)O_(3),TiN-(Mo,Nb)C,etc.The type and proportion of inclusions from the center to the edge of the vacuum induction ingot did not change significantly.The number density of inclusions from the center to the edge of the ingot varied less,and the size of inclusions became smaller from the center to the edge.In addition,thermodynamic calculations show that oxides(M_(2)O_(3))are present in the liquid phase and mainly contain Al,Ti,Cr,Fe and O elements.The nitride consists mainly of Ti and N and contains small amounts of Cr,C,Nb,and Mo elements.This is consistent with the results of industrial tests.As the temperature decreases,the precipitation phases such as M_(2)O_(3),MN,γ,MC,δ,γ'andμphases are gradually precipitated,where oxides and nitrides are present in the liquid phase.The contents of O and N elements are the main influencing factors for the inclusions content and precipitation temperature;when the nitrogen content is reduced to below 0.0015%,it can make MN precipitate below the liquid-phase line.

Ingredient Losses during Melting Binary Ni-Ti Shape Memory Alloys

Losses of the alloying elements during vacuum induction melting of the binary NiTi alloys were evaluated by visual observation and chemical analysis of the NiTi melted specimens and the scalp formed on the internal surface of the crucible. The results indicated that the major sources of the losses were （a） evaporation of the metals, （b） formation of the NiTi scalp and （c） the sprinkling drops splashed out of the melt due to the exothermic reactions occurring between Ni and Ti to form the NiTi parent phase. Quantitative evaluations were made for the metallic losses by holding the molten alloy for 0.5, 3, 5, 10 and 15 min at around 100℃ above the melting point inside the crucible.Chemical analysis showed that there existed an optimum holding time of 3 min during which the alloying elements were only dropped to a predictable limit. Microstructure, chemical composition, shape memory and mechanical properties of the cast metal ingots were determined to indicate the appropriate achievements with the specified 3 min optimum holding time.

CuCr25 W1 Ni2 contact material of vacuum interrupter

CuCr25W1Ni2 alloy was prepared by means of vacuum induction melting (VIM). A series of Cu/Cr alloys with different compositions (mass fraction, 25%～75%) and Cr grain sizes (up to 150 μm) were investigated for their differences in physical properties and breakdown voltage. The influence of alloy elements and microstructure on the performance of CuCr25W1Ni2 alloy was also discussed. Experimental results show that the chromium phase is strengthened and its size is minimized by the addition of tungsten powder. After electrical breakdown, very fine tungsten particles in the melt layer form the external nuclei in the solidification process. The microstructure of surface melt layer of CuCr25W1Ni2 alloy is much flatter. It can notably improve the dielectric strength. On the other hand, the nickel can enhance the mutual solubility of copper and chromium, and the whole alloy is strengthened. [

High Nitrogen Austenitic Stainless Steels Manufactured by Nitrogen Gas Alloying and Adding Nitrided Ferroalloys

A simple and feasible method for the production of high nitrogen austenitic stainless steels involves nitrogen gas alloying and adding nitrided ferroalloys under normal atmospheric conditions. Alloying by nitrogen gas bubbling in Fe-Cr-Mn-Mo series alloys was carried out in MoSi2 resistance furnace and air induction furnace under normal atmospheric conditions. The results showed that nitrogen alloying could be accelerated by increasing nitrogen gas flow rate, prolonging residence time of bubbles, increasing gas/molten steel interfaces, and decreasing the sulphur and oxygen contents in molten steel. Nitrogen content of 0.69% in 18Crl8Mn was obtained using air induction furnace by bubbling of nitrogen gas from porous plug. In addition, the nickel-free, high nitrogen austenitic stainless steels with sound and compact macrostructure had been produced in the laboratory using vacuum induction furnace and electroslag remelting furnace under nitrogen atmosphere by the addition of nitrided alloy with the maximum nitrogen content of 0.81%. Pores were observed in the ingots obtained by melting and casting in vacuum induction furnace with the addition of nitrided ferroalloys and under nitrogen atmosphere. After electroslag remelting of the cast ingots, they were all sound and were free of pores. The yield of nitrogen increased with the decrease of melting rate in the ESR process. Due to electroslag remelting under nitrogen atmosphere and the consequential addition of aluminum as deoxidizer to the slag, the loss of manganese decreased obviously. There existed mainly irregular Al2O3 inclusions and MnS inclusions in ESR ingots, and the size of most of the inclusions was less than 5 um. After homogenization of the hot rolled plate at 1 150℃ × 1 h followed by water quenching, the microstructure consisted of homogeneous austenite.

Hot cracking behavior of large size GH4742 superalloy vacuum induction melting ingot

The developing of large size superalloy vacuum induction melting(VIM)ingots is limited owing to hot cracking,The hot cracking behavior of the large size GH4742 superalloy VIM ingot was investigated via experiment and simulation.The microstructure was examined by optical microscopy,and element segregation was investigated by electron probe microanalysis.The solidification temperature range and yield strength at high temperature(YSHT)were calculated by JMatPro software.The results show that the variations of microstructure and element segregation in different locations are caused by different cooling rates.Moreover,the larger secondary dendrite arm spacing and serious element segregation of Nb accelerate hot cracking of the VIM ingot.In addition,the solidification temperature range is wider,and YSHT is lower in center than at edge of the ingot.Therefore,the hot cracking susceptibility is the highest in the center of the GH4742 superalloy VIM ingot.The critical criterion of element segregation for hot cracking is that the partition coeffcient of Nb should be larger than 0.5.

MICROSTRUCTURE AND PROPERTIES OF CuCr25 ALLOYS WITH DIFFERENT Ni CONTENT

CuCr25 alloys containing different Ni content were prepared by vacuum induction melting (VIM). The micro structure and properties were tested. The results show that with the increase of Ni content in CuCr25 alloys, the Cr phase changed from developed dendrite into nodular grains and was drastically refined; the electrical conductivity significantly decrease, but still reach the level of conventional CuCr50 when the Ni content is below 0.5%. The Ni content had little influence on their breakdown strength. The first breakdown sites transferred to the boundary of Cu and Cr phase for CuCr25Ni compared to the Cr phase for CuCr25 without Ni.

Evaluation of Mechanical Properties According to Nb Content of High Strength Steel Manufactured in VIM

As the aircraft and aerospace industry and the automobile industry are developed, the demand of reliable materials with high strength and high toughness is steadily increased. The grain miniature method which improves the ductility and the toughness simultaneously under high strength is the miniature of the casting microstructure. In this paper, the Nb which affects the austenite grain miniature is added by 0.00%, 0.03% and 0.06% in this steel and the ingot is manufactured in a vacuum induction melting furnace （VIM）. The casting microstructure and the mechanical property of the maraging steel according to Nb contents are analyzed by conducting the solution annealing and the age hardening after hot rolling. In this result, a specimen containing 0.03% Nb is most miniature. When it does the long time age hardening, the precipitation estimated as the carbide is appeared. The mechanical properties are excellent if a specimen containing 0.06% Nb does the age hardening during 8 h in 482℃.

Mechanism of yttrium in deep desulfurization of NiCoCrAIY alloy during vacuum induction melting process

In this study,yttrium as desulfurizer on the purification of Ni-20Co-20Cr-10Al-Y alloy during vac-uum induction melting(VIM)process using Y_(2)O_(3)cru-cibles was investigated experimentally.It is found that Y plays an important role on the desulfurizing of the NiCo-CrAIY alloy.Without any addition of Y,merely the employment of Y_(2)O_(3)crucibles could effectively reduce S content of the alloy melts from 28×10^(-6)to 6×10^(-6)-7×10^(-6).With addition of 0.8 wt%Y in the alloy,the concentration of S could further reduce 2×10^(7)3×10^(-6).The primary interactive mechanism between Y and molten alloy was concluded to be the synthesis reac-tion of NisY phase,Y2S3 phases and YAIO_(3)phase.In the desulfurize slags,Y2S3 phases and Y_(2)O_(3)phase are found.No secondary contamination is present in the alloy melts after addition of Y.

PROCESSING TECHNOLOGIES FOR TURBINE COMPONENTS

Processing technologies for the mass production of aero and industrial gas turbine engine hot-section components made by the investment casting process are discussed. Howmet Corporation is involved in most of these technologies because of the end-user's desire for a finished part. These technologies include pattern-making (using a variety of wax and plastic materials, rapid prototyping, 'hard' tooling, and wax injection machines), silica-zircon and alumina cores that produce internal passages, shells for very large parts and for use with alloys containing reactive elements, Ni, Co, and Ti alloys that are cleaner than ever before,zirconia, silica, and mullite crucibles;computer-controls,robotics,and the manufacture of vacuum casting furnaces; cleaning and finishing equipment designed to quickly process parts with minimal variation,and post-casting operations including hot isostatic pressing (HIP),heat treating,coating,and machining. These technologies will be discussed along with process capabilities required by today's turbine hot-section component suppliers.

Effect of vanadium addition on microstructure and properties of AI_(0.5)Cr_(0.9)FeNi_(2.5)multi-principal alloys

AI_(0.5)Cr_(0.9)FeNi_(2.5)V_(x)(x=0,0.2,0.4,0.6,0.8,1.0)multi-principal alloys were prepared by vacuum arc melting.The effect of vanadium addition on its microstructure and properties was investigated.The results show that the alloys of all components exhibited an FCC single-phase structure.With the addition of vanadium,the microstructure of the alloy changed from dendrites to equiaxed crystals,the grains were remarkably refined,and the layered CrV phase was exhibited,which improved the properties of the alloy.The yield strength of the alloy was slightly improved,and the alloys with various components presented good plasticity.When V content reached 0.8,the yield strength was 600 MPa,and no fracture occurred.Friction-wear testing showed that the wear debris was reduced with the addition of V element.The sample with V element content of 0.4 had the best friction and wear performance.The surface grooves became shallow,the worn debris was less,and the wear mechanism was mainly abrasive wear.The polarisation curve showed that the alloy with V element content of 0.2 has the best corrosion resistance.The passivation interval reached 900 mV.The corrosion potential and the corrosion current density were-496.299 mV and 2.759μA/cm^(2),respectively.

Effect of vanadium content on microstructure and properties of in situ TiC reinforced V_(x)FeCoNiCu multi-principal-element alloy matrix composites

V_(x)FeCoNiCu high entropy alloy matrix composites reinforced by in situ TiC particles(10 vol.%),i.e.,V_(x)FeCoNiCu/TiC composites,were fabricated from V–Fe–Co–Ni–Cu–Ti–C system using vacuum inductive melting method.With the content of vanadium increasing,the size of TiC particles decreased gradually.Meanwhile,vanadium agglomeration occurred slightly.The reaction mechanism of the mixed powder(Fe,V,Ti and C)and the mechanical properties of obtaining V_(x)FeCoNiCu/TiC composites were studied.It was found that three reactions occurred(Fe-Ti-FeTi-Fe_(2)Ti,FeTi-Fe_(2)Ti-Fe-Ti and Ti-C-TiC)in the heating process.The apparent activation energy for these three reactions was calculated and found to be 26.4,698.3 and 1879.0 kJ/mol,respectively.At room temperature,tensile strength and elongation increased first and then decreased with the increase in vanadium content and the microhardness increased gradually.The maximum tensile strength of the composites was determined to be 666 MPa,representing a 17.7%increase over that of FeCoNiCu/TiC high entropy alloy composites.