Probing the dynamics of quasicrystal growth using synchrotron live imaging

The dynamics of quasicrystal growth remains an unsolved problem in condensed matter. By means of synchrotron live imaging, facetted growth proceeding by the tangential motion of ledges at the solid-melt interface is clearly evidenced all along the solidification of icosahedral AlPdMn quasicrystals. The effect of interface kinetics is significant so that nucleation and free growth of new facetted grains occur in the melt when the solidification rate is increased. The evolution of these grains is explained in details, which reveals the crucial role of aluminum rejection, both in the poisoning of grain growth and driving fluid flow

Columnar and Equiaxed Solidification of Al-7 wt.% Si Alloys in Reduced Gravity in the Framework of the CETSOL Project

International audienceDuring casting, often a dendritic microstructure is formed, resulting in a columnar or an equiaxed grain structure, or leading to a transition from columnar to equiaxed growth (CET). The detailed knowledge of the critical parameters for the CET is important because the microstructure affects materials properties. To provide unique data for testing of fundamental theories of grain and microstructure formation, solidification experiments in microgravity environment were performed within the European Space Agency Microgravity Application Promotion (ESA MAP) project Columnar-to-Equiaxed Transition in SOLidification Processing (CETSOL). Reduced gravity allows for purely diffusive solidification conditions, i.e., suppressing melt flow and sedimentation and floatation effects. On-board the International Space Station, Al-7 wt.% Si alloys with and without grain refiners were solidified in different temperature gradients and with different cooling conditions. Detailed analysis of the microstructure and the grain structure showed purely columnar growth for nonrefined alloys. The CET was detected only for refined alloys, either as a sharp CET in the case of a sudden increase in the solidification velocity or as a progressive CET in the case of a continuous decrease of the temperature gradient. The present experimental data were used for numerical modeling of the CET with three different approaches: (1) a front tracking model using an equiaxed growth model, (2) a three-dimensional (3D) cellular automaton–finite element model, and (3) a 3D dendrite needle network method. Each model allows for predicting the columnar dendrite tip undercooling and the growth rate with respect to time. Furthermore, the positions of CET and the spatial extent of the CET, being sharp or progressive, are in reasonably good quantitative agreement with experimental measurements

Modelling of the transition from a planar faceted front to equiaxed growth : application to photovoltaic polycrystalline silicon

International audienceRecent experiments under X-ray examination have shown that a transition from planar front to equiaxed growth is likely to occur in the case of faceted interfaces. Such a transition is suspected to be at the origin of the sudden occurrence of deleterious small grains, among large columnar grains, observed in photovoltaic silicon ingots.A model is presented for the occurrence of equiaxed grains observed ahead of a planar faceted interface. Simple expressions are obtained which predict when the equiaxed structures should develop, in the case of rough (thermal dendrite) and of faceted equiaxed grains. These models provide a semiquantitative basis to discuss the Faceted front to Equiaxed structure Transition (FET). Then, it is applied to the case-study of photovoltaic silicon. Further developments are proposed to improve the model

Determination of the average nucleation undercooling of primary Al-phase on refining particles from Al–5.0wt% Ti–1.0wt% B in Al-based alloys using DSC

International audienceThe understanding and control of the transition from columnar to equiaxed growth (CET) is an essential issue according to the desired usage properties. In Al-based alloys, refiners are routinely added to favor equiaxed growth. In that case, equiaxed grains nucleate preferentially on the refiners and can compete with columnar grains. To predict CET, two main parameters have been studied in models: the particle density,N0 and the nucleation undercooling of the refining particles (TN).We have used DSC successfully to measure the critical value of the nucleation undercooling. Thanks to these results, the efficiency of the specific refining particles (Al–5.0 wt% Ti–1.0 wt% B) in refined Al–3.5 wt% Ni alloy has been proved.Additionally, these measurements clearly point out the lowest efficiency of the same particles in refined Al–7.0 wt% Si which is generally admitted to be due to a Si-poisoning effect. More generally, the nucleation undercooling measured can be used in models dedicated to the quantitative prediction of CET

Microstructural development during transient directional solidification of hypermonotectic Al-Bi alloys

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)Directional unsteady-state solidification experiments were performed with hypermonotectic Al-5.0 wt%Bi and 7.0 wt%Bi alloys. Thermal parameters such as the growth rate (upsilon) and the thermal gradient (G) were experimentally determined by cooling curves recorded along the casting length. The predominant Bi-rich phase was characterized by droplets embedded in the aluminum matrix. Both the interphase spacing (lambda) and the Bi-rich particles diameter (d) were measured along the casting length. These microstructural features were correlated to the solidification thermal parameters: growth rate, cooling rate and thermal gradient. An experimental law expressing). as a function of both G and upsilon was found to better represent the growth of hypermonotectic Al-Bi alloys. Moreover, it was found that the interphase spacing decreases with increasing alloy bismuth content. (C) 2010 Elsevier Ltd. All rights reserved.311045844591FA-PESP (The Scientific Research Foundation of the State of Sao Paulo, Brazil)Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)FAEPEX - UNICAMPConselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq

Al-Fe hypoeutectic alloys directionally solidified under steady-state and unsteady-state conditions

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)The aim of this work is to evaluate the cellular growth, the nature of Al-Fe intermetallic particles and the eutectic arrangement of Al-Fe hypoeutectic samples solidified at growth rates ranging from 0.05 to 2.5 mm/s. The samples grown at higher solidification velocities were obtained using a water-cooled directional solidification apparatus. A Bridgman-type furnace was used to grow samples in the lower range of solidification velocities and an air-cooled mold was used to generate experimental values in between those obtained by the other two techniques of directional solidification. All casting assemblies were set to support upward directional solidification. Based on the present results, a single experimental power law seems to be enough to fit all experimental values of cell spacing as a function of cooling rate. The wide range of solidification thermal parameters used in the present study was chosen due to the diversity of foundry processes used for the manufacture of Al-Fe alloys components. For instance, low solidification velocities are typical of sand casting processes while high velocities are typical of direct-chill (DC) castings. In order to investigate the nature of the Al-Fe intermetallics, these particles were extracted from the aluminum-rich matrix by using a dissolution technique. Such phases were then investigated by SEM-EDAX microscopy and X-ray diffraction (XRD). It was found that Al(3)Fe is the predominant intermetallic phase in the Bridgman-grown samples and Al(6)Fe prevails in the samples grown in the water-cooled solidification apparatus. (C) 2010 Elsevier B.V. All rights reserved.5041205210Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)FAEPEX - UNICAMPFrench Ministry of Foreign Affairs, Region Provence-Alpes-Cote d'Azur and BrazilFAPERN (The Scientific Research Foundation of the State of Rio Grande do Norte, Brazil)Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq

Microstructure and mechanical properties of Sn-Bi, Sn-Ag and Sn-Zn lead-free solder alloys

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)The aim of this paper is to develop a comparative evaluation of mechanical properties of as-cast Sn-Bi, Sn-Ag and Sn-Zn alloys as a function of the resulting microstructural arrays with a view to application as solder materials. The resulting microstructures, ultimate and yield tensile strengths and elongations of Sn-40 wt.% Bi, Sn-3.5 wt.% Ag and Sn-9 wt.% Zn alloys were examined and compared with the corresponding results of the traditional Sn-40 wt.% Pb solder alloy. Tensile tests were carried out using specimens selected from specific positions along the length of the directionally solidified castings and Hall-Petch type correlations have been proposed relating the resulting tensile properties of each alloy to a parametric scale of the microstructure. It was found that all Pb-free alloys examined comply with a compromise between compatible mechanical strength and environmental protection. The Sn-Bi alloy has the highest ultimate tensile strength of all alloys examined, while both Sn-Ag and Sn-Zn alloys are lighter and exhibited higher ductility than the Sn-Pb and Sn-Bi alloys. (C) 2013 Elsevier B.V. All rights reserved.57297106Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)Faepex/Funcamp (Foundation of the University of Campinas, Unicamp)Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP

High Cooling Rate Cells, Dendrites, Microstructural Spacings And Microhardness In A Directionally Solidified Al-mg-si Alloy

Transient unidirectional solidification experiments have been carried out with an Al-3 wt%Mg-1 wt%Si alloy under cooling rates (T) in the range 0.2-45 K/s. A reverse cells > dendrites transition is shown to occur with the high-cooling rate cellular region associated with T > 2 K/s and the dendritic region with T < 0.8 K/s. Experimental growth laws correlating the cellular and dendritic spacings with the cooling rate are proposed. It is shown that the microhardness is directly influenced by both morphologies of the Al-rich matrix and by the relative fractions of Mg2Si and Fe bearing intermetallics that vary differently with the cooling rate.636145149Avazkonandeh-Gharavol, M.H., Haddad-Sabzevar, M., Fredriksson, H., On the microsegregation of Al-Mg alloys by thermal analysis and numerical modeling (2014) J. Alloys Comp., 610, pp. 462-471Lavernia, E.J., Ayers, J.D., Srivatsan, T.S., Rapid solidification processing with specific application to aluminium alloys (1992) Int. Mater. Rev., 37, pp. 1-44Ninive, P.H., Lovvik, O.M., Strandlie, A., Density functional study of the β'' phase in Al-Mg-Si alloys (2014) Metall. Mater. Trans. A, 45 A, pp. 2916-2924Kaygisiz, Y., Marasli, N., Microstructural, mechanical and electrical characterization of directionally solidified Al-Si-Mg eutectic alloy (2015) J. Alloys Comp., 618, pp. 197-203Kashyap, K.T., Murali, S., Raman, K.S., Murthy, K.S.S., Casting and heat treatment variables of Al-7Si-Mg alloy (1993) Mater. Sci. Technol., 9, pp. 189-203Liu, Y.L., Kang, S.B., The solidification process of Al-Mg-Si alloys (1997) J. Mater. Sci., 32, pp. 1443-1447Verma, A., Kumar, S., Grant, P.S., O'Reilly, K.A.Q., Influence of cooling rate on the Fe intermetallic formation in an AA6063 Al alloy (2013) J. Alloys Comp., 555, pp. 274-282Fei, W.D., Kang, S.B., Effects of cooling rate on solidification process in Al-Mg-Si alloy (1995) J. Mater. Sci. Lett., 14, pp. 1795-1797Trivedi, R., Sekhar, J.A., Seetharaman, V., Solidification microstructures near the limit of absolute stability (1989) Metall. Trans. A, 20 A, pp. 769-777Mullins, W.W., Sekerka, R.F., Stability of a planar interface during solidification of a dilute binary alloy (1964) J. Appl. Phys., 35, pp. 444-451Cahn, R.W., Haasen, P., (1996) Physical Metallurgy, p. 2740. , fourth ed. Elsevier AmsterdamFu, H., Geng, X., High rate directional solidification and its application in single crystal superalloys (2001) Sci. Technol. Adv. Mater., 2, pp. 197-204Fu, J.W., Yang, Y.S., Guo, J.J., Tong, W.H., Effect of cooling rate on solidification microstructures in AISI 304 stainless steel (2008) Mater. Sci. Technol., 24, pp. 941-944Lee, J.H., Kim, H.C., Jo, C.Y., Kim, S.K., Shin, J.H., Liu, S., Trivedi, R., Microstructure evolution in directionally solidified Fe-18Cr stainless steels (2005) Mater. Sci. Eng. A, 413-414, pp. 306-311Goulart, P.R., Spinelli, J.E., Cheung, N., Ferreira, I.L., Garcia, A., Cellular growth during transient solidification of hypoeutectic Al-Fe alloys (2009) J. Alloys Comp., 470, pp. 589-599Gunduz, M., Çardili, E., Directional solidification of aluminium-copper alloys (2002) Mater. Sci. Eng. A, 327, pp. 167-185Ferreira, I.L., Lins, J.F.C., Moutinho, D., Gomes, L.G., Garcia, A., Numerical and experimental investigation of microporosity formation in a ternary Al-Cu-Si alloy (2010) J. Alloys Comp., 503, pp. 31-39Spinelli, J.E., Cheung, N., Garcia, A., On array models theoretical predictions versus measurements for the growth of cells and dendrites in the transient solidification of binary alloys (2011) Philos. Mag., 91, pp. 1705-1723Costa, T.A., Moreira, A.L., Moutinho, D.J., Dias, M., Ferreira, I.L., Spinelli, J.E., Rocha, O.L., Garcia, A., Growth direction and Si alloying affecting directionally solidified structures of Al-Cu-Si alloys (2015) Mater. Sci. Technol., , (in press)Rosa, D.M., Spinelli, J.E., Ferreira, I.L., Garcia, A., Cellular/dendritic transition and microstructure evolution during transient directional solidification of Pb-Sb alloys (2008) Metall. Mater. Trans. A., 39 A, pp. 2161-2174Rocha, O.L., Siqueira, C.A., Garcia, A., Cellular/dendritic transition during unsteady-sate unidirectional solidification of Sn-Pb alloys (2003) Mater. Sci. Eng. A, 347, pp. 59-69Kondoh, K., Oginuma, H., Kimura, A., Matsukawa, S., Aizawa, T., In-situ synthesis of Mg2Si intermetallics via powder metallurgy process (2003) Mater. Trans., 44, pp. 981-985Mondolfo, L.F., (1979) Aluminium Alloys: Structure and Properties, , Butterworths LondonCanté, M.V., Brito, C., Spinelli, J.E., Garcia, A., Interrelation of cell spacing, intermetallic compounds and hardness on a directionally solidified Al-1.0Fe-1.0Ni alloy (2013) Mater. Des., 51, pp. 342-346Brito, C., Siqueira, C.A., Spinelli, J.E., Garcia, A., Effects of cell morphology and macrosegregation of directionally solidified Zn-rich Zn-Cu alloys on the resulting microhardness (2012) Mater. Lett., 80, pp. 106-10

Cooling Thermal Parameters, Microstructure, Segregation And Hardness In Directionally Solidified Al-sn-(si;cu) Alloys

The morphology and length scale of the phases forming the microstructure of sliding bearing alloys are known to affect wear, mechanical and corrosion resistances. Al-Sn alloys have good anti-frictional properties due to the presence of Sn. However, with the current trends in engine design, these alloys are not able to support the demanded heavy loads. An alternative way to reach this requirement can be the alloying with third elements such as Si and Cu. Despite the importance of their application properties, studies on the development of microstructures of these multicomponent alloys are rare in the literature. In the present investigation Al-Sn-(Cu;Si) alloys were directionally solidified (DS) under transient heat flow conditions, and a thorough characterization is performed including experimental growth rates and cooling rates, segregation, optical and scanning electron microscopies and primary dendrite arm spacings, λ1. Experimental growth laws are proposed relating the dendritic spacing to solidification thermal parameters. Furthermore, the scale of the dendritic morphology, the distribution of second phases in interdendritic regions and the macrosegregation pattern are shown to affect the hardness along the length of the DS castings. Hall-Petch type equations are proposed relating hardness to λ1.723142Zhu, M., Gao, Y., Chung, C.Y., Che, Z.X., Luo, K.C., Li, B.L., Improvement of the wear behaviour of Al-Pb alloys by mechanical alloying (2000) Wear, 242, pp. 47-53Pathak, J.P., Mohan, S., Tribological behaviour of conventional Al-Sn and equivalent Al-Pb alloys under lubrication (2003) Bull Mater Sci, 26, pp. 315-320Noskova, N.I., Vil'danova, N.F., Filippov, Y.I., Churbaev, R.V., Pereturina, I.A., Korshunov, L.G., Preparation, deformation, and failure of functional Al-Sn and Al-Sn-Pb nanocrystalline alloys (2006) Phys Met Metallogr, 102, pp. 646-651Ran, G., Zhou, J., Xi, S., Li, P., Microstructure and morphology of Al-Pb bearing alloy synthesized by mechanical alloying and hot extrusion (2006) J Alloy Compd, 419, pp. 66-70Wu, X.F., Zhang, G.A., Influence of Sn content on the microstructure and dry sliding wear behaviour of hypereutectic Al-20Si alloy (2011) Adv Mater Res, pp. 265-268Lu, Z.C., Zeng, M.Q., Gao, Y., Zhu, M., Significant improvement of wear properties by creating micro/nano dual-scale structure in Al-Sn alloys (2012) Wear, 296, pp. 469-478Liu, X., Zeng, M.Q., Ma, Y., Zhu, M., Promoting the high load-carrying capability of Al-20wt%Sn bearing alloys through creating nanocomposite structure by mechanical alloying (2012) Wear, pp. 387-394Agafii, V.I., Petrenko, V.I., Fomichev, V.M., Yurchenko, V.I., Yurchenko, E.V., Dikusar, A.I., Electrospark alloying for deposition on aluminum surface of Al-Sn coatings and their wear resistance under dry friction (2013) Surf Eng Appl Electrochem, 49, pp. 181-188Bravo, A.E., Durán, H.A., Jacobo, V.H., Ortiz, A., Schouwenaars, R., Towards new formulations for journal bearing alloys (2013) Wear, 302, pp. 1528-1535Feyzullahoğlu, E., Ertürk, A.T., Güven, E.A., Influence of forging and heat treatment on wear properties of Al-Si and Al-Pb bearing alloys in oil lubricated conditions (2013) Trans Nonferr Met Soc, 23, pp. 3575-3583Lu, Z.C., Zeng, M.Q., Gao, Y., Zhu, M., Minimizing tribolayer damage by strength-ductility matching in dual-scale structured Al-Sn alloys: a mechanism for improving wear performance (2013) Wear, 304, pp. 162-172Rusin, N.M., Skorentsev, A.L., Improving the tribological properties of self-lubricating Al-Sn alloys by their severe plastic processing (2013) Appl Mech Mater, 379, pp. 110-114Sui, B., Zeng, J.M., Chen, P., Liang, L.H., Gan, W.K., Lu, J.B., Study on tribological performance of Al2O3 particle reinforced the Al-Sn bearing alloy (2014) Appl Mech Mater, pp. 137-140Mittal, R., Tomar, A., Singh, D., Wear behavior of disk shape spray formed Al-Si-Pb alloys (2014) J Mater Eng Perform, 23, pp. 975-981Yuan, G.C., Li, Z.J., Lou, Y.X., Zhang, X.M., Study on crystallization and microstructure for new series of Al-Sn-Si alloys (2000) Mater Sci Eng, A, 280, pp. 108-115Yuan, G.C., Zhang, X.M., Lou, Y.X., Li, Z.J., Tribological characteristics of new series of Al-Sn-Si alloys (2003) Trans Nonferrous Met Soc China, 13, pp. 774-780Kong, C.J., Brown, P.D., Harris, S.J., McCartney, D.G., The microstructures of a thermally sprayed and heat treated Al-20wt%Sn-3wt%Si alloy (2005) Mater Sci Eng A-Struct, 403, pp. 205-214Pramanick, A., Chatterjee, S., Bhattacharya, V., Chattopadhyay, K., Synthesis and microstructure of laser surface alloyed Al-Sn-Si layer on commercial aluminum substrate (2005) J Mater Res, 20, pp. 1580-1589Abd El-Salam, F., Abd El-Khalek, A.M., Nada, R.H., Wahab, L.A., Zahran, H.Y., Thermally induced structural and mechanical variations in ternary Al-Si based alloys (2009) Mater Sci Eng A-Struct, 527, pp. 281-286Abd El-Salam, F., Abd El-Khalek, A.M., Nada, R.H., Wahab, L.A., Zahran, H.Y., Effect of Sn content on the structural and mechanical properties of Al-Si alloy (2010) Mater Sci Eng, A, 527, pp. 1223-1229Nada, R.H., Abd El-Salam, F., Abd El-Khalek, A.M., Wahab, L.A., Zahran, H.Y., Effect of cyclic stress reduction on the creep parameters of Al-Si alloy with Ag and Sn additions (2012) Mater 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935-949Ferreira, I.L., Lins, J.F.C., Moutinho, D.J., Gomes, L.G., Garcia, A., Numerical and experimental investigation of microporosity formation in a ternary Al-Cu-Si alloy (2010) J Alloy Compd, 503, pp. 31-39Bouchard, D., Kirkaldy, J.S., Prediction of dendrite arm spacings in unsteady and steady-state heat flow of unidirectionally solidified binary alloys (1997) Metall Mater Trans B, 28, pp. 651-663Spinelli, J.E., Cheung, N., Garcia, A., On array models theoretical predictions versus measurements for the growth of cells and dendrites in the transient solidification of binary alloys (2011) Philos Mag, 91, pp. 1705-1723Rocha, O.L., Siqueira, C.A., Garcia, A., Heat flow parameters affecting dendrite spacings during unsteady-state solidification of Sn-Pb and Al-Cu alloys (2003) Metall Mater Trans A, 34, pp. 995-100