Alloy Melt Research Articles

Effect of Soret diffusion on the growth of spherical crystals in supercooled alloy melts under oscillatory flow.

The growth of spherical crystals in binary alloy melts with thermal diffusion effects under oscillatory flow is investigated analytically. Using the multiple scale method, we derive approximate analytical solutions for both the crystal interface growth rate and the solute concentration. Our results demonstrate that the Soret effect significantly influences both the solute concentration near the crystal interface and the crystal growth rate. Specifically, with a positive Soret coefficient, the growth rate of spherical crystals in a binary dilute alloy melt decreases as the coefficient increases, while the solute concentration near the interface increases. In contrast, with a negative Soret coefficient, the growth rate of the spherical crystals increases as the coefficient decreases, and the solute concentration near the interface decreases. Additionally, the presence of oscillatory flow markedly promotes the grain refinement induced by the Soret effect.

Improving interface joining strength of Ti6Al4V/AZ91D bimetal prepared by compound casting via Ni-coated Ti6Al4V lattice structure

The joining of titanium/magnesium (Ti/Mg) bimetals presents challenges due to the low mutual solubility and absence of metallurgical reactions between Ti and Mg. Herein we utilized the Ni-coated Ti6Al4V lattice structure to enhance the interfacial property of Ti6Al4V/AZ91D bimetal prepared by compound casting. The Box-Behnken design (BBD) was employed to optimize the lattice design. The resulting structure featured struts with a diameter (ds) of 2.4 mm, an aspect ratio (l/ds) ratio of 5.4, a tilt angle (ω) of 57°, and a node-to-strut diameter ratio (dn/ds) of 2.4. The optimized Ti6Al4V lattice structure manufactured by selective laser melting (SLM) exhibited α′ martensite with a high dislocation density, conferring exceptional tensile strength. The rough texture of the lattice surface enhanced adhesion with the Ni coating and improved wetting and reactivity between Ni and AZ91D alloy melt. This resulted in the formation of a serrated metallurgical interface with AZ91D alloy, which was primarily composed of α-Mg + Mg2Ni eutectic structure+τ-Ni2Mg3Al ternary phases. An impressive joining strength of 116.1 MPa was obtained under the optimized lattice structure, and the bimetal joint predominantly fails through the damage of AZ91D, aligning closely with simulated failure predictions.

Influence of highly dispersed phase of titanium carbide on physical and mechanical properties of alloys AM4.5Kd and AK10M2N

Dispersion-strengthened composite materials belong to the group of promising structural materials characterized by a diverse combination of properties. The work presents examples of the creation and heat treatment of composite materials based on aluminum alloys, strengthened by a dispersed phase of titanium carbide, and characterized by high hardness, elastic modulus and good wettability by the melt. The most accessible, inexpensive and effective way to obtain them is self-propagating high-temperature synthesis (SHS).The work shows the possibility of obtaining new aluminum matrix composite materials based on industrial aluminum alloys AM4.5Kd and AK10M2N by reinforcing them with 10 wt.% highly dispersed titanium carbide or AM4.5Kd–5.95 vol.% TiC and AK10M2N–5.78 vol.% TiC. The reinforcing phase is formed in alloy melts using the technology of SHS from the initial elemental components—titanium powder and carbon black. Using the obtained samples, an assessment was made of the uniformity of the ceramic phase distribution over the volume of the matrix alloys, which amounted to 0.15 and 0.12 for the samples AM4.5Kd–10%TiC and AK10M2N–10%TiC, respectively, which constitutes a high degree of uniformity.An assessment was made of physical properties such as porosity, density, electrical conductivity, as well as the coefficient of thermal linear expansion. Analysis of the data allows us to say that the final composite materials AM4.5Kd–10%TiC and AK10M2N–10%TiC have a slightly higher density (↑~4%) than the matrix alloys, due to the presence of a ceramic phase, low porosity values (~1%), lower TCLE (↓~6%) than matrix alloys and low electrical conductivity (~25% IACS). This article also presents data on the values of the mechanical properties of composite materials AM4.5Kd–10%TiC and AK10M2N–10%TiC. It has been shown that reinforcement with a ceramic phase contributes to a significant increase in hardness by 15 and 42 HB, as well as higher values of the compressive yield strength by 31 and 17 MPa, respectively, while maintaining a high level of relative deformation. The results obtained allow us to conclude that the developed composite materials can be recommended for products used under conditions of elevated temperatures and significant wear.

Enhancing melt foam stability, form-filling process, and pore structure evolution of shaped aluminum foam

This study explores the stability of Al–Si–Ca–Mg-Sc melt foams and investigates the melt foam filling process and the dynamic evolution of pore structures in the fabrication of foam aluminum profiles using the melt transfer foaming technique. The results show that Al–Si–Ca–Mg-Sc melt foam maintains high porosity and a stable pore structure even after 30 min of foaming, without any signs of boundary rupture or destabilization. This stability is attributed to the increased viscosity from finely dispersed second-phase particles, which hinder the growth, coalescence, and drainage of the melt foam. Regarding melt foam filling, enhanced filling capability is achieved by elevating the foaming temperature, extending the foaming time, and increasing the TiH2 addition. The melt foam exhibits a smooth flow from the lower part of the mold to the corners, completing the filling process with well-defined edges in the profile. During lateral movement for filling, a gradual increase in porosity, a decrease in pore number, and a slow enlargement of pore size and standard deviation along the lateral (x-axis) are observed. This is due to the slower liquid phase flow compared to the gas phase, resulting in bubble coalescence. After filling is complete, this phenomenon improves, contributing to a slow and stable evolution of the pore structure.Under optimized conditions of 1.4 wt% TiH2 addition at 600°Cfor 9 min of foaming with Al–Si–Ca–Mg-Sc alloy melting, we successfully fabricated foam aluminum profiles with complete filling, a porosity of 81.5%, an average pore size of 2–3 mm, and a uniform pore structure.

Construction of a mathematical model of turbulent heat and mass transfer processes for the case of electron beam melting of titanium alloy casts

This paper describes a mathematical model built for turbulent heat and mass transfer processes in the case of electron beam melting of titanium alloy ingots. The object of research is the conditions that ensure the quality of ingots. The model makes it possible to calculate the distribution of hydrodynamic flows in the liquid metal and temperature fields in the ingot, to determine the profile of the metal crystallization front, taking into account the interphase transition zones. The model solves the problem of finding the necessary melting regimes of ingots by calculation, in contrast to high-cost natural experiments. The thermal and hydrodynamic processes during the melting of a cylindrical ingot with a diameter of 110 mm of the newest titanium alloy Ti-6Al-7Nb for medical use were calculated and its melting parameters were determined. The small diameter of the ingot significantly facilitates its further machining. The geometry of the two-phase zone of the liquidus-solidus transition, which determines the crystallization front of the metal, was calculated. The position and geometry of this front greatly affects the quality of ingot formation and the concentration of the distribution of alloying elements and the homogeneity of the metal across its volume. A sufficiently flat crystallization front has been obtained, under which the given conditions are ensured. It was found that heat transfer in the liquid phase of the metal is mainly caused by heat and mass transfer due to its movement, and heat and mass transfer significantly depends on the power of the electron beam and its distribution on the surface of the bath. According to the calculated regimes, at the Institute of Electric Welding named after E. O. Paton, the National Academy of Sciences of Ukraine, high-quality ingots for the needs of the medical industry were smelted. The castings are used for the manufacture of light and ultra-strong endoprostheses and implants, which are chemically neutral and biologically and biomechanically compatible with the human body and do not cause rejection.

Al Alloy Melting Behavior and Interfacial Reactions with Steel Under Natural Convection

The Al alloy melting behavior and interfacial reactions during the steelmaking process of high-Al automotive steel were investigated in this study. The total dissolution time of Al bars (20 × 20 × 80 mm) in molten steel was quite short, decreasing from 21.4 s to 10.0 s with an increase in bath temperature from 1580 to 1620 °C. The Al alloy melting process at the molten steel temperature of 1600 °C included the formation of a solidified steel layer, the latter’s rapid melting, and Al alloy normal melting, while at 1600 °C, the process included a second increase in the thickness of the solidified layer. Because steel elements such as [Fe], [C], [O], and [N] could diffuse during the whole Al alloy melting process, an Fe (Al)-FeAl-FeAl2-Fe2Al5-Al diffusion layer along the direction of the Al-rich matrix could be found at the Fe–Al interface. Moreover, FexO, Al2O3, and unstable AlN inclusions could be observed in the FeAl layer. This study also investigated how to reduce the number of these easily formed inclusions. Decreasing the pre-heating process time and dissolved oxygen content could be useful in decreasing FexO and Al2O3 inclusion formation. Some small-sized AlN inclusions formed in the center of the Al bars where they could not come into contact with the molten steel directly during the melting process; even for the immersion time of only 1 second, these inclusions were not stable in molten steel at the refining temperature and disappeared during the melting process.

The microstructural development and erosion mechanism of BaZrO3/Al2O3 double ceramics by Ti–46Al–8Nb alloy melt

In this study, the erosion of BaZrO3/Al2O3 double ceramics by Ti–46Al–8Nb alloy melt was investigated at different melting temperatures (1833 K, 1873 K and 1913 K) and time (1800 s, 3600 s, 5400 s and 7200 s). The microstructure of erosion layer and the alloy ingot were analyzed as well as the oxygen content of the alloy ingot. The erosion mechanism was clarified in the kinetic perspectives. The results showed that the new oxide BaAl2O4 production was attached on the ingot surface, and two kinds of inclusions, i.e., (Ti, Zr)5(Si, Al)3 and YAlO3, were formed in the ingot matrix. The thickness of erosion layer, the oxygen content of ingot, and the volume fraction of inclusions increased with increasing melting temperatures and time. In addition, these three phenomena were controlled by the kinetics of dissolution, and the time exponents were approximately equaled to 0.5, indicating that the erosion mechanism was dissolution controlled by mutual diffusion between the double ceramics and alloy melts. The activation energies of three phenomena were determined by Arrhenius equation, and three kinetic models were further established.

Excess volume measurements of binary alloy liquids using electrostatic levitation: Magneto-volume effect on positive excess volume.

In this study, we investigate the excess volume (VE) of 24 binary miscible and compound alloy melts using electrostatic levitation. Notably, Pd50X50 (X = Fe, Co, and Ni) and Pt50Fe50 solid solutions with slightly negative or zero mixing enthalpy (ΔHmix) display pronounced positive VE and significantly improved liquid stability after alloying, whereas compound alloy liquids with negative ΔHmix exhibit negative VE. Moreover, the VE of Pd50X50 and Pt50X50 consistently decreases with the increasing number of electrons in X, indicating a magneto-volume effect observed in specific heat measurements. These findings suggest that the formation of excess volume is influenced by both magnetic and thermodynamic contributions.

Study on the influence of trace elements H on the properties of A356 aluminum alloy

Abstract The vacuum melt purification refining technology can significantly reduce the content of hydrogen elements in alloy melts and prevent defects such as hydrogen-induced pinholes. This article investigates the effect of hydrogen content on the chemical composition, mechanical properties, and structural defects of A356 alloy melt by using vacuum melt purification refining technology to reduce the hydrogen content in A356 alloy melt. The experimental results show that: 1) there is basically no loss of chemical elements during the vacuum melting process; 2) The use of vacuum refining and purification control technology can control the hydrogen content inside the melt to be ≤ 0.10ml/100g; 3) The effect of H content on the metallographic structure of A356 alloy is not significant, but it has a certain improvement on the tensile strength at room temperature, but the increase is ≤ 5%.

Effects of surface-active elements on wettability and interfacial reaction between DD5 superalloy and Al2O3-based ceramic shell

The study investigates the effects of oxygen-sulfur content, holding temperature, and time on the wettability and interfacial reactions between DD5 superalloy and Al2O3-based ceramic shells through non-in-situ sessile drop experiments. Lowering the oxygen-sulfur content in the DD5 master alloy, as well as reducing the holding temperature and time, leads to an increase in the wetting angle and a mitigation of interfacial reactions. Improved wettability promotes interfacial reactions, while intensified interfacial reactions further spread the alloy melt, enhancing its wettability. The main products of the interfacial reaction between the DD5 alloy and Al2O3-based ceramic shells are Al2O3 and Si, with the process being influenced by the presence of Al. When the oxygen-sulfur content is controlled within 6 ppmw, the wettability will undergo a characteristic transformation, resulting in a sharp increase in the wetting angle. It demonstrates that the ultra-pure DD5 master alloy plays a crucial role in reducing wettability and interfacial reaction, as well as slowing down the tendency of the hetero-crystal formation. Therefore, it is of great engineering significance to further reduce the content of oxygen-sulfur impurity elements in DD5 superalloy.

Microstructure and strength-conductivity synergy of Al-Mg-Si-Cu alloy sheets prepared via vacuum melting and thermo-mechanical treatment

This work has investigated the response of microstructural evolution on the strength and electrical conductivity (EC) of vacuum melted Al-Mg-Si-Cu alloys during T6 heat treatment, cold rolling (CR) and re-aging (RA). The precipitation behavior of nano-scaled precipitates during thermo-mechanical treatment was revealed. The strength- conductivity improvement mechanisms of the alloy were discussed. The results showed that compared with the non-vacuum melting alloy, there were superior enhancements in the strength and EC of the alloy prepared by vacuum melting due to the high compactness. After T6 heat treatment, nanoscale β", Q' and L phases were precipitated in the alloy sheet. Owing to the increased dislocation density and precipitate dissolution during CR, the strength of the alloy sheet was improved, followed by a decrease in EC. After RA, a good combination of strength and EC of the alloy sheet was obtained, i.e., ultimate tensile strength and EC were 350MPa and 57.48% IACS, respectively, which was associated with the formation of nano-sized precipitates and the decrease in solute atom concentration. The precipitates volume, dislocation density, grain refinement and solid solubility during thermo-mechanical treatment were the main factors determining the strength and EC of the alloy. This work provides a strategy for the preparation of high strength-conductivity Al alloys.

Methods of Processing Dental Chromium-Cobalt Alloys for Production of Metal Frameworks Faced with Ceramics to Obtain the Best Mechanical Properties.

BACKGROUND Modern prosthetic technologies make it possible to fabricate prosthetic restorations without material loss and to make prosthetic restorations with complex geometric shapes in a relatively simple way. One such technology is selective laser melting (SLM), or additive manufacturing of metal materials, better known as 3D printing from metal or selective laser melting, but currently the most commonly used method is casting. The present study investigated use of dental chromium-cobalt alloys for prosthetic bridges and compared methods of processing dental chromium-cobalt alloys to obtain the best mechanical properties. MATERIAL AND METHODS We used dental chromium-cobalt alloy (SCHEFTNER GMBH) for laser melting StarbondCoSEeasy Powder with grain size of 10-30 µm and StarbondCoS alloy casting, made in accordance with the European standard EN ISO 22674. SLM-made specimens and induction melted alloy castings were prepared for the study. A centrifugal casting system with induction current melting of the metal alloy was used to produce the samples. The melting and casting process is automatic and limits changes in chemical composition. RESULTS The results show that none of the samples changed their chemical composition, while the samples made by SLM had better mechanical properties. CONCLUSIONS The SLM technique makes it possible to produce restorations faster and cheaper without any loss of quality compared to restorations made with the casting technique. Casting technology reduces mechanical properties, but still provides good mechanical properties.

On tailored microstructure in AA 2024 alloy during in-situ microwave casting

In the present study, application of microwave energy was explored for tailoring the microstructure in AA 2024 alloy through directional solidification route. Microwave transparent (alumina) and absorbing (graphite) mould materials were utilized to investigate the effect of microwave interaction (electric and magnetic field components) with AA 2024 alloy on microstructure evolution in terms of dendrite size distribution and formation of eutectic phase. Results showed more pronounced eutectic phase gradient was developed using alumina mould. On the other hand, a more uniform distribution of the eutectic phase and grain size was observed with graphite mould. The development of the eutectic phase gradient is attributed to the effective microwave interaction with the AA 2024 alloy melt during solidification. This is primarily associated with the formation of an additional flux at the solid-liquid (S/L) interface of the alloy under the effect of magnetic field and an enhancement in diffusion flux due to mass transport caused by electric field component of microwave. Formation of AlCu, Al2Cu, and Al2CuMg intermetallic phases in both alumina and graphite mould casts was confirmed. Significantly higher hardness was observed at the higher eutectic phase sites within the alumina mould cast, whereas graphite mould casts exhibited better tensile properties.

Synthesis of complex concentrated silicide coatings via reactive melt-infiltration: Exploring interfacial phenomena between Si-B melt and MoNbTaW high-entropy alloy

High-entropy silicide (HES) coatings are a promising solution to the problem of poor oxidation resistance of metallic refractory alloys. However, their practical development is still in the early stages. For the first time, this study evaluates the feasibility of synthesizing complex concentrated silicide coatings using a reactive melt infiltration approach. For this purpose, a sessile drop experiment was carried out in which a binary eutectic silicon‑boron alloy (Si8B at.%) was subjected to contact heating with the MoNbTaW refractory high entropy alloy (RHEA) substrate at temperatures up to 1450 °C. After the high-temperature test, the solidified couple was characterized by X-ray diffraction, scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy, electron backscatter diffraction systems, and microhardness techniques. The coating had an average thickness of 75 μm and was composed of different layers, including a primary MSi2 layer, a transition MSi2 + M5Si3 silicide layer, and M5Si3 silicides (M = metal). Additionally, borosilicides and boride particles were dispersed throughout the layers. However, future research should prioritize refining process parameters to eliminate porosity and improve the integrity of the coating layer.

Wettability and Interfacial Reaction between the K492M Alloy and an Al2O3 Shell.

In this study, wettability behavior and the interaction between the K492M alloy and an Al2O3 shell were investigated at 1430 °C for 2~5 min. The microstructural characterization of the alloy-shell interface was carried out by optical microscopy (OM) and scanning electron microscopy (SEM). The results indicated that the interaction could cause a sand adhesion phenomenon affecting the alloy, and the attached products were Al2O3 particles. In addition, the wetting angles of the alloys located on the shell were 125.2°, 109.4°, 97.0°, and 95.0°, respectively, as the contact time was increased from 2 to 5 min. Apparently, the wettability of the alloy in relation to the shell had a relationship with the contact time, where a longer contact time was beneficial to the permeation of the alloy into the shell and the interaction between the two components. No significant chemical products could be detected in the interaction layer, indicating that only the occurrence of the physical dissolution of the shell took place in the alloy melt.

Microstructure refinement, mechanical performances and degradability of biomedical Zn-2Cu alloy by ultrasonic melting and homogenization treatment

Zn alloys are deemed to be desired body implant materials because of their moderate degradation rate. In this paper, the microstructural evolution, mechanical performances, and degradability of Zn-2Cu alloy prepared by ultrasonic melt treatment (UMT) with different ultrasonic powers (0 W, 300 W, 600 W, and 900 W) were systematically studied. Under the condition of UMT, the coarse α-Zn grains of Zn-2Cu alloy were refined into fine equiaxed grains and the mean size was significantly decreased from 133.4 μm to 65.3 μm when the ultrasound power was enhanced. The precipitating CuZn5 phase was significantly refined from the coarse block into the spherical shape. Moreover, the fraction of the CuZn5 precipitates of the Zn-2Cu alloy was greatly reduced with the increase of ultrasonic power. Tensile tests showed that the ultimate tensile strength (UTS), yield strength (YS), and elongation (El) of Zn-2Cu alloy were remarkably enhanced to 203 MPa, 167 MPa, and 8.14 %, respectively, when the Zn-2Cu alloy melting was treated by 600 W power. It was found by electrochemical polarization test that the degradation rate of Zn-2Cu alloy treated by UMT with 0 W, 300 W, 600 W, and 900 W power in Hank’s solution was gradually decreased to 1.6312 mm/a, 1.3206 mm/a, 1.0992 mm/a, and 1.2832 mm/a, respectively. In addition, after the Zn-2Cu alloys were immersed in Hank’s solution for 30 days, the degradation rate of samples was summarized as 0 W alloy (0.472 mm/a) > 300 W alloy (0.436 mm/a) > 900 W alloy (0.412 mm/a) > 600 W alloy (0.398 mm/a). The studies verified that the UMT was a very valuable technology for preparing Zn-2Cu alloy, which can meet the requirement of mechanical properties and degradable rate as a promising implant material.

Coupled CFD-DEM with Flow and Heat Transfer to Investigate the Melting and Motion of Alloy

Coupled CFD-DEM with Flow and Heat Transfer to Investigate the Melting and Motion of Alloy

Anisotropic corrosion behavior of laser-based direct energy deposited H13 steel in molten ADC12 aluminum alloy

The immersion corrosion experiment of laser-based direct energy deposited H13 steel in ADC12 aluminum alloy melt was conducted to evaluate the demands for corrosion resistance after mold repair. The effect of the anisotropic microstructure of the deposited H13 steel on corrosion behavior was elucidated by characterizing the microstructure before and after corrosion. The results show that the microstructural heterogeneity affects the initiation, development and stabilization process of corrosion. Corrosion tends to initiate near the heat-affected zone due to the heterogeneous distribution of grain size, carbides, and dislocation density. Planes with weak microstructural heterogeneity are less likely to develop cracks in the intermetallic compounds (IMCs) layer during the corrosion development stage, thus exhibiting a slower corrosion rate. The IMCs layer of plane with weak microstructural heterogeneity stabilizes more quickly during the corrosion stabilization stage. The plane perpendicular to the build direction exhibits the highest corrosion resistance due to fewer corrosion initiation locations and the weakest microstructural heterogeneity. Furthermore, the composite structure of carbide core + Si phase shell, generated during corrosion, contributes to improving localized corrosion resistance. This study provides insights into understanding the influence of the heterogeneous microstructure from additive manufacturing on the reaction-diffusion process and offers guidance on direction selection when preparing components for applications in contact with aluminum melts using additive manufacturing techniques.

The Effect of Nitrogen on the Dihedral Angle Between Fe−Ni Melt and Ringwoodite: Implications for the Nitrogen Deficit in the Bulk Silicate Earth

AbstractNitrogen (N) is extremely depleted in the bulk silicate Earth (BSE). However, whether the silicate magma ocean was as N‐poor as the present‐day BSE is unknown. We performed multi‐anvil experiments at 20 GPa and 1,673−2,073 K to determine the dihedral angle of Fe−Ni−N alloy melt in ringwoodite matrix to investigate whether percolation of Fe‐rich alloy melt in the solid mantle can explain N depletion in the BSE. The dihedral angles ranged from 112° to 137°, surpassing the wetting boundary. Our experiments suggest that N removal from the mantle by percolation of Fe‐rich alloy melt to the Earth's core is unlikely. Therefore, besides N loss to space during planetesimal and planetary differentiation, as well as its segregation into the Earth core, the stranded Fe‐rich metal in the deep mantle could be a hidden N reservoir, contributing to the anomalous depletion of N in the observable BSE.

Effect of in-situ forging assisted squeeze casting on the forming quality and mechanical properties of automobile control arm

The squeeze casting technique offers promising prospects for a wide range of applications, as it provides an effective solution to address the challenges associated with the poor casting performance of wrought aluminum alloys. In this paper, we implemented in-situ forging assisted squeeze casting (IFSC) to form an automobile control arm using a high-strength Al–Zn–Mg–Cu alloy modified with Zr and Er. The solidification defects, microstructures, and mechanical properties of the part were investigated under different pressures and in-situ forging using various analytical techniques. With the increase of squeezing pressure from 0 MPa to 120 MPa, the ultimate tensile strength (UTS) of the sample increases from 500 MPa to 593.3 MPa, and the elongation is 4.35 %. After in-situ forging, the tensile strength of the sample is 600.9 MPa and the elongation is 5.59 %. UTS is comparable to squeeze casting, but the elongation is increased by 28.5 %. The results indicate that increasing the forming pressure enhances the surface quality of the parts and reduces the solidification defects. In addition, increasing the forming pressure not only refines the grain but also improves the grain morphology and enhances the uniformity of the structure. The squeezing pressure can enhance the contact between the alloy melt and the mold, increasing the metal's cooling rate and promoting nucleation for grain refinement. In-situ forging further facilitates liquid phase feeding, reduces alloy defects, and improves the overall mechanical properties.