Ultrasound cavitation induced nucleation in metal solidification: An analytical model and validation by real-time experiments

Microstructural refinement of metallic alloys via ultrasonic melt processing (USMP) is an environmentally friendly and promising method. However, so far there has been no report in open literature on how to predict the solidified microstructures and grain size based on the ultrasound processing parameters.In this paper, an analytical model is developed to calculate the cavitation enhanced undercooling and the USMP refined solidification microstructure and grain size for Al-Cu alloys. Ultrafast synchrotron X-ray imaging and tomography techniques were used to collect the real-time experimental data for validating the model and the calculated results. The comparison between modeling and experiments reveal that there exists an effective ultrasound input power intensity for maximizing the grain refinement effects for the Al-Cu alloys, which is in the range of 20-45 MW/m². In addition, a monotonous increase in temperature during USMP has negative effect on producing new nuclei, deteriorating the benefit of microstructure refinement due to the application of ultrasound.     

Sc在Al-Zn-Mg-Cu超高强铝合金中作用机理的电子理论研究

通过晶胞平移获得Al-Zn-Mg-Cu合金中α-Al,Al₃Sc及η相原子集团模型,采用自编软件建立α-Al/液态Al界面、α-Al/Al₃Sc界面原子团模型.用递归法计算合金中各组织的态密度、结合能、费米能级,合金元素Sc与空位相互作用能等电子参数.依据电子参数解释合金晶粒细化、腐蚀的物理本质.研究表明： Al₃Sc从液态金属析出时释放的能量比α-Al从液态金属析出时所释放的能量少,可先于α-Al从液态金属中析出;且α-Al 关键词： 电子结构 腐蚀 超高强Al合金     

Influence of the evolution of heat-resistant phases on elevated-temperature strengthening mechanism and deformation behavior in Al–Si multicomponent alloys

Evolution of the heat-resistant phases and deformation behavior of α-Al matrix of four alloys have been characterized by SEM and EBSD. The strengthening mechanisms influenced by morphology and distribution of the heat-resistant phases were described. And the strain contouring of the α-Al matrix after deformation was rendered. The heat-resistant phases with block-like as reticular or semi-reticular network distribution exist in grain boundary can effectively provide elevated-temperature strength for alloys, while the strain contouring of α-Al matrix is mainly concentrated in the area with fewer intermetallic phases. It is shown that intermetallic phase evolution corresponds to extrusion treatment and the formation of eutectic Si and primary Si, highly interconnected networks of intermetallic phases exist in the alloy in which the primary Si and the eutectic Si are simultaneously present or disappeared. And only the disappearance of the primary Si and the extrusion treatment will destroy the network structure of the intermetallic phases. A reticular or semi-reticular microstructure is more capable of matching strength and plasticity and facilitating uniform deformation of the α-Al matrix. And the destruction of this microstructure is allowed to accommodate more plastic strain before failure.     

Melting and solidification characteristics of Zr-, Ni-, and Mn-containing 354-type Al-Si-Cu-Mg cast alloys

This study investigated the effects of adding Zr, as a base alloying element, besides Ni and Mn in different amounts and combinations on the melting and solidification characteristics of 354-type Al-Si-Cu-Mg alloys. Differential scanning calorimetry (DSC) was used to characterise the sequence of reactions occurring during the heating and/or cooling cycles; whereas scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS) techniques were used to observe and identify existing intermetallic phases. Nickel proved to have a retarding effect on the kinetics of precipitation of the α-Al network and the eutectic Al-Si structure. Also, the presence of Ni consumed a considerable amount of Cu to form Al-Cu-Ni particles instead of Al₂Cu particles. Results revealed that solution treatment at 495°C for 5?h was sufficient to dissolve a large amount of Al₂Cu particles in the α-Al matrix, which is mandatory for a successful aging treatment of the alloys studied. Additions of these transition elements produced new intermetallic phases such as (Al,Si)₃(Ti,Zr), (Al,Si)₃Zr, Al₉FeNi, Al₃Ni, Al₃CuNi, and Al₉FeSi₃Ni₄Zr, in addition to the other phases, namely α-Al, eutectic silicon, Al₂Cu, Mg₂Si, Q-phase (Al₅Cu₂Mg₈Si₆), commonly observed in 354-type alloys, and Fe-based intermetallic phases including β-Al₅FeSi, α-Al₁₅(Fe, Mn)₃Si₂, and π-Al₈FeMg₃Si_6. Superheating the melt at 800°C instead of 750°C had an advantageous effect in that Al₃Zr particles originating from the Al-15%Zr master alloy were dissolved and hence coarse Zr-containing particles were barely spotted in the microstructures examined.     

Alloying effects of the elements with a positive heat of mixing on the glass forming ability of Al-La-Ni amorphous alloys

The effects of Sn and Ga additions on the glass forming ability(GFA)of(Al86La5Ni9)100 xSnx(x=0,0.2,0.3,0.5,0.7,1 and 2at.%)and(Al86La5Ni9)100 xGax(x=0,0.2,0.5,1 and 1.5 at.%)alloys were systematically investigated.Unlike common microalloying methods,both Sn and Ga have a positive heat of mixing with the main component of Al.Our analysis confirmed that proper Sn addition can suppress the strong formation ofα-Al and enhance the GFA due to the positive heat of mixing between Sn and Al and the large difference in their atomic sizes.While the addition of Ga to the base alloy acted as the nucleation cites forα-Al and accelerated precipitation of theα-Al phase,thus deteriorating the GFA.     

Structure and magnetism of Fe-rich nanostructured Fe–Ni metastable solid solutions

New futures on the physical properties of ferromagnetic FeNi alloys have been found combining in situ neutron diffraction experiments and magnetic measurements in mechanical milled Fe-rich Fe–Ni metastable solid solutions. Apart from the well-known Invar effect, on heating these materials are characterised by the existence of a first-order martensite–austenite transformation that takes place at some system-dependent temperature. On cooling, the transformation occurs at a lower temperature than on heating; for Fe₈₀Ni₂₀ the size of the effect being larger than 100 °C, much more than the values found in conventional FeNi alloys. These results are discussed considering intrinsic features as magnetovolume effects and/or extrinsic effects such as small grain size and the existence of defects.     

Dendritic growth and solute trapping in rapidly solidified Cu-based alloys

Rapid solidification of binary Cu-22%Sn peritectic alloys and Cu-5%Sn-5%Ni-5%Ag quaternary alloys was accomplished by glass fluxing, drop tube and melt spinning methods. The undercooled, by glass fluxing method, Cu-22%Sn peritectic alloy was composed of α(Cu) and δ(Cu41Sn11) phases. If rapidly solidified in a drop tube, the alloy phase constitution changed from α(Cu) and δ(Cu41Sn11) phases into a single supersaturated (Cu) phase with the reducing of droplet diameter, and the maximum solubility of Sn in (Cu)...     

Influence of impurity elements on the nucleation and growth of Si in high purity melt-spun Al–Si-based alloys

The nucleation and growth of Si has been investigated by TEM in a series of high purity melt spun Al–5Si (wt%)-based alloys with a trace addition of Fe and Sr. In the as-melt-spun condition, some twinned Si particles were found to form directly from the liquid along the grain boundary. The addition of Sr into Al–5Si-based alloys promotes the twinning of Si particles on the grain boundary and the formation of Si precipitates in the α-Al matrix. The majority of plate-shaped and truncated pyramid-shaped Si precipitates were also found to nucleate and grow along {111}_α-Al planes from supersaturated solid solution in the α-Al matrix. In contrast, controlled slow cooling decreased the amount of Si precipitates, while the size of the Si precipitates increased. The orientation relationship between these Si precipitates and the α-Al matrix still remained cube to cube. The β-Al₅FeSi intermetallic was also observed, depending on subsequent controlled cooling.     

First-principles calculations on Al/AlB2 interfaces

The AlB₂ (1 1 1) surfaces and Al (1 1 1)/AlB₂ (0 0 0 1) interface were studied by first-principles calculations to clarify the heterogeneous nucleation potential of α-Al grains on AlB₂ particles in purity aluminium and hypoeutectic Al-Si alloys. It is demonstrated that the AlB₂ (0 0 0 1) surface models with more than nine atomic layers exhibit bulk-like interior, wherein the interlayer relaxations localized within the top three layers are well converged. The outmost layer of AlB₂ free surface having a preference of metal atom termination is evidenced by surface energy calculations. With Al atoms continuing the natural stacking sequence of bulk AlB₂, Al-Al metallic bonds are formed across interface during the combination of Al atoms with Al-terminated AlB₂ surface. The calculated interfacial energy of the Al/AlB₂ interface is much larger than that between the α-Al and aluminium melts, elucidating the poor nucleation potency of α-Al grains on AlB₂ particles from thermodynamic considerations.     

Ultrasonic semi-solid coating soldering 6061 aluminum alloys with Sn–Pb–Zn alloys

In this paper, 6061 aluminum alloys were soldered without a flux by the ultrasonic semi-solid coating soldering at a low temperature. According to the analyses, it could be obtained that the following results. The effect of ultrasound on the coating which promoted processes of metallurgical reaction between the components of the solder and 6061 aluminum alloys due to the thermal effect. Al₂Zn₃ was obtained near the interface. When the solder was in semi-solid state, the connection was completed. Ultimately, the interlayer mainly composed of three kinds of microstructure zones: α-Pb solid solution phases, β-Sn phases and Sn–Pb eutectic phases. The strength of the joints was improved significantly with the minimum shear strength approaching 101 MPa.     

Microstructure effect on microtopography of chemically etched α + β Ti alloys

Microstructure effect on chemical etching behavior of the annealed Ti-6Al-4V and Ti-3Al-2.5V titanium (Ti) alloys was compared with that of unalloyed commercially pure titanium. The microstructural evolution of structure phases after annealing the titanium and its alloys at temperature near and above β transus and followed by furnace cooling to room temperature was studied using optical microscope, scanning electron microscope and X-ray diffraction techniques. The microstructure study illustrates that the heat treatment enhanced partitioning effect allows extensive formation of hemispherical and near spherical pits roughened surface to be readily acquired by chemically etching the annealed α + β titanium alloys. The kinetics of the chemical etching reaction process show a linear dependence on time. The annealed α + β titanium alloys that exhibit relatively lower weight loss and thickness reduction rate illustrate less chemical activity than the annealed unalloyed titanium.     

Microstructural modification by laser surface remelting and its effect on the corrosion resistance of an Al-9 wt%Si casting alloy

Aluminum alloys with silicon as a major alloying element constitute a class of materials, which provides the most significant part of all shaped castings manufactured. Such alloys have a wide range of applications in the automotive and aerospace industries. The literature presents contradictory results and no satisfactory explanations concerning to resulting microstructures provided by laser surface remelting (LSR) and its effect on the electrochemical behavior of Al-Si alloys. The aim of this study was to investigate the effect of microstructural refinement by LSR on corrosion resistance of an Al-9 wt%Si casting alloy. As-cast samples were subjected to a continuous 1 kW CO₂ laser. Corrosion resistance has been analyzed by an electrochemical impedance spectroscopy (EIS) technique and polarization curves carried out in both 0.5 M NaCl and 0.5 M H₂SO₄ solutions at 25 °C. An equivalent circuit has also been proposed and impedance parameters were simulated by the ZView^® software. It was found that the structural modification provided by the LSR process induces a decreasing effect on the corrosion resistance when compared to that of the untreated sample.     

Influence of Cr content on structure and magnetic properties of Fe-Si-Al-Cr powders

As a kind of soft magnetic metallic material, flaky FeSiAl powders have been studied and used widely. Transition metal chromium can improve the magnetic properties of FeSiAl. This article prepared Fe₈₅Si_9.5-xAl_5.5Cr_x (x=0, 2, 4, 6 wt%) alloys powders by adding chromium to replace silicon in alloys. The morphology and microstructure of alloys powders were studied, electromagnetic parameters were measured and microwave absorption properties in the frequency range from 0.5 to 18 GHz were analyzed. With the increase of Cr content, α-Fe (Al, Si) superlattice phases appeared in alloys powders, and then disappeared. Excessive Cr precipitated from the alloys when its content reaches 6 wt%. The minimum reflection loss (-20 dB) among the four powders was 2 wt% Cr content at the frequency of 11.5 GHz. The peaks of reflection loss shifted to the low frequency range with increase in Cr content.     

An overview and critical assessment of the mechanisms of microstructural refinement during ultrasonic solidification of metals

A refined, equiaxed grain structure and the formation of finer primary intermetallic phases are some of the notable benefits of ultrasonic processing of liquid/solidifying melts. Ultrasonic treatment (UST) has been widely explored in Al and Mg-based alloys due to its operational versatility and scalability. During UST, the refinement of grain and primary intermetallic phases occurs via cavitation-induced fragmentation mechanisms. In addition, UST improves the efficiency (activation of particles) of the conventional grain refinement process when potent particles are added through master alloys. Though the UST’s ability to produce refined as-cast structures is well recognized, the understanding of the refinement mechanisms is still debated and unresolved. Significant efforts have been devoted to understanding these mechanisms through the use of sophisticated techniques such as in-situ/ real-time observation, lab-scale and commercial-scale casting processes. All these studies aim to demonstrate the significance of cavitation, fragmentation modes, and alloy chemistry in microstructure refinement. Although the physical effects of cavitation and acoustic streaming (fluid flow) are primary factors influencing the refinement, the dominant grain refinement mechanisms are affected by several solidification variables and casting conditions. Some of these include melt volume, solute, cooling rate, potent particles, grain growth (equiaxed, columnar or dendritic), and the cold zones of the casting where the onset of nucleation occurs. This review aims to provide a better insight into solidification variables emphasizing the importance of cold zones in generating fine structures for small- and large-volume (direct chill) castings. Another important highlight of this review is to present the relatively less explored mechanism of (acoustic) vibration-induced crystallization and discuss the role of cavitation in achieving a refined ingot structure.     

Temperature dependence of atomic clusters and magnetic properties of α-phase Fe-V alloy by Mössbauer and VSM studies

In this work, α-phase Fe-12 V alloy (at.%) with high total magnetostriction is selected to perform Mössbauer and Vibrating Sample Magnetometer (VSM) measurements to investigate the temperature dependence of atomic clusters and the magnetic properties. The results show that with increasing temperature, the ferromagnetism firstly drops and then slightly increases, and finally decreases severely, which is mainly determined by the variations of the three kinds of atomic clusters (Fe-rich, V-rich and free-Fe) in the alloy. The hyperfine magnetic field, which decreases with temperature, is always dominated by the Fe-rich clusters. The atomic combination of the free-Fe clusters also determines the magnetic properties in the temperature range from room temperature to 600 °C; however, the free-Fe clusters contribution to the hyperfine magnetic fields tends to become zero above 600 °C, whereas that of the V-rich becomes obvious. When the temperature is high enough, the hyperfine magnetic field decreases sharply due to the destruction of the ordered Fe-rich state. VSM was selected to understand the relationship between the magnetic moment and the heating temperature, and the Curie temperature (T_C=836.36 °C) of the Fe-12 V alloy was obtained as well. Finally, the formula reflecting the magnetic moment of the α-phase Fe-12 V alloy varying with temperature is also successfully derived.     

Glass formation and microstructure evolution in Al–Ni–RE (RE = La,Ce, Pr,Nd and misch metal) ternary systems

Glass formation has been systematically studied in melt-spun Al-rich Al–Ni–RE (RE?=?La, Ce, Pr, Nd and Mm; Mm?=?misch metal) alloys by navigating the compositions following the observation of microstructure evolution in the resulting ribbons. The optimum glass-forming regions are similarly located around Al₈₅Ni₁₀RE₅ and found in the centre of the composites with primary phase α-Al, Al₁₁RE₃ and Al₃Ni. The similarities in the critical cross-section below which a component is fully amorphous and the optimum compositions in these Al–Ni–RE systems are interpreted in terms of their competing crystalline phases and thermodynamic properties. Interestingly, it is indicated that Ni content is markedly higher than RE content in the best glass-forming alloys, which may be associated with strong interaction between Ni–Al atom pairs and the dense packing due to Ni-centred clusters.     

Laser surface alloying of Ni-plated steel with CO2 laser

Laser surface alloying of low carbon steel electroplated with thin (10 μm) Ni using an 850 W CW CO₂ laser is reported for the first time. Fe-Ni binary alloys of different concentrations are formed by varying laser traverse speed from 0.5 to 5 m/min. The phase transformation from α to α + γ is discussed as a function of Ni contents. Development of microstructure in the modified zone is analysed in terms of solidification rate and Ni concentration. A three-fold increase in the microhardness of the binary alloy is observed. Formation of homogenous, adherent and crack free surface alloys is reported.     

Microstructure characterization of mechanosynthesized nanocrystalline NiFe2O4 by Rietveld's analysis

Nanocrystalline nickel ferrite (NiFe₂O₄) is synthesized at room temperature by high-energy ball milling the stoichiometric mixture of (1:1 mol%) of NiO and α-Fe₂O₃ powders. The structural and microstructural evolution of NiFe₂O₄ caused by milling is investigated by X-ray powder diffraction. The relative phase abundance, particle size, r.m.s. strain, lattice parameter changes of different phases have been estimated employing Rietveld structure refinement analysis of X-ray powder diffraction data. Particle size and content (wt%) of both NiO and α-Fe₂O₃ phases reduce rapidly with increasing milling time and a significant amount of nanocrystalline NiFe₂O₄ is formed within 1 h of ball milling. Particle sizes of all the phases reduce to ∼10 nm within 5 h of milling and remain almost unchanged with increasing milling time up to 20 h. Lattice parameter of cubic NiO decreases linearly with increasing milling time, following the Vegard's law of solid-solution alloy. A continuous decrease in lattice parameter of cubic NiFe₂O₄ phase clearly suggests that smaller Ni atoms have occupied some of the vacant oxygen sites of ferrite lattice. Cation distribution both in octahedral and tetrahedral sites changes continuously with milling time and the normal spinel lattice formed at early stage of milling, transforms to inverse spinel lattice in the course of milling. High-resolution transmission electron microscope (HRTEM) micrographs of 11 h milled sample corroborates the findings of X-ray profile analysis.     

Microstructural behavior on particle surfaces and interfaces in Sm2Fe17N3 powder compacts during low-temperature sintering

Sm₂Fe₁₇N₃ sintered compacts were prepared below 450 °C by a high-pressure current sintering technique. The coercivity of the sintered compacts decreased linearly as the sintering temperature increased. Transmission electron microscopic analyses indicated that thin Fe-rich layers containing α-Fe phases were formed just inside the initial oxide layer on the particle surfaces and interfaces in the sintered samples. The generation of α-Fe phases was supposed to cause the coercivity decrease. In addition, X-ray photoelectron spectroscopy analysis revealed that Fe₂O₃ and FeO contained in the oxide layer of the raw powder disappeared subsequent to heat treatment. These results suggested that the α-Fe phases were generated by the oxidation–reduction reaction between the initial iron oxides and the primary Sm₂Fe₁₇N₃ phase but not by thermal decomposition or exogenous oxidation during sintering. This mechanism was supported by the fact that extending the sintering time did not result in any further decrease in the coercivity.     

Pre-treatments applied to oxidized aluminum surfaces to modify the interfacial bonding with bis-1,2-(triethoxysilyl)ethane (BTSE): Part II. Anodized 7075-T6 Al alloy

The methods of X-ray photoelectron spectroscopy (XPS), secondary-ion mass spectrometry (SIMS), and scanning electron microscopy (SEM) have been used to investigate aspects of the bonding of bis-1,2-(triethoxysilyl)ethane (BTSE) onto anodized samples of 7075-T6 aluminum alloy that have been subjected to the various pre-treatments considered in Part I. The oxide layer thins when this sample is subjected to a Forest Products Laboratory (FPL) treatment; topographical changes are detected by SEM after only 5 min, and the “scallop structures” increase in size for longer times of the FPL treatment. These 7075-Al surfaces adsorb more BTSE than the high-purity Al samples considered in Part I, although the interfacial bonding indicated by the [AlOSi]⁺/[Al₂O]⁺ SIMS ratios measured for the former samples are constant for different times of FPL treatment, unlike the situation for high-purity Al. Heating anodized 7075-Al samples, either before or after FPL treatment, has no significant effect on the subsequent BTSE adsorption, but a H₂ plasma treatment can enhance the interfacial Al-O-Si bonding with a decrease in the total BTSE polymerization.