Microstructural evolution during remelting of laser surface alloyed hyper-monotectic Al-Bi alloy

The present investigation explores the possibility of synthesizing a two-phase microstructure consisting of a fine dispersion of bismuth particles in an aluminium matrix using the laser surface alloying technique. The possibility of controlling the size distribution of bismuth particles by subsequent remelting is also investigated. The microstructural analysis of the surface alloyed samples shows that the average size of the bismuth particles reduces with increase in laser scan speed. In order to understand the factors that determine the nature of the size distribution of the particles, a detailed model is developed. The model incorporates heat and fluid flow induced by the laser to arrive at the evolution of the temperature and velocity of the melt in three dimensions. Using these as inputs, a kinetic analysis of the nucleation, growth and coarsening induced by collision-controlled coalescence of the bismuth particles from the melt is carried out. Comparison with the experiments indicates that coalescence due to convection plays an important role in the evolution of the size distribution of bismuth particles

Laser cladding of quasi-crystal-forming Al-Cu-Fe-Bi on an Al-Si alloy substrate

We report here the results of an investigation aimed at producing coatings containing phases closely related to the quasi-crystalline phase with dispersions of soft Bi particles using an Al-Cu-Fe-Bi elemental powder mixture on Al-10.5 at. pct Si substrates. A two-step process of cladding followed by remelting is used to fine-tune the alloying, phase distribution, and microstructure. A powder mix Al64CU22.3Fe11.7Bi2 of has been used to form the clads. The basic reason for choosing Bi lies in the fact that it is immiscible with each of the constituent elements. Therefore, it is expected that Bi will solidify in the form of dispersoids during the rapid solidification. A detailed microstructural analysis has been carried out by using the backscattered imaging mode in a scanning electron microscope (SEM) and transmission electron microscope (TEM). The microstructural features are described in terms of layers of different phases. Contrary to our expectation, the quasi-crystalline phase could not form on the Al-Sisubstrate. The bottom of the clad and remelted layers shows there growth of aluminum. The formation of phases such as blocky hexagonal Al-Fe-Si and a ternary eutectic (Al + CuAl2 + Si) have been found in this layer. The middle layer shows the formation of long plate-shaped Al13Fe4 along with hexagonal Al-Fe-Si phase growing at the periphery of the former. The formation of metastable Al-Al6Fe eutectic has also been found in this layer. The top layer, in the case of the as-clad track, shows the presence of plate-shaped Al13Fe4along with a 1/1 cubicrational approximant of a quasi-crystal. The top layer of the remelted track shows the presence of a significant amount of a 1/1 cubicrational approximant. In addition, the as-clad and remelted microstructures show a fine-scale dispersion of Bi particles of different sizes formed during monotectic solidification. The remelting is found to have a strong effect on the size and distribution of Bi particles. The dry-sliding wear properties of the samples show the improvement of wear properties for Bi-containing clads. The best tribological properties are observed in the as-clad state, and remelting deteriorates the wear properties. The low coefficient offriction of the as-clad and remelted track is due to the presence of approximant phases. There is evidence of severe subsurface deformation during the wear process leading to cracking of hard phases and a change in the size and shape of soft Bi particles. Using these observations,we have rationalized possible wear mechanisms in the Bi-containing surface-alloyed layers

The ω phase formation during laser cladding and remelting of quasicrystal forming AlCuFe on pure aluminum

We report the formation ω phase in the remelted layers during laser cladding and remelting of quasicrystal forming Al65Cu23.3Fe11.7 alloy on pure aluminum. The ω phase is absent in the clad layers. In the remelted layer, the phase nucleates at the periphery of the primary icosahedral phase particles. A large number of ω phase particles forms enveloping the icosahedral phase growing into aluminum rich melt, which solidify as υ-Al solid solution. On the other side it develops an interface with aluminum. A detailed transmission electron microscopic analysis shows that ω phase exhibits orientation relationship with icosahedral phase. The composition analysis performed using energy dispersive x-ray analyzer suggests that this phase has composition higher aluminum than the icosahedral phase. The analysis of the available phase diagram information indicates that the present results represent large departure from equilibrium conditions. A possible scenario of the evolution of the ω phase has been suggested

Microstructural evolution during remelting of laser surface alloyed hyper-monotectic Al–Bi alloy

The present investigation explores the possibility of synthesizing a two-phase microstructure consisting of a fine dispersion of bismuth particles in an aluminium matrix using the laser surface alloying technique. The possibility of controlling the size distribution of bismuthparticles by subsequent remelting is also investigated. The microstructural analysis of the surface alloyed samples shows that the average size of the bismuth particles reduces with increase in laser scan speed. In order to understand the factors that determine the nature of the size distribution of the particles, a detailed model is developed. The model incorporates heat and fluid flow induced by the laser to arrive at the evolution of the temperature and velocity of the melt in three dimensions. Using these as inputs, a kinetic analysis of the nucleation, growth and coarsening induced by collision-controlled coalescence of the bismuth particles from the melt is carried out. Comparison with the experiments indicates that coalescence due to convection plays an important role in the evolution of the size distribution of bismuth particles

Laser cladding of quasicrystal forming Al–Cu–Fe on aluminum

Composite quasicrystalline coatings are developed by laser cladding of an elemental powder mixture of aluminum, copper and iron on an aluminum substrate. Some of the tracks are remelted to see the effect of phase formation and related changes in hardness during remelting. The clad layers start growing with a cellular morphology from the substrate. The icosahedral phase forms in all the tracks along with some aluminides. It has also been found that the icosahedral phase forms both by a peritectic reaction between the liquid and $Al_{13}Fe_4$ and by direct nucleation from the liquid. This is a clear indication of a different levels of undercooling that the liquid undergoes before the nucleation of the primary phase inside the clad layers during laser processing. The formation of $Al_{13}Fe_4$ with a ten-pointed star like morphology has also been found at the bottom of the clad. The remelting of the clad tracks leads to a change in microstructure as far as phase formation is concerned. The formation of long lath-shaped $Al_{13}Fe_4$ can be observed in the remelted layer. The hardness profiles of the clad and remelted layers reveal a hardness $(HV_{0.025})$ around 600