Freeze casting of aqueous coal fly ash/alumina slurries for preparation of porous ceramics

A porous mullite-matrix composite with a bimodal pore structure has been prepared by a freeze casting route using water/coal fly slurry system. The top and bottom parts of the sintered freeze cast body consisted of solid particles and micropores, which were irregularly distributed. However, the middle section was made up of small lamellar pores and porous ceramic walls, aligned along the solidification direction. The porosity of mullite composites was in the range 67-55% after sintering at 1300-1500 °C. The addition of 3Y-ZrO₂ reduced the porosity, especially material in sintered at 1500 °C due to relatively high densification. The compressive strength of the porous composite with 10 wt% 3Y-ZrO₂ addition, sintered at 1500 °C exhibited a maximum value of ∼41 MPa.     

Experimental investigation on the flame front resistance of gas channel growth with melt formation in iron ore sinter beds

The resistance of the flame front within the solid bed constitutes a fundamental and crucial area in porous bed combustion as the flame front propagation is highly related to the productivity and product quality. This paper focuses on the iron ore sintering, a thermal agglomeration process in steel mills. The results from a detailed experimental study of the pilot-scale pot tests under the conditions of a wide range of fuel rate are presented. The primary objective is to provide better understanding of the growth of gas channels relating to melt formation in the flame front and its resistance to flow. The sintering bed was divided into several zones based on the temperature profile and component distribution. Even though there is a continuous one-to-one replacement of humidified zone with porous sintered zone, a constant air flow rate during sintering could be obtained, indicating the ～100?mm high-temperature zone has a controlling effect on sintering bed permeability. The specific pressure drop value in high-temperature zone increases from ～3?kPa in upper bed to ～7?kPa in bottom bed, which varies with the bed temperature and structure properties. Both the green bed and sintered bed were scanned by X-ray computed tomography, the reconstruction and image analysis showed that the sintered bed has large gas channels and many more closed pores due to solid-melt-gas coalescence. More melt is generated when the heat is accumulated along the bed or input higher coke content, showing a propensity to suppress the gas channel growth and amplify the mismatch of gas transportation along the bed. Higher coke rate leads to a higher resistance in flame front, resulting in a slower flame front speed. These results are aimed to provide quantitative validation for improvements of a numerical sintering model in a future work.     

Porous structure, permeability, and mechanical properties of polyolefin microporous films

Microporous films of polyolefins, namely, polyethylene and polypropylene, have been prepared using the process based on the extrusion of the melt with the subsequent annealing, uniaxial extension, and thermal fixation. The influence of the conditions used for preparation of the films on their morphology, porosity, number and sizes of through-flow channels, and mechanical properties has been investigated. It has been found that a significant influence on the characteristics of the porous structure of the films is exerted by the degree of orientation of the melt at extrusion, the annealing temperature, and the degree of uniaxial extension of the films. The threshold values of these parameters, at which through-flow channels are formed in the films, have been determined. It has been shown using filtration porosimetry that polyethylene films have a higher permeability to liquids as compared to the polypropylene samples (240 and 180 L/(m² h atm), respectively). The porous structure of the polyethylene films is characterized by larger sizes of through pores than those of the polypropylene samples (the average pore sizes are 210 and 160 nm, respectively), whereas the polypropylene films contain a larger number of through-flow channels.     

氩气流量对多晶硅定向凝固炉热场的影响

耦合求解了多晶硅定向凝固炉内热传导、热辐射、熔体和氩气热对流等各种耦合换热,比较分析了不同氩气流量下定向凝固炉内部热场分布和硅熔体流动结构。结果表明,当氩气流量增大到一定值时,氩气流对凝固过程中硅熔体流动和热输运的影响显著增强。     

Peculiarities of gallium crystallization in confined geometry

The freezing and melting phase transitions for gallium embedded into a porous glass with a pore size of about 8 nm were studied using acoustic, NMR, and x-ray techniques. It was shown that the broadened solidification and melting transitions upon deep cooling up to complete freezing at 165 K were due to the formation of β-Ga within pores. The offset of confined β-Ga melting was lowered by about 21 K compared to the bulk β-Ga melting point. Both melting and freezing in pores were irreversible. The fulfillment of some special thermal conditions led to gallium crystallization into other modifications. The role of heterogeneous crystallization in freezing of confined gallium is discussed.     

Effect of energy density on defect evolution in 3D printed Zr-based metallic glasses by selective laser melting

In this study, the defects in 3D printed Zr-based bulk metallic glasses(BMGs) fabricated by selective laser melting(SLM) under different energy densities have been investigated via both experimental and simulation approaches. Different defects, including balling, interlayer pores, open pores and metallurgical pores, are detected in the 3D-printed Zr-based MGs depending on the energy inputs. Balling mainly occurs at a relatively low energy density(E<8.33 J/mm^3) due to the incomplete melting of particles, while interlayer pores and open pores are formed at modest energy densities(E=13.89-16.67 J/mm^3) because of incomplete welding and insufficient filling of molten liquid between layers. Fine metallurgical pores appear on the upper surface at relatively high energy densities(E=20.83-27.78 J/mm^3), which originate from gas escaping from molten pools during rapid solidification of the melt. Computational fluid dynamics(CFD) simulations are carried out to verify the experimental observations. The CFD simulations reveal that the various defects formed in the 3D-printed Zr-based BMG are related to the melt flow behaviours in the molten pools under different energy densities. The present work provides in-depth understandings of defect formation in the SLM process and provides methods for eliminating these defects in order to enhance the mechanical performance of 3D printed BMGs.     

Al-Ti-B细化工业纯铝凝固组织演变过程数值模拟

采用耦合群体动力学方法与元胞自动机方法建立了细化处理条件下铝合金凝固微观组织演变的数值模型.该模型考虑了a-Al的非均匀形核过程、晶粒的初始球形长大以及之后的枝晶生长过程.利用建立的模型模拟了Al-5Ti-1B中间合金细化工业纯铝凝固组织演变过程.结果表明:形核初始阶段,熔体中存在充足数量的有效形核粒子, a-Al形核率随着熔体过冷度的增大逐渐增高;形核开始不久后, a-Al的异质形核过程由熔体中有效形核粒子数量控制,直到再辉发生,形核停止.模拟分析了中间合金添加量以及熔体冷却速度对工业纯铝凝固组织演变过程的影响,模拟结果与实验结果相符,验证了模型的准确性.     

Microstructure,texture and magnetic properties of strip-cast 1.3% Si non-oriented electrical steels

In this work, the evolution of microstructure, texture and magnetic properties of non-oriented 1.3% silicon steel processed using the twin-roll strip casting was investigated, especially under different solidification structures. A number of microstructures about the as-cast strips show that the initial solidification structure of casting a strip can be controlled by the melt superheats. The microstructures with the average grain size of ∼100–400 μm can be obtained in strips when the melt superheats are from 20 to 60 °C. A nearly random, diffuse, homogeneous texture under a low melt superheat, but comparatively developed {100} oriented grains are formed under a high melt superheat through the cast strip thickness. The relatively low core loss and high magnetic induction can be obtained in the cold rolled and annealed sheets when increasing the initial grain size of cast-strip. The textures in annealed sheets with coarse initial grain size are characterized by the relatively strong Goss component and {001} fiber but weak γ-fiber component, which lead to the high permeability.     

Horizontal continuous casting of metals with mould excited by ultrasonic waves

The thermal and mechanical conditions which exist during continuous casting of metals at the interface between bar and mould determine the cooling of the bar as well as the friction between bar and mould.Ultrasonic excitation of a horizontally-operating, continuous casting mould increased considerably the maximum throughput. The average value of the inner wall temperature of the mould rose during ultrasonic excitation. Periodic temperature fluctuations decrease during exposure to ultrasonic waves and a more even cooling of the bars is achieved. The force of removal was also reduced. In particular, peaks in the force when the bars are stuck together are reduced.The ultrasonic treatment also improved the surface finish. There is a relation between the temperature fluctuations of the inner side of the mould and the peak-to-peak roughness height. Grain refinement occurs as well as a more even grain distribution in the casting direction.     

Aluminum integral foams with tailored density profile by adapted blowing agents

The goal of the present work is the variation of the structure of aluminum integral foams regarding the thickness of the integral solid skin as well as the density profile. A modified die casting process, namely integral foam molding, is used in which an aluminum melt and blowing agent particles (magnesium hydride MgH₂) are injected in a permanent steel mold. The high solidification rates at the cooled walls of the mold lead to the formation of a solid skin. In the inner region, hydrogen is released by thermal decomposition of MgH₂ particles. Thus, the pore formation takes place parallel to the continuing solidification of the melt. The thickness of the solid skin and the density profile of the core strongly depend on the interplay between solidification velocity and kinetics of hydrogen release. By varying the melt and blowing agent properties, the structure of integral foams can be systematically changed to meet the requirements of the desired field of application of the produced component.     

Fourier thermal analysis of solidification kinetics in molten aluminium and in presence of ultrasonic field

In this paper a comparison between the Newtonian and Fourier method analysis available in thermal analysis techniques is reported. The experimental solidification of liquid aluminium under various conditions has been studied. Thermal analysis is a tool in elucidating the thermal events involved in liquid to solid transformation. The Newtonian method predicts a maximum in heat generation at the onset of solidification, while the Fourier method incorporates the effect of thermal gradient and predicts two heat generation peaks during the solidification process. This comparison between the Fourier and Newtonian method indicates that their predictions are appreciably different. In order to elucidate the effect of ultrasonic waves on solidification process, the measurements were carried out under similar conditions both with and without sonication. Our studies have shown that in presence of the ultrasonic field the kinetics of solidification is changed, leading namely to a decreased undercooling degree of the melt and thermal diffusivity.     

熔体初始温度对液态金属Ni凝固过程中微观结构演变影响的模拟研究

采用量子 Sutton-Chen多体势, 对熔体初始温度热历史条件对液态金属Ni快速凝固过程中微观结构演变的影响进行了分子动力学模拟研究. 采用双体分布函数g(r)曲线、键型指数法、原子团类型指数法和三维可视化等分析方法对凝固过程中微观结构的演变进行了分析. 结果表明: 熔体初始温度对凝固微结构有显著影响, 但在液态和过冷态时的影响并不明显, 只有在结晶转变温度T_c附近才开始充分显现出来. 体系在1×10¹² K/s的冷速下, 最终均形成以1421和1422键型或面心立方(12 0 0 0 12 0)与六角密集(12 0 0 0 6 6) 基本原子团为主的晶态结构. 末态时, 不同初始温度体系中的主要键型和团簇的数目有很大的变化范围, 且与熔体初始温度的高低呈非线性变化关系. 然而, 体系能量随初始温度呈线性变化关系, 初始温度越高, 末态能量越低, 其晶化程度越高. 通过三维可视化分析进一步发现, 在初始温度较高的体系中, 同类团簇结构的原子出现明显的分层聚集现象, 随着初始温度的下降, 这种分层现象将被弥散开去. 可视化分析将更有助于对凝固过程中微观结构演变进行更为深入的研究. 关键词： 液态金属Ni 熔体初始温度 微观结构 分子动力学模拟     

Modelling of anisotropic sintering in crystalline ceramics

We present a model that describes anisotropic shrinkage during sintering in a powder compact of aligned, elongated particles by deriving the anisotropic sintering stress and the anisotropic generalized viscosity as a function of material and geometric parameters. The powder compact consists of elongated particles, which are perfectly aligned and simply packed with elliptical pores at all the quadra-junctions between the particles. The model considers mass transport by grain boundary diffusion and surface diffusion. Shrinkage rates are calculated for a variety of geometries and are compared to kinetic Monte Carlo simulations.     

Electrically Conductive Multiwall Carbon Nanotubes/Poly(vinyl alcohol) Composites with Aligned Porous Morphologies

Electrically conductive multiwall carbon nanotubes (MWNTs)/poly(vinyl alcohol) (PVA) composites with aligned porous structure were obtained by a directional freeze-drying process. The results show that the morphologies of the MWNTs/PVA composite can be tailored by adding different contents of MWNTs in the PVA matrix. Because of the aligned porous structure of the MWNTs/PVA composites, the conductivity property of MWNTs/PVA composite does not coincide absolutely with the universal percolation theory. In the aligned porous MWNTs/PVA composites, the existence of the micro-pores destroys the uniform distribution of the conductive network along the direction perpendicular to the aligned pores and results in a nonuniform distribution conductive network. When being used to monitor flowing vapors in pipes, compared with a film sensor with the thickness from several decades to hundreds of microns, the aligned porous conductive MWNTs/PVA composite with micron-sized pores should be a much better sensor.     

Origin of diffusional light scattering at the non-equilibrium crystal-melt interface

A new model is proposed to explain the anomalous dynamic light scattering observed at the growing crystal-melt interface. With a small initial concentration of dissolved gas in the melt, the concentration at the interface can be driven above saturation by the rejection of solute by the advancing solidification front. Microbubbles of gas can then form near the interface. Because of surface tension, for fixed supersaturation there is a unique bubble size that can exist in equilibrium with the fluid.     

Anisotropic thermal conduction in a polymer liquid subjected to shear flow

Flow-induced anisotropic thermal conduction in a polymer liquid is studied using force Rayleigh scattering. Time-dependent measurements of the complete thermal diffusivity tensor, which includes one off-diagonal and three diagonal components, are reported on an entangled polymer melt subjected to a uniform shear deformation. These data, in conjunction with mechanical measurements of the stress, provide the first direct evidence that the thermal conductivity tensor and the stress tensor are linearly related in a deformed polymer liquid.     

Near-eutectic Zn-Mg alloys: Interrelations of solidification thermal parameters,microstructure length scale and tensile/corrosion properties

Zn-Mg alloys are considered to have potential application in bone implants, since both metals are biocompatible and have biodegradable characteristics. Adding Mg to Zn can boost mechanical and corrosion resistances. However, the literature is very limited on quantifying the interrelation of solidification parameters, microstructural features and mechanical/corrosion properties of Zn-Mg alloys. The present study examines the interrelations of alloy Mg content, macrosegregation effects, morphology and scale of the matrix and eutectic phases, nature of intermetallics and tensile and corrosion properties of near-eutectic Zn-Mg alloys. The alloys samples are obtained by unsteady-state directional solidification resulting in a wide range of solidification thermal parameters and microstructures. We examine microstructural features of both dendritic and complex regular eutectic phases. It is shown that the eutectic exhibits a bimodal pattern with neighboring areas of coarse and fine lamellae. Experimental growth laws relating the primary, secondary and eutectic spacings to the solidification cooling rate and growth rate are proposed. Hall-Petch type equations are derived expressing tensile strength and elongation to dendritic and eutectic spacings. Electrochemical parameters determined by polarization curves during corrosion tests and SEM analyses of corroded areas have shown that the alloy having an essentially eutectic microstructure is associated with better corrosion resistance.     

NANOSTRUCTURED Zr-BASED ALLOYS-PHASE FORMATION AND MECHANICAL PROPERTIES

Newly developed nanostructured Zr/Ti-Al-TM multiphase alloys can provide a large bandwidth of interesting properties, such as mechanical properties. Bulk materials with nanocrystalline/ amorphous and (nano)quasicrystalline/ amorphous microstructure with different volume fractions of nanophases and with different grain sizes can be obtained by slowly cooling the melt as well as by solid state reactions. Multiphase structures are realized either by partial de-vitrification of bulk glass-forming alloys or by defined addition of inert compounds upon alloying. Special preparation techniques e.g. copper mould casting and subsequent controlled annealing and mechanical alloying combined with hot consolidation of powders are described. The phase formation and transformation processes and the thermal stability of such materials in dependence on alloy composition and processing parameters are discussed in detail. Currently, the exploration of properties with respect to potential applications of these nanostructured alloys is still at the beginning. First investigations on the contributions of different phases/ volume fractions to the overall mechanical behaviour will be shown. At room temperature, the deformation behaviour of amorphous/crystalline bulk samples is governed by contributions of all existing phases yielding a high strength of the material.     

非晶纤维的制备和力学行为

将块体材料制备成微纳米纤维时,其力学性能会得到进一步的提高,甚至具备块体材料所没有的力学行为.非晶态材料可经过熔体拉丝一次性成型而得到所需尺寸的均匀纤维,纤维表面质量好,其制备过程相对简单且节能.由于非晶材料短程有序、长程无序的结构,具备优异的力学性能,所以非晶纤维有着广泛的应用前景和基础研究价值.本文对能制备成非晶纤维且有优异力学性能的材料做了简单介绍,对非晶纤维的制备方法及其成型物理机制、非晶纤维的力学行为及其物理机制进行了综述,最后总结了非晶纤维的制备和力学行为的研究中存在的问题,对非晶纤维的发展前景做了展望.     

Melt-spun magnetically anisotropic SmCo5 ribbons with high permanent performance

We have succeeded in preparing magnetically anisotropic SmCo₅ ribbons with high permanent performance by single-roller melt spinning at low wheel velocity. The anisotropy is associated with a crystallographic texture formed during melt-spinning process, with the c-axis parallel to the longitudinal direction of the ribbons. The formation of the crystallographic texture is attributed to a directional solidification process resulting from a thermal gradient. A remanence of 9.1 kG, remanence ratio of 0.9, intrinsic coercivity of 16.2 kOe and energy product of 18.2 MGOe at room temperature are obtained in the melt-spun and subsequently annealed SmCo₅ ribbons prepared at 5 m/s.