Dendritic Alloys Research Articles

Cast Microstructure and Crystallographic Features of Al3Sc Dendrites in High Sc-Contained Al-Sc Alloys

Al-Sc alloys containing high Sc content are employed as sputtering targets for the fabrication of high-performance piezoelectric films during magnetic sputtering. Due to the high proportion of the Al3Sc phase, their workability is quite limited, and they are often used in the as-cast state. In this study, the crystallography of Al3Sc dendrites in as-casted Al-10at.%Sc and Al-20at.%Sc samples is examined using electron backscatter diffraction (EBSD). With increasing Sc content, the fraction of Al3Sc also increases. The Al3Sc dendrites exhibit a cubic relationship with the Al matrix in both alloys. However, in Al-10%Sc alloys, the facets of the Al3Sc dendrites are parallel to {001} planes, while twinning is observed in Al-20at.%. The twinning plane is parallel to the {111} plane, and the dendrite growth direction aligns with the <110> directions. The different morphologies of the dendrite structures in these two alloys are discussed in relation to thermodynamic and kinetic considerations based on the phase diagram and nucleation rate.

The Impact of Two and Three Dimensional Assumptions on Coupled Structural Mechanics and Microstructure Solidification Modelling

It is usual for computational efficiency to simulate growing alloy dendrites during solidification using a two-dimensional model. However, the fidelity of such simulations is to be questioned, since observations show that three-dimensional models lead to significantly more realistic results in comparison to experiments under many situations. Even in thin sample cases, the properties affecting, for example, mechanical behaviour are intrinsically three-dimensional. However, partly due to the lack of published work on the, topic the impact of 2D assumptions on the evolution and structural mechanical behaviour of dendrites has not been properly explored. In this study, solidification using the Cellular Automata (CA) method was coupled to a Finite Volume Structural Mechanics Solver (FVSMS) capable of both 2D and 3D modelling, applied to a selection of representative problems which clearly demonstrate that structural mechanics is another factor in the modelling of dendrites where two-dimensional assumptions can lead to significantly altered behaviour when compared to three-dimensional reality.

Time evolution of interface shape distribution of equiaxed dendrite: A phase-field study

An understanding of the morphology of growing dendrites in alloys is needed for an analysis of microsegregation, as well as an estimation of the permeability for macroscopic fluid dynamics. Quantitative phase-field simulations were used to study the growth process of three-dimensional (3D) equiaxed dendrites in an Al-1.0 mass%Cu alloy during continuous cooling. The dendrites were analysed using an interface shape distribution (ISD) map, which provides the probability of the local interface having a morphology with a given curvedness (C) and shape factor (S). Morphological changes in the microstructure can be measured sensitively from the change in the average value of the curvedness 〈C〉 relative to the solid volume fraction. The ISD map continued to change over time during continuous cooling, implying that it was not time-invariant. Furthermore, when microstructural changes occurred, similarities between the ISD maps were observed, independent of the cooling rates and system sizes.

Ductilizing Ti19Zr19Hf19Nb19TM5Be19 (TM = Fe, Co, Ni and Cu) high-entropy bulk metallic glass composites via in-situ precipitated refractory high-entropy alloy dendrites

In this work, a series of Ti19Zr19Hf19Nb19TM5Be19 (at.%, TM = Fe, Co, Ni and Cu) high-entropy bulk metallic glass composites (HE-BMGCs) were successfully developed to address the absence of tensile ductility in high-entropy bulk metallic glasses (HE-BMGs). It is shown that the mechanical properties of HE-BMGCs are jointly affected by the two constituent phases of refractory high-entropy alloy (RHEA) dendrites and HE-BMG matrix. The present composites show that the good tensile ductility as well as excellent work-hardening capability at ambient temperature. Based on the post-deformation microstructure and theoretical analyses, cross slips dominate the deformation mechanism of HE-BMGCs, and it is found that the dislocation multiplication mechanism composed of dislocation pinning and double cross-slip is very prevalent in current composites. Therein, the dislocation multiplication of RHEA dendrites facilitates the inhibition and retardation to the propagation of shear bands in the HE-BMG matrix, which is responsible for the good tensile ductility of HE-BMGCs. Additionally, the excellent work-hardening capability of composites is attribute to severe dislocation interactions caused by intrinsic local-regional multicomponent fluctuations and dislocation cross-slips in RHEA dendrites. Our research results not only aid in understanding the underlying deformation mechanism of HE-BMGCs, but also offer a novel perspective for designing the ductile high-entropy dual-phase alloys.

Investigation of isothermal continuous hot deformation behavior of the new as-cast alumina-forming austenitic alloy

Multi-pass isothermal continuous hot deformation experiments were designed for homogenization and recrystallization in the as-cast alumina-forming austenite (AFA) heat-resistant alloy. Flow curves and microstructure characterization were used to study the grain evolution with different deformation parameters in each pass. In particular, attention was paid to the dendrites and segregated phase. Under different hot deformation conditions, the alloys show significant work-hardening characteristics, which result from the strengthening effect of the primary segregated MC-type carbide. The increase in deformation temperature contributes significantly to dynamic recrystallization (DRX), and the main mechanism of DRX is discontinuous DRX (DDRX). The continuous DRX (CDRX) is less occurring. Static recrystallization (SRX) occurs during the isothermal holding time between deformation passes. SRX becomes more and more apparent with temperature and the holding time. The increase in the deformation passes leads to a gradual disappearance of the alloy dendrites and an increase in the recrystallization volume fraction. Meanwhile, the segregated phase gradually decomposes into particles and partially dissolves. However, the segregated phase particles eventually show band-like distribution. SRX grains around the segregated phase will exhibit similar orientations due to particle-stimulated nucleation (PSN) mechanisms. Until the grain size increases to the point that it can escape from particle restraint, it will transform to random orientation. The above study confirms that multi-pass isothermal continuous hot deformation can improve the as-cast microstructure and guide practical industrial production.

Achieving equiaxed microstructure and isotropic mechanical properties of additively manufactured AZ31 magnesium alloy via ultrasonic frequency pulsed arc

The high cooling rate and thermal gradient in the wire arc additive manufacturing (WAAM) process often leads to a tendency towards columnar grains or columnar dendrites in magnesium alloys, which can result in anisotropic mechanical properties and are therefore undesirable. To address this challenge, a novel ultrasonic frequency pulsed (UFP) arc used as heat source is applied to alter the conditions in the WAAM process and promote equiaxed growth of magnesium grains. Experimental results indicate that the AZ31 magnesium alloy deposit produced by the UFP-WAAM exhibits full equiaxed-grain microstructure along the building direction. Without any additional treatments, the AZ31 magnesium alloy deposit displays promising mechanical properties, such as isotropic tensile strength and excellent ductility.

Revealing complex microstructure formation mechanisms in the Al[formula omitted]Cr[formula omitted]Fe[formula omitted]Ni[formula omitted]Ti[formula omitted] compositionally complex alloy

The complex phase evolution sequence of a promising new high temperature structural alloy with composition Al20Cr20Fe35Ni20Ti5 (at.%) has been studied in situ using an electromagnetic levitation (EML) setup combined with time-resolved high energy X-ray diffraction (XRD), as well by scanning transmission electron microscopy (STEM) observations during in situ heating. These experiments were supplemented by both scanning electron microscopy (SEM) and high resolution STEM observations of the as-cast alloy microstructure, as well as by energy dispersive X-ray spectroscopy (EDS) composition measurements. Differential scanning calorimetry (DSC) was used to identify liquidus, solidus, A2 ↔ B2, and B2 ↔ L21 transition temperatures. The results obtained by these complementary techniques indicate that the alloy forms primary dendrites of A2-structured body-centered cubic (bcc) phase initially from the melt, followed by ordered bcc of B2-structure in interdendritic regions once compositional segregation has sufficiently enriched the remaining liquid. Ordered B2 precipitates form within the primary A2-structured dendrites and the interdendritic B2 regions undergo a continuous decomposition reaction into a maze-like arrangement of A2 and B2/L21 phases below the solidus. Below approximately 1380 K, the B2 domains in both dendritic and interdendritic regions likely undergo a continuous ordering transition to the L21 phase. The experimental observations of Al20Cr20Fe35Ni20Ti5 are found to be in good agreement with CALPHAD predictions but suggest that the solubility limits of the L21-Heusler phase in the database should be relaxed to include greater Fe solubility for the Ni sublattice and to consider deviations in order parameter from stoichiometric ordering.

Porous Ni-Cu Alloy Dendrite Anode Catalysts with High Activity and Selectivity for Direct Borohydride Fuel Cells.

A porous Ni-Cu alloy dendrite catalyst covered by Ni nanoparticles (Ni-np@NC) has been fabricated by an ultrafast and controllable strategy. The research results show that the morphology of the Ni-Cu alloy depends strongly on the Cu2+concentration. Moreover, the Ni-np@NC catalyst demonstrates excellent selectivity and activity toward the borohydride oxidation reaction (BOR). Furthermore, on the Ni-np@NC catalyst electrode, the overpotential merely requires 169 mV at a current density of 10 mA cm-2 for BOR, and the fuel efficiency may reach 70%. The direct borohydride fuel cell using the Ni-np@NC/C anode can export a maximum power density of 218 mW cm-2, much higher than that using the noble-based anode reported in the literature. The remarkable enhancement of Ni-np@NC catalyst performances is on the back of the unique morphology of porous dendrite covered by nanoparticles and the introduction of Cu.

Microstructure and Corrosion Resistance of AA4047/AA7075 Transition Zone Formed Using Electron Beam Wire-Feed Additive Manufacturing.

A gradient transition zone was obtained using electron beam deposition from AA4047 wire on AA7075 substrate and characterized for microstructures, tensile strength and corrosion resistance. The microstructure of the transition zone was composed of aluminum alloy grains, Al/Si eutectics and Fe-rich and Si-rich particles. Such a microstructure provided strength comparable to that of AA7075-T42 substrate but more intense corrosion due to the higher amount of anodic Mg2Si particles. The as-deposited AA4047 zone formed above the transition zone was composed of aluminum alloy dendrites and interdendritic Al/Si eutectics with low mechanical strength and high corrosion potential.

Effect of Sc microalloying on microstructure evolution and mechanical properties of extruded Al–Zn–Mg–Cu alloys

The effect of microalloying Sc on the microstructure and mechanical properties of Al–Zn–Mg–Cu alloys was experimentally investigated through X-ray diffraction, optical microscopy, scanning electron microscopy, electron backscatter diffraction, and transmission electron microscopy characterizations and tensile tests. The presence of Sc caused the formation of the primary Al3Sc phase and behaved a significant modifying effect on the cast microstructure with an equiaxed microstructure attained in the Sc-bearing alloys rather than the dendrites in Sc-free alloys. In the subsequent thermal extrusion processing, a remarkable grain refinement and retardation of recrystallization occurred, because the nano-sized Al3Sc dispersoids contributed to the pinning effect on the dislocation movement and grain boundary migration in the Sc-bearing alloys. The mechanical properties were significantly improved with the addition of Sc. The superior comprehensive mechanical properties in the Sc-bearing alloys were achieved via the optimal extrusion at 350 °C with the yield strength and ultimate tensile strength of 373.7 ± 3 MPa and 490.3 ± 5 MPa, respectively. The strong strengthening behavior of the Sc addition in the extruded alloys is mainly attributed to the grain refinement and the dispersoid strengthening from the Al3Sc particles. The corresponding contributions to the increase in yield strength derived from the grain refinement and the dispersoid strengthening were estimated, which indicated that the highest particle density attained by extrusion at 350 °C resulted in the excellent mechanical properties of the Sc-bearing alloys.

A 2D model for prediction of nanoparticle distribution and microstructure evolution during solidification of metal matrix nanocomposites

A 2D numerical model to predict the microstructure evolution in binary alloy matrix nanocomposites is presented. The main novelty of the model is that it captures the effect of nanoparticles on binary alloy dendrite growth and microstructure evolution. Diffusion based transport of nanoparticles is solved using a nanoparticle concentration defined in a similar way to an alloying element. Engulfment or rejection of nanoparticles at the solidification interface is implemented by defining a partition coefficient. The diffusivity of nanoparticles is calculated based on nanoparticle movement due to Brownian motion. The governing equations for binary alloy solidification are formulated using the volume averaged enthalpy method with a probabilistic nucleation model for grain nucleation. The effect of nanoparticles on solidification is incorporated through modifications of the solute diffusion field and interfacial energy. The developed model is used for predicting the effect of nanoparticle concentration and nanoparticle radius on dendrite growth and microstructure evolution. From single dendrite study, it is observed that the dendrite size decreases with increase in nanoparticle concentration while it increases with increase in nanoparticle radius. During microstructure evolution, increased non-homogeneity in nanoparticle distribution is observed with increase in nanoparticle concentration and more uniform distribution is observed with increase in nanoparticle radius.

Fractal Correlation Dimensions Analysis of Al–Si Dendrites

Solidification dendrites in metal alloys have intricate shapes with fractal elements, making fractal dimension an attractive potential method for more completely quantifying these important shapes. However, fractal analysis as usually applied to dendrites has some pitfalls, which we demonstrate here on micrographs of dendrites from two different aluminum–silicon alloys with different solidification velocities. Box dimension and a more rigorous analysis of correlation dimension were calculated for each sample, but both measures exhibited non-uniform scaling. Further analysis using the Takens–Theiler estimator of correlation dimension revealed a transition between two distinct scaling regimes: a small-scale exponent associated with dendrite boundary texture and the large-scale with overall dendrite morphology. The scaling transition between regimes may prove useful as an automated alternative to secondary dendrite arm spacing. Overall, the investigations give further insight into the quantitative description of complex dendritic structures and clarify the ability of fractal analysis to describe this important solidification morphology.

Numerical Simulation of Ni-Cu Alloy Dendrite Growth with Boundary Heat Flux

Evolution of the dendrite growth and the distribution of concentration and temperature fields in a Ni-0.4083 at.% Cu alloy was simulated. The dendrite morphology was greatly affected by boundary conditions. The result shows that the solid/liquid interface of dendrite was most instable and grew most fast under extraction boundary condition. The re-calescence occurred under the extraction boundary condition and Zero-Neumann boundary condition, but not under the heating boundary condition.

Electrodeposition of bimetallic NiAu alloy dendrites on carbon papers as highly sensitive disposable non-enzymatic glucose sensors

The bimetallic NiAu alloy dendrites were directly grown on the carbon papers using template free electrodeposition approaches, which demonstrated superior non-enzymatic glucose sensing performance. The enhanced electrochemical performance may be due to the dendrite structure and the low charge transfer resistance originating from the synergistic effect of Ni and Au.

Controllable constructing alloy dendrites with fractal structure as free‐standing electrode for enhanced oxygen evolution

Controllable constructing alloy dendrites with fractal structure as free‐standing electrode for enhanced oxygen evolution

Binary alloy dendrite growth in presence of shrinkage induced convection

In this paper, the effect of shrinkage induced flow on binary alloy dendrite growth is investigated. The standard enthalpy model for dendritic solidification is modified to incorporate unequal phase densities and coupled with a flow solver to simulate shrinkage driven flow. Simulations show that shrinkage induced convection towards the solidification interface leads to increased solute accumulation at the interface resulting in reduced solidification rate. Thus even if the change in volume due to density difference is considered, the predicted growth rate will not be accurate unless shrinkage driven convection is incorporated in the model. The effect of Lewis number on shrinkage is also investigated and it is found that the relative decrease in dendrite growth rate due to shrinkage induced flow is not affected significantly by change in Lewis number.

Influence of Minor Cr-Additions to the Growth of Columnar Dendrites in Al-Zn Alloys: Influence of Icosahedral Short Range Order in the Liquid

The effect of minute Cr additions on dendritic growth directions in Al-20 wt pct Zn alloy has been investigated. As first evidenced by Gonzales and Rappaz (Metall Mater Trans A 37:2797–2806, 2006) Al-Zn alloys exhibit a Dendrite Orientation Transition (DOT), from 〈100〉 below 25 wt pct Zn to 〈110〉 above 60 wt pct, regardless of the solidification speed. The DOT has been interpreted as a modification of the solid–liquid interfacial energy anisotropy (Gonzales and Rappaz, 2006; Haxhimali et al. in Nat Mater 5:660–664, 2006). However, 0.02 to 0.1 wt pct addition of Cr in Al-20 wt pct Zn drastically modifies the dendrite trunk direction from 〈100〉 to 〈110〉 at low solidification speed, typically 200 μm/s. Even more surprising, 〈100〉 dendrite trunks are retrieved in Al-20 wt pct Zn-0.1 wt pct Cr when the speed is increased to 1000 μm/s, but with the concurrent formation of twinned dendrites. Minute additions of Cr have been reported recently to promote icosahedral short range order (ISRO) in liquid Al-Zn, thus reducing the atomic mobility (Kurtuldu et al. in Acta Mater 115:423–433, 2016) and modifying the nucleation kinetics (Kurtuldu et al. in Acta Mater 61:7098–7108, 2013). The present results indicate that ISRO also modifies the attachment kinetics of icosahedral clusters rather than individual atoms, and is most likely responsible of growth direction change in Al-Zn-Cr alloy and of twinned dendrites formation.

Combined Effect of Thermal Anisotropy and Forced Convection on the Growth of Binary Alloy Equiaxed Dendrites

A numerical model has been developed to simulate the growth of an equaixed binary alloy dendrite under the combined effect of thermal anisotropy and forced convection. A semi implicit–explicit approach is used where the velocity and pressure fields are solved implicitly using the SIMPLER algorithm, while energy and species conservation equations are treated explicitly. The effect of thermal anisotropy present in the solid crystal is implemented by the addition of a departure source term in the conventional isotropic heat transfer based energy equation. The departure source represents the anisotropic part of the diffusive term in the isotropic heat transfer based energy equation. Simulations were performed to find the relative effect of convection strength and thermal anisotropy on the growth rate and morphology of a dendrite. Subsequently, parametric studies were conducted to investigate the effect of thermal anisotropy ratio, inlet flow velocity, undercooling temperature, and the relative strength of the thermal to mass diffusivity ratio by analyzing the variation of the equilibrium tip velocity of the top and left arms, the arm length ratio (ALR), and the equivalent grain radius. Based on simulations, a chart has been developed, which demarcates different regimes in which convection or thermal anisotropy is the most dominant factor influencing the dendrite growth rate. The model has also been extended to study the growth of multiple dendrites with random distribution and orientation. This can be useful for the simulation of microstructure evolution under the combined effect of convection and thermal anisotropy.

Segregation behaviors of Sc and unique primary Al3Sc in Al-Sc alloys prepared by molten salt electrolysis

This work mainly deals with the segregating behaviors of Sc and the growth of unique primary Al3Sc in Al-Sc alloys prepared by molten salt electrolysis. The alloys contain 0.23–1.38 wt%Sc where Sc segregation is observed. It is found that a high current density and long electrolysis time are in favor of high Sc content, and so do the high temperature and the addition level of Sc2O3. Sc content at the edge of Al based alloy (average Sc content: 0.75 wt%) can be as high as 1.09 wt%, while it is merely 0.24 wt% at the central area. The cooling rates have a strong impact on the morphology and particle size of primary Al3Sc, but a weak influence on Sc segregation. The cusped cubic and dendritic primary Al3Sc can precipitate in the prepared Al-Sc alloys. In a slightly hypereutectic Al-0.67 wt%Sc alloy, a large and cusped dendrite grows from the edge into the center. The primary and secondary dendritic arms can be as long as 600 and 250 μm, respectively. The Sc segregating behaviors in Al-Sc alloys is due to the mechanism controlled by the limited diffusion rate of Sc in liquid Al. This can involve the establishment of a near spherical discharge interface between liquid Al and the electrolyte. The Sc rich layer near Al-molten salt interface may provide the potential primary nuclei and sufficient Sc atoms for the growth of large dendritic primary Al3Sc.

Application of the Correlation between Hardness and Strength in Conventional Al Alloys into Semi Solid Processed Products

In the field of material production and application, strength and hardness are the two most common properties of metallic materials. It’s one familiar phenomenon that the hardness of one certain alloy has positive relationship with its strength in conventional dendritic alloys. When it comes to non-dendritic semi-solid alloys, it’s unclear that the relationship is still right or not. In this paper, the molecular mechanics, as well as finite element simulation and experimental verification were combined to study the internal deformation regularity of metallic material and the correlation between the two parameters was illustrated. Firstly, the displacement of solid atom in metallic crystal cell was well described in the view of energy cost. Secondly, the total strain amount under local indenting deformation (resistant boundary) and overall impressing deformation (free boundary) were compared to study the correlation between hardness and compression strength in semi-solid globule grain alloy. Finally, the data collected in semi-solid processed products was applied to be compared against traditional casting and wrought aluminum alloys.