The NBS: Processing/Microstructure/Property Relationships in 2024 Aluminum Alloy Plates

As received plates of 2024 aluminum alloy were examined. Topics covered include: solidification segregation studies; microsegregation and macrosegregation in laboratory and commercially cast ingots; C-curves and nondestructive evaluation; time-temperature precipitation diagrams and the relationships between mechanical properties and NDE measurements; transmission electron microscopy studies; the relationship between microstructure and properties; ultrasonic characterization; eddy-current conductivity characterization; the study of aging process by means of dynamic eddy current measurements; and Heat flow-property predictions, property degradations due to improve quench from the solution heat treatment temperature

Effect of strontium and cooling rate upon eutectic temperatures of A319 aluminum alloy

DTA analysis was used to investigate the solidification reactions of alloy A319 with either 12 or 136 ppm of Sr added. Strontium does not affect primary solidification of (Al) dendrites but modifies the kinetics of the (Al)–Si eutectic. The effects of Sr level and of cooling rate on the characteristic temperatures for the (Al)–Si and other eutectic reactions are described

Phase field modeling of electrochemistry I: Equilibrium

A diffuse interface (phase field) model for an electrochemical system is developed. We describe the minimal set of components needed to model an electrochemical interface and present a variational derivation of the governing equations. With a simple set of assumptions: mass and volume constraints, Poisson's equation, ideal solution thermodynamics in the bulk, and a simple description of the competing energies in the interface, the model captures the charge separation associated with the equilibrium double layer at the electrochemical interface. The decay of the electrostatic potential in the electrolyte agrees with the classical Gouy-Chapman and Debye-H\"uckel theories. We calculate the surface energy, surface charge, and differential capacitance as functions of potential and find qualitative agreement between the model and existing theories and experiments. In particular, the differential capacitance curves exhibit complex shapes with multiple extrema, as exhibited in many electrochemical systems.Comment: v3: To be published in Phys. Rev. E v2: Added link to cond-mat/0308179 in References 13 pages, 6 figures in 15 files, REVTeX 4, SIUnits.sty. Precedes cond-mat/030817

Phase field modeling of electrochemistry II: Kinetics

The kinetic behavior of a phase field model of electrochemistry is explored for advancing (electrodeposition) and receding (electrodissolution) conditions in one dimension. We described the equilibrium behavior of this model in [J. E. Guyer, W. J. Boettinger, J.A. Warren, and G. B. McFadden, ``Phase field modeling of electrochemistry I: Equilibrium'', cond-mat/0308173]. We examine the relationship between the parameters of the phase field method and the more typical parameters of electrochemistry. We demonstrate ohmic conduction in the electrode and ionic conduction in the electrolyte. We find that, despite making simple, linear dynamic postulates, we obtain the nonlinear relationship between current and overpotential predicted by the classical ``Butler-Volmer'' equation and observed in electrochemical experiments. The charge distribution in the interfacial double layer changes with the passage of current and, at sufficiently high currents, we find that the diffusion limited deposition of a more noble cation leads to alloy deposition with less noble species.Comment: v3: To be published in Phys. Rev. E v2: Attempt to work around turnpage bug. Replaced color Fig. 4a with grayscale 13 pages, 7 figures in 10 files, REVTeX 4, SIunits.sty, follows cond-mat/030817

Phase-field modeling of microstructural pattern formation during directional solidification of peritectic alloys without morphological instability

During the directional solidification of peritectic alloys, two stable solid phases (parent and peritectic) grow competitively into a metastable liquid phase of larger impurity content than either solid phase. When the parent or both solid phases are morphologically unstable, i.e., for a small temperature gradient/growth rate ratio ($G/v_p$), one solid phase usually outgrows and covers the other phase, leading to a cellular-dendritic array structure closely analogous to the one formed during monophase solidification of a dilute binary alloy. In contrast, when $G/v_p$ is large enough for both phases to be morphologically stable, the formation of the microstructurebecomes controlled by a subtle interplay between the nucleation and growth of the two solid phases. The structures that have been observed in this regime (in small samples where convection effect are suppressed) include alternate layers (bands) of the parent and peritectic phases perpendicular to the growth direction, which are formed by alternate nucleation and lateral spreading of one phase onto the other as proposed in a recent model [R. Trivedi, Metall. Mater. Trans. A 26, 1 (1995)], as well as partially filled bands (islands), where the peritectic phase does not fully cover the parent phase which grows continuously. We develop a phase-field model of peritectic solidification that incorporates nucleation processes in order to explore the formation of these structures. Simulations of this model shed light on the morphology transition from islands to bands, the dynamics of spreading of the peritectic phase on the parent phase following nucleation, which turns out to be characterized by a remarkably constant acceleration, and the types of growth morphology that one might expect to observe in large samples under purely diffusive growth conditions.Comment: Final version, minor revisions, 16 pages, 14 EPS figures, RevTe

Pattern Stability and Trijunction Motion in Eutectic Solidification

We demonstrate by both experiments and phase-field simulations that lamellar eutectic growth can be stable for a wide range of spacings below the point of minimum undercooling at low velocity, contrary to what is predicted by existing stability analyses. This overstabilization can be explained by relaxing Cahn's assumption that lamellae grow locally normal to the eutectic interface.Comment: 4 pages, 5 eps figure

Microstructural evolution under low shear rates during Rheo processing of LM25 alloy

© ASM InternationalMicrostructural features of LM25 alloy processed by two different routes: (1) conventional casting, and(2)shear casting based on inclined heated surface are studied. The microstructures of the primary phase for the shear-cast samples show rosette or ellipsoidal morphologies. Heat transfer of contacting melt with the inclined tube surface and shear stress exerted on the layers of the melt as result of gravitational force are crucial parameters for the microstructural evolution. Compared to those produced by conventional casting, shear-cast samples have a much improved tensile strength and ductility due to globular microstructure

Phase-Field Approach for Faceted Solidification

We extend the phase-field approach to model the solidification of faceted materials. Our approach consists of using an approximate gamma-plot with rounded cusps that can approach arbitrarily closely the true gamma-plot with sharp cusps that correspond to faceted orientations. The phase-field equations are solved in the thin-interface limit with local equilibrium at the solid-liquid interface [A. Karma and W.-J. Rappel, Phys. Rev. E53, R3017 (1996)]. The convergence of our approach is first demonstrated for equilibrium shapes. The growth of faceted needle crystals in an undercooled melt is then studied as a function of undercooling and the cusp amplitude delta for a gamma-plot of the form 1+delta(|sin(theta)|+|cos(theta)|). The phase-field results are consistent with the scaling law "Lambda inversely proportional to the square root of V" observed experimentally, where Lambda is the facet length and V is the growth rate. In addition, the variation of V and Lambda with delta is found to be reasonably well predicted by an approximate sharp-interface analytical theory that includes capillary effects and assumes circular and parabolic forms for the front and trailing rough parts of the needle crystal, respectively.Comment: 1O pages, 2 tables, 17 figure

Effect of Magnetic-Field on the Microstructure and Macrosegregation in Directionally Solidified Pb-Sn Alloys

An investigation into the influence of a transverse magnetic field (0.45 T) on the mushy zone morphology and macrosegregation in directionally solidified hypoeutectic Pb-Sn alloy shows that the field has no influence on the morphology of dendritic arrays. The field does, however, cause severe distortion in the cellular array morphology. Cellular arrayed growth with the magnetic field results in an extensive channel formation in the mushy zone, as opposed to the well-aligned and uniformly distributed cells formed in the absence of the field. The channels are produced due to the anisotropy in the thermosolutal convection caused by the magnetic field. Macrosegregation, however, along the length of the directionally solidified samples is not influenced by this magnetic field for either the cellular or dendritic arrays