横向限制下凝固微观组织演化的相场法模拟

凝固过程中横向限制挡板的存在对晶体微观结构的演化存在重要的影响, 不同性质的横向挡板将产生不同的限制效应, 对最终凝固微观组织形成起着决定性作用. 本文利用非等温相场模型, 定性地模拟了纯金属Ni凝固过程中横向限制的存在对其枝晶微观形貌演化的影响, 研究了不同尺寸及性质的横向挡板对枝晶微观结构形成的影响, 讨论了横向限制对不同初始枝晶间距枝晶形貌发展的作用. 计算结果表明, 横向限制挡板的存在将直接影响凝固过程中微观组织的形貌演化过程并最终改变微观结构. 随着横向挡板间距的减小, 微观组织变化更加明显; 挡板初始温度越低, 枝晶形貌改变越明显; 初始枝晶间距越大, 形貌变化越明显; 不同挡板高度对微观结构具有基本相同的影响. 关键词： 相场模拟 微观组织演化 横向限制     

二元合金微观偏析的相场法数值模拟

使用耦合溶质场的相场模拟研究了Ni-Cu二元合金枝晶生长过程中固相溶质扩散系数D_s 对枝晶形貌和微观偏析等的影响.计算结果表明，随着D_s的减少，固液界 面前沿溶质扩散层越薄，枝晶生长越有利，枝晶尖端生长的速度越大，侧向分支越发达；D< sub>s越小，固相中溶质成分的波动越强烈，随着D_s的增大，固相中溶质 成分的波动相应减小；溶质微观偏析程度随D_s的增大而减小. 关键词： 相场方法 微观偏析 固相扩散系数 数值模拟     

采用多相场法研究三维层片共晶生长的厚度效应

采用Kim,Kim,Suzuki和Ode提出的KKSO多相场模型,研究了固定层片间距不同层片厚度条件下三维过共晶层片生长形态的演化行为.研究表明,层片厚度对层片生长过程有较大影响.当层片厚度较小时,厚度效应较弱,类似于二维生长.随着层片厚度的增加,厚度效应逐渐增强并开始产生厚度方向的振荡失稳,造成层片取向的偏转.层片厚度的进一步增加,使层片宽度方向和层片厚度方向的振荡交替出现.当层片厚度大于层片宽度时,厚度效应逐渐强于宽度效应,最终宽度方向的振荡被抑制,仅在厚度方向形成类似于二维的1λ振荡. 关键词： 数值模拟 多相场 三维层片生长 层片厚度     

相场法模拟弹性场对沉淀相变组织演化及相平衡成分的影响

采用相场法模拟沉淀组织在不均匀共格本征弹性场及外加约束弹性应变作用下的演化历程，探讨了不均匀共格本征弹性场及外加约束弹性应变对共格沉淀组织演化的影响规律，并分析了弹性场在沉淀相变中对基体与沉淀相的平衡成分的影响. 关键词： 相场法 沉淀组织 弹性场 相平衡成分     

Ti-45at.% Al合金定向凝固过程中显微组织演化的计算机模拟

采用基于溶质扩散控制模型CA方法对Ti-45at.% Al合金定向凝固过程中显微组织演化过程进行了数值模拟.模拟结果表明,在温度梯度较高时,初生晶核间距无论大小,均可通过分枝或竞争生长而使一次胞晶/枝晶间距得到调整.在抽拉速度一定情况下,随着温度梯度增加,胞晶/枝晶间距减小,在温度梯度一定情况下,随着抽拉速度增大,观察到胞晶/枝晶混合结构,混合结构区随温度梯增大而增大,模拟结果与实验观察相符合. 关键词： Ti-45at.% Al合金 定向凝固 组织演化 数值模拟     

Fe-Cr合金晶界偏析及辐照加速晶界偏析的相场模拟

基于WBM相场模型对热力学条件和辐照条件下Fe-Cr合金晶界处Cr元素偏析行为进行了模拟.模拟结果表明温度对Fe-Cr合金晶界处Cr元素的偏析有很大影响:当温度低于500℃时,晶界处的偏析量很小;而当温度高于500℃时晶界处的偏析量增加明显.基体中Cr元素含量对晶界Cr元素的相对偏析量也有显著影响:随着基体中Cr元素含...     

三维枝晶生长的相场法数值模拟研究

基于薄界面限制、耦合界面能各向异性的相场模型,采用动态计算区域的加速算法,对纯物质的三维枝晶生长进行了定量模拟,真实再现了枝晶的生长过程.对枝晶尖端进行了剖切分析,表明主枝截面上各向异性没有主枝方向各向异性明显;对枝晶尖端生长速度、尖端半径、Peclet数及临界稳定性参数σ^*进行模拟计算,并与同条件下报道值进行了对比分析,两者符合良好,并得到了与结晶理论相一致的枝晶生长规律,证实了相场方法模拟三维空间枝晶生长可行有效. 关键词： 相场方法 枝晶生长 微观组织 三维数值模拟     

Ni75Cr25-xAlx合金中L12相和D022相形核孕育期的微观相场模拟

基于微观相场动力学模型,运用原子图像、平均长程序参数和平均成分偏离序参数,研究了Al浓度对Ni75Cr25-xAlx合金中L12相和D022相形核孕育期的影响以及孕育期与沉淀相析出顺序之间的关系.结果表明,L12相和D022相的形核孕育期不仅与Al浓度有关,而且与两相析出的先后顺序密切相关.当Al浓度小于7.5%时,先析出相为D022相,随着Al浓度的增大,D022相形核孕育期延长,后析出的L12相的形核孕育期也延长,L12相的原子簇聚速度加快;当Al浓度大于7.5%时,先析出相为L12相,随着Al浓度的增大,L12相的形核孕育期缩短,后析出的D022相形核孕育期也缩短.当Al浓度为7.5%时,L12相和D022相几乎同时析出,两者的孕育期没有明显的差别.     

微通道内冰晶生长过程的相场模拟

为研究微通道内冰晶生长的微观机理以便提出相应的防结冰措施,建立了微通道内结冰过程的相场模型,模型中引入了实际边界条件的影响(取为第三类边界条件),相场计算中采用随机方法生成晶核。基于有限差分法对相场模型进行了数值求解,对不同边界条件影响强度(以努塞尔数Nu表征)下冰晶生长过程进行了系统研究。研究结果表明：边界对微通道内的冰晶生长影响显著,Nu越大,微通道内冰晶生长第一阶段(冰晶未扩展到边界时)结晶速率越大,使得充分结晶(定义为结晶百分数达到80%)所需总时间越短;同时应在结冰初始阶段对其进行及时干预才能有效防止结冰。     

相场法模拟第二相颗粒对柱状晶形成的影响

基于定向退火条件下的移动热区模型,采用相场法研究第二相颗粒对多晶材料中柱状晶结构形成的影响.结果表明:第二相颗粒对柱状晶结构的形成具有抑制作用,其抑制作用随第二相颗粒体积分数的增加和第二相颗粒尺寸的减小而增强.定向退火条件下第二相颗粒对晶粒极限尺寸的影响遵循Zener关系.为了获得良好的柱状晶结构,应尽量减少材料中第二相颗粒的体积分数及其在晶界上的弥散分布.     

Investigation of Ti-6Al-4V alloy acoustic softening

High power ultrasonic vibration is widely used for improving manufacturing processes such as machining and metal forming. High frequency mechanical vibration affects material properties and friction forces in contacting surfaces. Flow stress reduction under superimposed ultrasonic vibration is called as acoustic softening. The amount of this parameter should be determined for ultrasonic assisted metal forming processes. For determination of this parameter for workhorse Ti-6Al-4V alloy, experimental setup was designed and fabricated. Then tensile test under longitudinal ultrasonic vibration was performed for different ultrasonic powers. Results show that ultrasonic vibration has considerable effect on plastic behavior of the alloy and decreases flow stress. Also, increasing ultrasonic power leads to higher acoustic softening. Yield stress reduction up to 9.52%, ultimate stress reduction up to 4.55% and elongation up to 13% were obtained at 340 W ultrasonic power. After applying ultrasonic vibrations and its termination, hardness of specimens were measured in which increase up to 9% was observed.     

CO2 laser gas assisted nitriding of Ti-6Al-4V alloy

Laser gas assisted nitriding of Ti-6Al-4V alloy is carried out and nitride compounds formed and their concentration in the surface vicinity are examined. SEM, XRD and XPS are accommodated to examine the nitride layer characteristics. Microhardness across the nitride layer is measured. Temperature field and nitrogen distribution due to laser irradiation pulse is predicted. It is found that the nitride layer appears like golden color; however, it becomes dark gold color once the laser power irradiation is increased. The δ-TiN and ?-TiN are dominant phases in the surface vicinity. The needle like dendrite structure replace with the feathery like structure in the surface region due to high nitrogen concentration. No porous or microcracks are observed in the nitrided layer, except at high power irradiation, in this case, elongated cracks are observed in the surface region where the nitrogen concentration is considerably high.     

Assessment of precipitates of aged Ti-6Al-4V alloy by ultrasonic attenuation

Abstract

Ti-6Al-4V alloy with different microstructures was investigated by means of ultrasonic attenuation measurements. Widmanstätten and equiaxed microstructures were obtaining by heat treating a Ti-6Al-4V alloy. These two microstructures were over-aged at 545 °C at different ageing times. In order to find out the factors affecting the variation in the ultrasonic attenuation, the heat-treated samples were examined by optical microscopy and scanning electron microscopy. Based on the theory of ultrasonic attenuation in a solid media, the mechanisms of ultrasonic attenuation in the Ti-6Al-4V alloy with different microstructures were analysed. It was found that in both cases with Widmanstätten and equiaxed microstructures, the ultrasonic attenuation increased with frequency. After ageing, the ultrasonic attenuation was mainly attributed to the scattering loss which included the stochastic and the Rayleigh scattering due to the precipitation of Ti₃Al particles homogeneously distributed in the α phase. Data analysis presented in the study showed that ultrasonic attenuation yields more accurate area fractions of precipitates predictions when a polynomial fit is performed.     

Hydrogen peroxide treatment on Ti-6Al-4V alloy: A promising surface modification technique for orthopaedic application

Ti-6Al-4V alloy was treated with various concentrations (5 wt.%, 15 wt.% and 25 wt.%) of hydrogen peroxide (H₂O₂) and then heat treated to produce an anatase titania layer. The surface modified substrates were immersed in simulated body fluid (SBF) solution for the growth of an apatite layer on the surface and the formed apatite layer was characterized using various surface characterization techniques. The results revealed that titania layer with anatase nature was observed for all H₂O₂ treated Ti-6Al-4V alloy, irrespective of the H₂O₂ concentrations. Ti-6Al-4V alloy treated with 15 wt.% and 25 wt.% of H₂O₂ induced apatite formation, however 5 wt.% of H₂O₂ treated Ti-6Al-4V failed to form apatite layer on the surface. The electrochemical behaviour of H₂O₂ treated specimens in SBF solution was studied using potentiodynamic polarization and electrochemical impedance spectroscopy. Ti-6Al-4V alloy treated with 25 wt.% of H₂O₂ solution exhibited low current density and high charge transfer resistance values compared to specimens treated with other concentrations of H₂O₂ and untreated Ti-6Al-4V alloy.     

Surface characteristics of self-assembled microporous Ti-6Al-4V compacts fabricated by electro-discharge-sintering in air

A single electro-discharge-sintering (EDS) pulse (1.0 kJ/0.7 g), from a 300 (F capacitor, was applied to atomized spherical Ti-6Al-4V powder in air to produce microporous compact. A solid core surrounded by a porous layer was self-assembled by a discharge in the middle of the compact. X-ray photoelectron spectroscopy was used to study the surface characteristics of the compact material. C, N, O and Ti were the main constituents, with smaller amounts of Al and V. The surface was lightly oxidized and was primarily in the form of TiO₂. A lightly etched EDS sample showed the surface form of metallic Ti, indicating that EDS breaks down the oxide film of the as-received Ti-6Al-4V powder during the discharge process. The EDS Ti-6Al-4V compact surface also contained small amounts of TiN in addition to TiO₂, resulting in the reaction between nitrogen in air and the Ti substrate in times as short as 125 μs.     

Investigation of the voltage and time effects on the formation of hydroxyapatite-containing titania prepared by plasma electrolytic oxidation on Ti-6Al-4V alloy and its corrosion behavior

Producing titania and hydroxyapatite (HA) bioceramic coating on titanium alloys increases corrosion resistance and biocompatibility of these alloys. Plasma electrolytic oxidation (PEO) is one of the effective techniques for producing this type of coating. This method produces coatings with enough thickness and appropriate adhesion. In this study, titania and HA were directly produced on Ti-6Al-4V by applying PEO process in a Ca- and P-containing electrolyte by changing voltage and time parameters. Morphology and cross section, chemical composition and elements of coatings were investigated by scanning electron microscope, X-ray diffraction and energy dispersive spectroscopy, respectively. Corrosion behavior of the samples was also examined by potentiodynamic polarization and electrochemical impedance spectroscopy. The results indicated that the formation of HA phase with titania needs a minimum voltage below which HA is not formed. By increasing the operation time, the amount of the formed HA increased. Also, the sample coated at 500 V and 15 min showed the best corrosion behavior in Ringer's solution.     

Fabrication of Zr and Zr-N surface alloying layers and hardness improvement of Ti-6Al-4V alloy by plasma surface alloying technique

Titanium alloys are very attractive materials because they have high specific strength, excellent corrosion and erosion resistance in many active environments. However, their low hardness values and poor tribological properties require improvement of their surface properties. The present study is concerned with the fabrication of Zr and Zr-N alloying layers in the surfaces of Ti-6Al-4V substrates by plasma surface alloying technique. The microstructure, chemical composition and hardness of the surface alloying layers were analyzed to understand the mechanisms of surface alloying and hardness improvement. The Zr and Zr-N surface alloying layers formed were homogeneous and compact, in which the surface alloying elements all displayed gradient distributions. The Zr and Zr-N surface alloying layers all enhanced the surface hardness of Ti-6Al-4V alloy. Zr-N surface alloying resulted in greater improvement in hardness and the maximum microhardness of (1.37 ± 0.04) × 10³ HK was obtained at the subsurface, which was much higher than that of the untreated Ti-6Al-4V alloy. The Zr-N surface alloying layer consisted of an outer nitride layer and an inner diffusion zone of Zr and N, and its very high hardness owed to the formation of the nitride layer. The mechanism of hardness improvement of Zr surface alloyed Ti-6Al-4V alloy was solid solution strengthening.     

Grain refining of Ti-6Al-4V alloy fabricated by laser and wire additive manufacturing assisted with ultrasonic vibration

The formation of the coarse columnar crystal structure of Ti-6Al-4V alloy in the process of additive manufacturing greatly reduces the mechanical performance of the additive manufactured parts, which hinders the applications of additive manufacturing techniques in the engineering fields. In order to refine the microstructure of the materials using the high intensity ultrasonic via the acoustic cavitation and acoustic flow effect in the process of metal solidification, an ultrasonic vibration technique was developed to a synchronous couple in the process of Laser and Wire Additive Manufacturing (LWAM) in this work. It is found that the introduction of high-intensity ultrasound effectively interrupts the epitaxial growth tendency of prior-β crystal and weakens the texture strength of prior-β crystal. The microstructure of Ti-6Al-4V alloy converts to fine columnar crystals from typical coarse columnar crystals. The simulation results confirm that the acoustic cavitation effect applied to the molten pool created by the high-intensity ultrasound is the key factor that affects the crystal characteristics.     

Experimental investigation and metallographic characterization of fiber laser beam welding of Ti-6Al-4V alloy using response surface method

In the present study, experimental investigations of fiber-laser-beam-welding of 5 mm thick Ti-6Al-4V alloy are carried out based on statistical design of experiments. The relationship between the process parameters such as welding power, welding speed, and defocused position of the laser beam with the output responses such as width of the fusion zone, size of the heat affected zone, and fusion zone area are established in terms of regression models. Also, the most significant process parameters and their optimum ranges are identified and their percentage contributions on output responses are calculated. It is observed that welding power and speed plays the major role for full penetration welding. Also, welding power shows direct effect whereas welding speed shows the inverse effect on the output responses. The bead geometry is influenced by the defocused position of the laser beam due to the change in power density on the workpiece surface. However, overall fusion zone area is unaffected. Mechanical characterization of the welded samples such as microstructural analysis, hardness, and tensile tests are conducted. It is noticed that the hardness value of the FZ is higher than the HAZ and BM zone due to the difference in cooling rate during welding which promotes the formation of α′ martensitic phase in the FZ. Also, an average hardness value in the FZ is compared for two different defocusing positions (i.e. 1 and 2 mm). It is found that hardness value is higher for 1 mm defocused position than 2 mm due the decrement in grain size below a critical range at 2 mm defocused position. The ultimate tensile strength and % elongation of the welded samples are degraded as compared to BM which can be further improved by post heat treatment.