Grain refinement and nucleation processes in Aluminium alloys through liquid shearing

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.The industrial practice of grain refinement of aluminium alloys involves the addition of inoculant particles to initiate alpha-aluminium grains at small undercoolings. This results in a uniformly fine, equiaxed as-cast microstructure and is commonly achieved using Al-Ti-B additions. The phase responsible for initiation of grains in aluminium melts inoculated with Al-Ti-B was determined during the 1990s; since that time, scientific understanding of grain refinement has advanced rapidly. However, one of the main problems of addition inoculants is impurities which is added to the melt and may affect the desired characteristics of the product. With regards to this problem other methods of refinement and the mechanisms of refining have not been fully understood and prediction of as-cast Microstructures in aluminium alloys has much scope for improvement. In this thesis: 1-Factors in establishing equiaxed microstructure were analysed and the origin of equiaxed grains were explored. Then the nucleation process and the involved mechanisms were investigated in depth and control of nucleation process to achieve a fine and uniform structure was set as target. 2-Refinement of microstructure with introduction of shearing was evaluated and the process of refinement in the mushy zone (semisolid state) as a base line was established. Then introduction of shearing above liquidus as a development was analysed and outstanding refinement was seen with shearing above liquidus which have not been investigated properly elsewhere. 3- The mechanisms of refinement by introducing shearing were investigated and the refining mechanisms below and specifically above liquidus were investigated systematically. As results an appropriate understanding about the mechanisms of nucleation and refinement above liquidus was established. 4- Finally, with simulation the most dominant factor in approaching fine grain size by applying shear was identified and the results of experimental examination was verified by simulation.UK Department of Trade and Industry (DTI

Initial crystallisation or nucleation in a liquid aluminium alloy containing spinel seeds

Step-by-step in situ near-atomic-resolution observations were presented for initial crystallization or nucleation in a liquid Al-10Mg (wt%) alloy containing spinel (MgAl 2 O 4 ) seeds. Ordering of Al atoms was observed in the alloy at the interface with spinel at the superheat of 73 °C or at the melt temperature of 680 °C, where three ordered layers of Al atoms formed and disappeared alternately. When cooled to the approximate liquidus of the alloy, 607 °C, three similar but more stable ordered layers of Al atoms formed. Subsequent crystallization occurred first through the formation of partially close-packed Al atoms on the solid-like outer ordered layer of Al atoms, followed by further crystallization into more close-packed Al atoms

Grain refinement and nucleation processes in aluminium alloys through liquid shearing

The industrial practice of grain refinement of aluminium alloys involves the addition of inoculant particles to initiate alpha-aluminium grains at small undercoolings. This results in a uniformly fine, equiaxed as-cast microstructure and is commonly achieved using Al-Ti-B additions. The phase responsible for initiation of grains in aluminium melts inoculated with Al-Ti-B was determined during the 1990s; since that time, scientific understanding of grain refinement has advanced rapidly. However, one of the main problems of addition inoculants is impurities which is added to the melt and may affect the desired characteristics of the product. With regards to this problem other methods of refinement and the mechanisms of refining have not been fully understood and prediction of as-cast Microstructures in aluminium alloys has much scope for improvement. In this thesis: 1-Factors in establishing equiaxed microstructure were analysed and the origin of equiaxed grains were explored. Then the nucleation process and the involved mechanisms were investigated in depth and control of nucleation process to achieve a fine and uniform structure was set as target. 2-Refinement of microstructure with introduction of shearing was evaluated and the process of refinement in the mushy zone (semisolid state) as a base line was established. Then introduction of shearing above liquidus as a development was analysed and outstanding refinement was seen with shearing above liquidus which have not been investigated properly elsewhere. 3- The mechanisms of refinement by introducing shearing were investigated and the refining mechanisms below and specifically above liquidus were investigated systematically. As results an appropriate understanding about the mechanisms of nucleation and refinement above liquidus was established. 4- Finally, with simulation the most dominant factor in approaching fine grain size by applying shear was identified and the results of experimental examination was verified by simulation.EThOS - Electronic Theses Online ServiceUK Department of Trade and Industry (DTI)GBUnited Kingdo

On the selection of boundary conditions for top tensioned risers facing wave induced vibrations

The severe ocean environment is obviously the source of many uncertain random loads on offshore structures. This harsh environment when acting on the slender top tensioned risers with high aspect ratio (L/D) causes multimodal vibration leading to fatigue failure. Thus, a reliable stress analysis procedure should be applied in the assessment of their long-term behaviors. This research is a study on the effect of boundary conditions on the total and local response of offshore risers due to loads in different sea states. A FEM code is developed for discretization of riser’s structural model and was run for the riser of Amirkabir semisubmersible vessel for 87 sea states in the Caspian Sea and four boundary conditions. The results show that the most severe stresses in the riser don’t happen essentially in the harshest environment. The comparison of boundary conditions shows that clamped-clamped boundaries lead to lowest stress values while the riser experiences a wider band of stress in the pinned-pinned boundary type. While the riser top end boundary condition highly influences the displacements and stresses even in the lower part of riser

Characterization of Nash Equilibrium Strategy for Heptagonal Fuzzy Games

In this paper, the Nash equilibrium strategy of two-person zero-sum games with heptagonal fuzzy payoffs is considered and the existence of Nash equilibrium strategy is studied. Also, based on the fuzzy max order several models in heptagonal fuzzy environment is constructed and the existence of their equilibrium strategies is proposed. In the sequel, the existence of Pareto Nash equilibrium strategies and weak Pareto Nash equilibrium strategies is investigated for fuzzy matrix games. Finally, the relation between Pareto Nash equilibrium strategy and parametric bi-matrix games is established

Microstructure refinement by tool rotation-induced vibration in incremental sheet forming

This paper presents a study of employing tool rotation-induced vibrations in incremental sheet forming (V-ISF) to produce sheet metal parts with laminated ultrafine-grained structures. Non-axisymmetric tools were developed to generate tool vibration and surface shear deformation of sheet material during forming. Using the V-ISF process, magnesium sheets of AZ31 were formed to the hyperbolic cones and laminated ultrafine grains with higher micro hardness were obtained by tool generated low frequency vibrations with large amplitudes. To further investigate surface shear deformation induced during processing, the hole-deformation analysis of samples cut from the formed hyperbolic cones was performed. This study found that large surface shear deformation of the sheet and the tool vibration during incremental forming are the two key factors for the formation of laminated ultrafine grains. The developed V-ISF process has a great potential to produce sheet metal parts with refined grains and greater micro hardness

DEAF1 is a Pellino1-interacting protein required for interferon production by Sendai virus and double-stranded RNA

Double-stranded (ds) RNA of viral origin, a ligand for Melanoma Differentiation-associated gene 5 (MDA5) and Toll-Like Receptor 3 (TLR3), induces the TANK-Binding Kinase 1 (TBK1)-dependent phosphorylation and activation of Interferon Regulatory Factor 3 (IRF3) and the E3 ubiquitin ligase Pellino1, which are required for interferon β (IFNβ) gene transcription. Here, we report that Pellino1 interacts with the transcription factor Deformed Epidermal Autoregulatory Factor 1 (DEAF1). The interaction is independent of the E3 ligase activity of Pellino1, but weakened by the phosphorylation of Pellino1. We show that DEAF1 binds to the IFNβ promoter and to IRF3 and IRF7, that it is required for the transcription of the IFNβ gene and IFNβ secretion in MEFs infected with Sendai virus or transfected with poly(I:C). DEAF1 is also needed for TLR3-dependent IFNβ production. Taken together, our results identify DEAF1 as a novel component of the signal transduction network by which dsRNA of viral origin stimulates IFNβ production

Grain refinement of Al-Mg-Sc alloy by ultrasonic treatment

In foundry practice, ultrasonic treatment has been used as an efficient technique to achieve grain refinement in aluminium and magnesium alloys. This article shows the strong effect of pouring temperature and ultrasonic treatment at various temperatures on the grain refinement of Al-1 wt% Mg-0.3 wt% Sc alloy. Without ultrasonic treatment, a fine grain structure was obtained at the pouring temperature of 700 °C. The average grain size sharply decreases from 487 ± 20 to 103 ± 2 μm when the pouring temperature decreases from 800 to 700 °C. Ultrasonic vibration proved to be a potential grain refinement technique with a wide range of pouring tem- perature. A microstructure with very fine and homogeneous grains was obtained by applying ultrasonic treatment to the melt at the temperature range between 700 and 740 °C, before pouring. Cavitation-enhanced hetero- geneous nucleation is the mechanism proposed to explain grain refinement by ultrasound in this alloy. Moreover, ultrasonic treatment of the melt was found to lead to cast samples with hardness values similar to those obtained in samples submitted to precipitation hardening, suggesting that ultrasonic treatment can avoid carrying out heat treatment of cast parts.This research was supported by The Project Bridging The Gap, funded by the Erasmus Mundus External Cooperation Window Programme. Acknowledgements also to the University of Minho, for the provision of research facilities

Microstructural evolution in solution heat treatment of gas- atomised Al alloy (7075) powder for cold spray

Cold gas dynamic spray is being explored as a repair technique for high-value metallic components, given its potential to produce pore and oxide-free deposits of between several micrometers and several millimeters thick with good levels of adhesion and mechanical strength. However, feedstock powders for cold spray experience rapid solidification if manufactured by gas atomization and hence can exhibit non-equilibrium microstructures and localized segregation of alloying elements. Here, we used sealed quartz tube solution heat treatment of a precipitation hardenable 7075 aluminum alloy feedstock to yield a consistent and homogeneous powder phase composition and microstructure prior to cold spraying, aiming for a more controllable heat treatment response of the cold spray deposits. It was shown that the dendritic microstructure and solute segregation in the gas-atomized powders were altered, such that the heat-treated powder exhibits a homogeneous distribution of solute atoms. Micro-indentation testing revealed that the heat-treated powder exhibited a mean hardness decrease of nearly 25% compared to the as received powder. Deformation of the powder particles was enhanced by heat treatment, resulting in an improved coating with higher thickness (* 300 lm compared to * 40 um for untreated feedstock). Improved particle–substrate bonding was evidenced by formation of jets at the particle boundaries