Directional solidification of superalloys

This invention relates to the directional solidification of superalloys, in particular nickel-based superalloys, by imposition of a predetermined temperature profile in the solidification front and, depending on the desired results, a predetermined rate of advance of said solidification front, whereas castings of markedly superior fatigue resistance are produced

Five-dimensional imaging of freezing emulsions with solute effects

The interaction of objects with a moving solidification front is a common feature of many industrial and natural processes such as metal processing, the growth of single-crystals, the cryopreservation of cells, or the formation of sea ice. Solidification fronts interact with objects with different outcomes, from the total rejection to their complete engulfment. We image the freezing of emulsions in 5D (space, time, and solute concentration) with confocal microscopy. We show the solute induces long-range interactions that determine the solidification microstructure. The local increase of solute concentration enhances premelting, which controls the engulfment of droplets by the front and the evolution of grain boundaries. Freezing emulsions may be a good analogue of many solidification systems where objects interact with a solidification interface.Comment: 23 pages, 4 figures, 31 reference

Solidification behavior and microstructural evolution of near-eutectic Zn-Al alloys under intensive shear

Copyright @ 2009 ASM International. This paper was published in Metallurgical and Materials Transactions A, 40(1), 185 - 195 and is made available as an electronic reprint with the permission of ASM International. One print or electronic copy may be made for personal use only. Systematic or multiple reproduction, distribution to multiple locations via electronic or other means, duplications of any material in this paper for a fee or for commercial purposes, or modification of the content of this paper are prohibited.The effect of intensive shear on the solidification behavior and microstructural evolution of binary Zn-Al alloys is presented at hypoeutectic, eutectic, and hypereutectic compositions. It is found that the intensive shear, applied on the eutectic melt prior to solidification at a temperature above but close the eutectic temperature, can significantly reduce the size of eutectic cells, but the solidified microstructure still remains the lamellar morphology. For applying intensive shear on the melt during solidification, the nucleation occurs at temperatures very close to the equilibrium condition and requires very small undercooling for both the primary solidification and the eutectic solidification. The intensive shear can significantly alter the microstructural morphology. In contrast to the dendritic morphology formed in the conventional solidification, the primary Al-rich phase in hypoeutectic Zn-Al alloy and the primary Zn-rich phase in hypereutectic Zn-Al alloy under intensive shear exhibit fine and spherical particles, respectively. The lamellae morphology of Zn-rich phase and Al-rich phase formed in the conventional eutectic solidification exhibit fine and spherical particles. The increase of intensity of shear promotes the independence of solid Zn-rich particles and Al-rich particles during the eutectic solidification, resulting in the uniform and separate distribution of two solid particles in the matrix. It is speculated that the high intensity of shear can result in the independent nucleation of individual eutectic phase throughout the whole melt, and the separate growth of solid phases in the subsequent solidification

Thermal analysis applied to estimation of solidification kinetics of Al–Si aluminium alloys

Evaluation of solidification kinetics by thermal analysis is a useful tool for quality control of Al–Si melts before pouring provided it is rapid and highly reproducible. Series of thermal analysis records made with standard cups are presented that show good reproducibility. They are evaluated using a Newton’s like approach to get the instantaneous heat evolution and from it solidification kinetics. An alternative way of calculating the zero line is proposed which is validated by the fact that the latent heat of solidification thus evaluated is within 5% of the value calculated from thermodynamic data. Solidification kinetics was found highly reproducible provided appropriate experimental conditions were achieved: high enough casting temperature for the cup to heat up to the metal temperature well before solidification starts; and equal and homogeneous temperatures of the metal and of the cup at any time in the temperature range used for integration

Effect of Re-impacting Debris on the Solidification of the Lunar Magma Ocean

Anorthosites that comprise the bulk of the lunar crust are believed to have formed during solidification of a Lunar Magma Ocean (LMO) in which these rocks would have floated to the surface. This early flotation crust would have formed a thermal blanket over the remaining LMO, prolonging solidification. Geochronology of lunar anorthosites indicates a long timescale of LMO cooling, or re-melting and re-crystallization in one or more late events. To better interpret this geochronology, we model LMO solidification in a scenario where the Moon is being continuously bombarded by returning projectiles released from the Moon-forming giant impact. More than one lunar mass of material escaped the Earth-Moon system onto heliocentric orbits following the giant impact, much of it to come back on returning orbits for a period of 100 Myr. If large enough, these projectiles would have punctured holes in the nascent floatation crust of the Moon, exposing the LMO to space and causing more rapid cooling. We model these scenarios using a thermal evolution model of the Moon that allows for production (by cratering) and evolution (solidification and infill) of holes in the flotation crust that insulates the LMO. For effective hole production, solidification of the magma ocean can be significantly expedited, decreasing the cooling time by more than a factor of 5. If hole production is inefficient, but shock conversion of projectile kinetic energy to thermal energy is efficient, then LMO solidification can be somewhat prolonged, lengthening the cooling time by 50% or more

Solute trapping and diffusionless solidification in a binary system

Numerous experimental data on the rapid solidification of binary systems exhibit the formation of metastable solid phases with the initial (nominal) chemical composition. This fact is explained by complete solute trapping leading to diffusionless (chemically partitionless) solidification at a finite growth velocity of crystals. Special attention is paid to developing a model of rapid solidification which describes a transition from chemically partitioned to diffusionless growth of crystals. Analytical treatments lead to the condition for complete solute trapping which directly follows from the analysis of the solute diffusion around the solid-liquid interface and atomic attachment and detachment at the interface. The resulting equations for the flux balance at the interface take into account two kinetic parameters: diffusion speed $V_{DI}$ on the interface and diffusion speed $V_D$ in bulk phases. The model describes experimental data on nonequilibrium solute partitioning in solidification of Si-As alloys [M.J. Aziz et al., J. Cryst. Growth {\bf 148}, 172 (1995); Acta Mater. {\bf 48}, 4797 (2000)] for the whole range of solidification velocity investigated.Comment: Regular article in Physical Review E, Vol. 76 (2007

Method of growing composites of the type exhibiting the Soret effect

A predetermine amount of segregation is introduced into a molten sample of a composite that exhibits the Soret effect, such amount approximating the amount of segregation resulting from directional solidification of the sample. The molten sample is then directionally solidified starting at the end opposite the end richer in the constituent that would migrate toward the cooler part of a liquid solution of the composite maintained in a temperature gradient. Since solidification commences at the end deficient in such constituent, its migration toward the interface between the solid and liquid during the solidification will compensate for the deficiency, yielding a more homogeneous product

Finite Volume Simulation Framework for Die Casting with Uncertainty Quantification

The present paper describes the development of a novel and comprehensive computational framework to simulate solidification problems in materials processing, specifically casting processes. Heat transfer, solidification and fluid flow due to natural convection are modeled. Empirical relations are used to estimate the microstructure parameters and mechanical properties. The fractional step algorithm is modified to deal with the numerical aspects of solidification by suitably altering the coefficients in the discretized equation to simulate selectively only in the liquid and mushy zones. This brings significant computational speed up as the simulation proceeds. Complex domains are represented by unstructured hexahedral elements. The algebraic multigrid method, blended with a Krylov subspace solver is used to accelerate convergence. State of the art uncertainty quantification technique is included in the framework to incorporate the effects of stochastic variations in the input parameters. Rigorous validation is presented using published experimental results of a solidification problem

Linear Contraction Behavior of Low-Carbon, Low-Alloy Steels During and After Solidification Using Real-Time Measurements

A technique for measuring the linear contraction during and after solidification of low-alloy steel was developed and used for examination of two commercial low-carbon and low-alloy steel grades. The effects of several experimental parameters on the contraction were studied. The solidification contraction behavior was described using the concept of rigidity in a solidifying alloy, evolution of the solid fraction, and the microstructure development during solidification. A correlation between the linear contraction properties in the solidification range and the hot crack susceptibility was proposed and used for the estimation of hot cracking susceptibility for two studied alloys and verified with the real casting practice. The technique allows estimation of the contraction coefficient of commercial steels in a wide range of temperatures and could be helpful for computer simulation and process optimization during continuous casting. © 2013 The Minerals, Metals & Materials Society and ASM International