Coupling in situ synchrotron X-ray tomographic microscopy and numerical simulation to quantify the influence of intermetallic formation on permeability in aluminium–silicon–copper alloys

AbstractThe influence of the β-Al5FeSi intermetallic phase on permeability evolution during solidification in an Al–Si–Cu alloy with a columnar dendritic microstructure has been numerically studied at solid fractions between 0.10 and 0.85. The fluid flow simulations were performed on a semisolid microstructure extracted directly from a single solidifying specimen, enabling the first study of permeability variation on an individual microstructure morphology that is evolving in solid fraction. The 3-D geometries were imaged at the TOMCAT beamline using 4-D (3-D+time) in situ synchrotron-based X-ray tomographic microscopy. The results illustrate the major effect of intermetallic particles on flow blockage and permeability. Intermetallics that grow normal to the flow direction were found to have a greater impact on the flow field in comparison to intermetallics in the parallel flow direction. An analytical expression, based on the anisotropic Blake–Kozeny model, was developed with a particle blockage term that takes into account the effects of intermetallic particles on permeability. In the regime of primary-phase solidification, a good fit between the analytical expression and the simulation results is found

Quantitative Assessment of Deformation-Induced Damage in a Semisolid Aluminum Alloy via X-ray Microtomography

Semisolid tensile testing combined with X-ray microtomography (XMT) was used to characterize the development of internal damage as a function of strain in an aluminum-magnesium alloy, AA5182. Novel techniques were developed to allow the quantification of both the size evolution and orientation of the damage to determine mechanisms controlling the early stage growth and localization. During the initial stages of semisolid deformation, it was observed that strain was accommodated by both the growth of as-cast porosity and the detection of new damage-based voids. As the volume fraction of damage increases, the growth of voids occurs in an orientation perpendicular to the loading direction, both through expansion within the grain boundary liquid and void coalescence. The damage then localizes, causing failur

Connectivity of Phases and Growth Mechanisms in Peritectic Alloys Solidified at Low Speed: an X-Ray Tomography Study of Cu-Sn

The variety of microstructures that form at low solidification speed in peritectic alloys, bands, and islands, or even coupled (or cooperative) growth of the primary α and peritectic β phases, have been previously explained by nucleation-growth mechanisms. In a recent investigation on Cu-Sn, a new growth mechanism was conjectured on the basis of two-dimensional (2-D) optical microscopy and electron backscattered diffraction (EBSD) observations made in longitudinal sections. In the present contribution, synchrotron-based tomographic microscopy has been used to confirm this mechanism: α and β phases totally interconnected in three dimensions and bands (or islands) can result from an overlay mechanism, rather than from a nucleation events sequence. When the lateral growth of a new layer is too fast, an instability can lead to the formation of a lamellar structure as for eutectic alloy

Effects of iron-rich intermetallics and grain structure on semisolid tensile properties of Al-Cu 206 cast alloys near solidus temperature

The effects of iron-rich intermetallics and grain size on the semisolid tensile properties of Al-Cu 206 cast alloys near the solidus were evaluated in relation to the mush microstructure. Analyses of the stress–displacement curves showed that the damage expanded faster in the mush structure dominated by plate-like β-Fe compared to the mush structure dominated by Chinese script-like α-Fe. While there was no evidence of void formation on the β-Fe intermetallics, they blocked the interdendritic liquid channels and thus hindered liquid flow and feeding during semisolid deformation. In contrast, the interdendritic liquid flows more freely within the mush structure containing α-Fe. The tensile properties of the alloy containing α-Fe are generally higher than those containing β-Fe over the crucial liquid fraction range of ~0.6 to 2.8 pct, indicating that the latter alloy may be more susceptible to stress-related casting defects such as hot tearing. A comparison of the semisolid tensile properties of the alloy containing α-Fe with different grain sizes showed that the maximum stress and elongation of the alloy with finer grains were moderately higher for the liquid fractions of ~2.2 to 3.6 pct. The application of semisolid tensile properties for the evaluation of the hot tearing susceptibility of experimental alloys is discussed

Formation of hot tear under controlled solidification conditions

Aluminum alloy 7050 is known for its superior mechanical properties, and thus finds its application in aerospace industry. Vertical direct-chill (DC) casting process is typically employed for producing such an alloy. Despite its advantages, AA7050 is considered as a "hard-to-cast" alloy because of its propensity to cold cracking. This type of cracks occurs catastrophically and is difficult to predict. Previous research suggested that such a crack could be initiated by undeveloped hot tears (microscopic hot tear) formed during the DC casting process if they reach a certain critical size. However, validation of such a hypothesis has not been done yet. Therefore, a method to produce a hot tear with a controlled size is needed as part of the verification studies. In the current study, we demonstrate a method that has a potential to control the size of the created hot tear in a small-scale solidification process. We found that by changing two variables, cooling rate and displacement compensation rate, the size of the hot tear during solidification can be modified in a controlled way. An X-ray microtomography characterization technique is utilized to quantify the created hot tear. We suggest that feeding and strain rate during DC casting are more important compared with the exerted force on the sample for the formation of a hot tear. In addition, we show that there are four different domains of hot-tear development in the explored experimental window-compression, microscopic hot tear, macroscopic hot tear, and failure. The samples produced in the current study will be used for subsequent experiments that simulate cold-cracking conditions to confirm the earlier proposed model.This research was carried out within the Materials innovation institute (www.m2i.nl) research framework, project no. M42.5.09340

Modeling Hot Tearing during Solidification of Steels: Assessment and Improvement of Macroscopic Criteria through the Analysis of Two Experimental Tests

International audienceHot tearing is an unacceptable defect found in products and parts obtained by solidification processes such as ingot and continuous casting. It consists of the development of cracks during solidification, in regions that are not completely solidified, more precisely, in areas of mushy zones with a high fraction of solid (typically 0.9 and beyond), when the material undergoes deformations associated with tensile stress. In this study, two hot tearing tests have been studied in order to evaluate the predictive capability of several macroscopic criteria published in the literature. The first test is a new test specifically designed for constrained shrinkage by the present authors, while the second test is an ingot bending test developed in the 1980s. For both tests, a thermal-mechanical analysis is performed, in order to provide the key variables for the different selected criteria. A comparison with experimental results allows us to make a critical assessment of those criteria regarding their ability to predict crack occurrence. The criterion initially proposed by Won et al.[7] has been found to be the best suited for the prediction of solidification cracking. Because this criterion is essentially based on the "brittle temperature range," (BTR) critical considerations regarding nonequilibrium solidification have led to suggest an extension of this criterion. This new macroscopic criterion improves the prediction capacity

Achieving homogeneity in a high-Fe β-Ti alloy laser-printed from blended elemental powders

Blended Elemental powders are an emerging alternative to pre-alloyed powders in metal additive manufacturing due to the wider range of alloys producible with them and the cost savings from not developing novel feedstock. In this study, in situ alloying and concurrent microstructure evolution during SLM are investigated by performing SLM on a BE Ti-185 powder while tracking the surface temperatures via Infra-red imaging and phase transformation via synchrotron X-ray Diffraction. We then performed post-mortem electron microscopy (Backscatter Electron imaging, Energy Dispersive X-ray Spectroscopy and Electron Backscatter Diffraction) to further gain insight into microstructure development. We show that although exothermic mixing aids the melting process, laser melting results only in a mixture of alloyed and unmixed regions. Full alloying and thus a consistent microstructure is only achieved through further thermal cycling in the heat-affected zone