Advances in Ductile Iron Research: new metallurgical understanding and its technological significance

The present work gives an updated view about important metallurgical concepts, concerning the influence that solidification structure, microsegregation, piece size and austenite characteristics, exert on final microstructure, properties and processing control. The discussions are based on original results obtained by using special experimental techniques developed by the authors. New evidences about the solidification macrostructure, microsegregation patterns and austenite type (recrystallized and non recrystallized), allow a better understanding of the solidification and the solid state transformations taking place in conventional and thin wall ductile iron castings.Fil: Sikora, Jorge Antonio. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Mar del Plata. Instituto de Investigaciones en Ciencia y Tecnología de Materiales. Universidad Nacional de Mar del Plata. Facultad de Ingeniería. Instituto de Investigaciones en Ciencia y Tecnología de Materiales; ArgentinaFil: Boeri, Roberto Enrique. Consejo Nacional de Investigaciones Científicas y Técnicas. Centro Científico Tecnológico Conicet - Mar del Plata. Instituto de Investigaciones en Ciencia y Tecnología de Materiales. Universidad Nacional de Mar del Plata. Facultad de Ingeniería. Instituto de Investigaciones en Ciencia y Tecnología de Materiales; Argentin

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

Phase field simulation of dendritic microstructure in additively manufactured titanium alloy

Additive manufacturing (AM) processes for metals, such as selective laser sintering and electron beam melting, involve rapid solidification process. The microstructure of the fabricated material and its properties strongly depend on the solidification. Therefore, in order to control and optimize the AM process, it is important to understand the microstructure evolution. In this work, using Ti-6Al-4V as a model system, the phase field method is applied to simulate the microstructure evolution in additively manufactured metals. First, the fundamental governing equations are presented. Then the effects of various processing related parameters, including local temperature gradient, scan speed and cooling rate, on dendrites’ morphology and growth velocity are studied. The simulated results show that the dendritic arms grow along the direction of the heat flow. Higher temperature gradient, scan speed and cooling rate will result in small dendritic arm spacing and higher growth velocity. The simulated dendritic morphology and arm spacings are in good agreement with experimental data and theoretical predictions

Direct Laser Fabrication of a Gas Turbine Engine Component - Microstructure and Properties - Part I

This paper presents the development of a new technique for the production of abrasive turbine blade tips by direct laser processing. This superalloy cermet component is an integral part of the low pressure turbine sealing system in a demonstrator engine. Direct laser fabrication of this component fiom a bed a loose powder results in significant cost savings and improved performance over the currently employed production technique. The technology has been demonstrated by fabricating a prototype lot of 100 blade tips, which will be subjected to an engine test. This is the first instance of a direct fabrication method applied to the production of functional engine hardware. This research was funded by the United States Air Force contract F33615-94- C-2424 titled "Affordable Turbine Blade Tips".Mechanical Engineerin

Multiphase imaging of freezing particle suspensions by confocal microscopy

Ice-templating is a well-established processing route for porous ceramics. Because of the structure/properties relationships, it is essential to better understand and control the solidification microstructures. Ice-templating is based on the segregation and concentration of particles by growing ice crystals. What we understand so far of the process is based on either observations by optical or X-ray imaging techniques, or on the characterization of ice-templated materials. However, in situ observations at particle-scale are still missing. Here we show that confocal microscopy can provide multiphase imaging of ice growth and the segregation and organization of particles. We illustrate the benefits of our approach with the observation of particles and pore ice in the frozen structure, the dynamic evolution of the freeze front morphology, and the impact of PVA addition on the solidification microstructures. These results prove in particular the importance of controlling both the temperature gradient and the growth rate during ice-templating.Comment: 20 pages, 9 figure

Microstructure control during twin roll casting of an AZ31 magnesium alloy

The existing twin roll casting technique for magnesium alloys suffers heterogeneity in both microstructure and chemistry and downstream processing is required to improve the strip quality, resulting in cost rise. In the present work, twin roll casting was carried out using an AZ31 magnesium alloy, with the application of intensive shearing melt conditioning prior to casting. The effect of process parameters such as pouring temperature and casting speed on microstructure control during casting and subsequent downstream processing was studied. Experimental results showed that the melt conditioning treatment allowed the production of AZ31 strips with uniform and refined microstructure free of centreline segregations. It was also shown that an optimized combination of pouring temperature and casting speed, in conjunction with a strip thickness control operation, resulted in uniformly distributed stored energies due to enhanced plastic deformation, which promoted recrystallization during casting and subsequent heat treatment. Strips prepared by twin roll casting and homogenization developed similar microstructural features to those prepared by twin roll casting followed by lengthy downstream processing by homogenization, hot rolling and annealing and displayed a weaker basal texture, exhibiting a potentially better formability.The EPSRC (UK

Atomic-scale grain boundary engineering to overcome hot-cracking in additively-manufactured superalloys

There are still debates regarding the mechanisms that lead to hot cracking in parts build by additive manufacturing (AM) of non-weldable Ni-based superalloys. This lack of in-depth understanding of the root causes of hot cracking is an impediment to designing engineering parts for safety-critical applications. Here, we deploy a near-atomic-scale approach to investigate the details of the compositional decoration of grain boundaries in the coarse-grained, columnar microstructure in parts built from a non-weldable Ni-based superalloy by selective electron-beam melting. The progressive enrichment in Cr, Mo and B at grain boundaries over the course of the AM-typical successive solidification and remelting events, accompanied by solid-state diffusion, causes grain boundary segregation induced liquation. This observation is consistent with thermodynamic calculations. We demonstrate that by adjusting build parameters to obtain a fine-grained equiaxed or a columnar microstructure with grain width smaller than 100 $\mu$m enables to avoid cracking, despite strong grain boundary segregation. We find that the spread of critical solutes to a higher total interfacial area, combined with lower thermal stresses, helps to suppress interfacial liquation.Comment: Accepted version at Acta Materiali

Effect of iron on the microstructure and mechanical property of Al-Mg-Si-Mn and Al-Mg-Si diecast alloys

This article is made available through the Brunel Open Access Publishing Fund. Copyright @ 2012 Elsevier B.V.This article has been made available through the Brunel Open Access Publishing Fund.Al–Mg–Si based alloys can provide super ductility to satisfy the demands of thin wall castings in the application of automotive structure. In this work, the effect of iron on the microstructure and mechanical properties of the Al–Mg–Si diecast alloys with different Mn concentrations is investigated. The CALPHAD (acronym of Calculation of Phase Diagrams) modelling with the thermodynamic properties of the multi-component Al–Mg–Si–Mn–Fe and Al–Mg–Si–Fe systems is carried out to understand the role of alloying on the formation of different primary Fe-rich intermetallic compounds. The results showed that the Fe-rich intermetallic phases precipitate in two solidification stages in the high pressure die casting process: one is in the shot sleeve and the other is in the die cavity, resulting in the different morphologies and sizes. In the Al–Mg–Si–Mn alloys, the Fe-rich intermetallic phase formed in the shot sleeve exhibited coarse compact morphology and those formed in the die cavity were fine compact particles. Although with different morphologies, the compact intermetallics were identified as the same α-AlFeMnSi phase with typical composition of Al24(Fe,Mn)6Si2. With increased Fe content, β-AlFe was found in the microstructure with a long needle-shaped morphology, which was identified as Al13(Fe,Mn)4Si0.25. In the Al–Mg–Si alloy, the identified Fe-rich intermetallics included the compact α-AlFeSi phase with typical composition of Al8Fe2Si and the needle-shaped β-AlFe phase with typical composition of Al13Fe4. Generally, the existence of iron in the alloy slightly increases the yield strength, but significantly reduces the elongation. The ultimate tensile strength maintains at similar levels when Fe contents is less than 0.5 wt%, but decreases significantly with the further increased Fe concentration in the alloys. CALPHAD modelling shows that the addition of Mn enlarges the Fe tolerance for the formation of α-AlFeMnSi intermetallics and suppresses the formation of β-AlFe phase in the Al–Mg–Si alloys, and thus improves their mechanical properties.EPSRC and JL