Dendrite Arm Research Articles

Powder Synthesis and Characterization of Al0.5CoCrFeNi High-Entropy Alloy for Additive Manufacturing Prepared by the Plasma Rotating Electrode Process.

The Al0.5CoCrFeNi high-entropy alloy powder was produced by using a plasma rotating electrode process. The morphology, microstructure, and physical properties of the powder were characterized. The powder exhibited a smooth surface and a narrow particle size distribution with a single peak. The relationships between particle size and secondary dendrite arm space as well as cooling rate were evaluated as follows: λ = 0.0105d + 0.062 and vc = 4.34 × 10-5d-2 + 2.62 × 10-2d-3/2, respectively. The Al0.5CoCrFeNi powder mainly consisted of fcc + bcc phases. As the powder particle size decreased, the microstructure of the powder changed from dendritic to columnar or equiaxed, along with a decrease in the fcc content and an increase in the bcc content. The tap density (4.76 g cm-3), flowability (15.01 s × 50 g-1), oxygen content (<300 ppm), and sphericity (>94%) of the powder indicated suitability for additive manufacturing.

Experimental study on the micro-mechanical parameters of Ni-based single-crystal superalloys using nanoindentation and element distribution analysis

Ni-based single-crystal superalloys are normally prepared by directional solidification. Due to different solidification sequences, Ni-based single-crystal superalloys exhibit a typical dendritic arm structure, and the element segregation in the dendritic arm can affect the high temperature mechanical properties of the alloy. Solid solution treatment has a certain extent to reduce the inter-dendritic and dendritic arm between the concentrations of the elements, thereby changing the alloy micro-nano view parameters to improve the high temperature mechanical properties of the alloy. In this study, nanoindentation experiments were carried out on the inter-dendritic and dendritic arm of the cast and solid solution samples. The micromechanical parameters were calculated. The amounts of changes in elemental concentration were discussed with the results of the energy dispersive spectroscopy and electron probe microanalysis, so as to analyse the relationship between the micromechanical parameters and the changes in elemental concentration. The results show that solid solution treatment has a significant impact on the elastic modulus, with an increase of 114.7% of the inter-dendritic region and an increase of 142.7% of the dendritic arm. However, solid solution treatment has little effect on the hardness, with no significant change in the hardness of the inter-dendritic region and an increase of 43.86% of the dendritic arm. Solid solution treatment has a more significant effect on improving the segregation behavior of Al and Co elements, with the segregation coefficients of Al and Co elements in the inter-dendritic region decreasing and increasing by 36% and 19%, and the segregation coefficients of Al and Co elements in the dendritic arm region decreasing and increasing by 29% and 34%.

The microstructure and precipitated phase dependence of plastic deformation and fracture mechanism in repaired IN718 alloy by directed energy deposition

This work studied microstructural evolution, precipitate behaviors, and micro-hardness distribution along the built direction of directed energy deposited IN718 alloy. In combination with digital image correlation and crystallographic orientation analysis, the plastic deformation and fracture mechanisms of coarse columnar grains were explored in detail. The columnar grains in the deposition zone (DZ) grow along the <001> direction in the crystallography and gradually widen with increasing built height. The misorientation angle per unit length within individual columnar grains first decreases and then slows down to ∼ 0.07 °/μm when the deposition height is ∼ 1.8 mm. The micro-hardness in the DZ is gradually decreased along the built direction, which may be due to the increasing average columnar grain width and primary dendrite arm spacing, as well as reducing the volume fraction of the γ'' + γ' phases. During the uniaxial tensile loading, most plastic deformation always occurs in the DZ irrespective of the lowest hardness in the heat-affected zone (HAZ). The nucleation of microvoids is ascribed to the granular Laves phase debonding from the γ matrix. The number of microvoids gradually decreases with increasing distance from the fracture surface, which may be attributed to the strain-controlled nucleation of microvoids. EBSD results substantiated that the columnar grains near the fracture surface occur to severe lattice rotation, leading to the Kernel misorientation angle distribution in each grain interior increasing to about 1° ∼ 4°.

Effect of cooling rate and Nb addition on the strengthening in eutectic CoCr1.3FeMnNi0.7Nbx (0 ≤ x ≤ 0.45) high entropy alloys comprising of low stacking fault energy FCC phase

The CoCr1.3FeNi0.7MnNbx (0.3 ≤ x ≤ 0.45) eutectic high entropy alloy (EHEA) comprising of ultrafine lamellae of low stacking fault energy (SFE = 11 mJ/m2) face centered cubic (FCC) and Laves phase are synthesized at cooling rates of 2.5–10 K/s (arc melted ingots, AMIs) and 4.2 × 102 K/s (suction cast bars, SCBs). The microstructural investigation suggests that secondary dendritic arm spacing (SDAS) and interlamellar spacing are refined in SCBs due to a higher cooling rate than the AMIs. Whereas, deformation twins evolve in FCC phase due to its low SFE. The EHEAs exhibit a high yield strength of 1327 MPa for x = 0.367 SCB and a large fracture strain of 20% for x = 0.3 AMI under compression. Systematic investigation on the influence of Nb addition, microstructure refinement, and evolution of deformation twins during straining on the strengthening mechanisms reveals that the phase interface strengthening, solid solution strengthening, and twin boundary strengthening play critical roles in providing the high flow stress. The post-deformation analysis and the presence of multiple positive slopes in work hardening curves confirms that the concurrent effect of the evolution of dislocations, deformation twins, and their mutual interactions are solely responsible for the severe strain hardening at multiple stages during plastic deformation. The low values of strain rate sensitivity (0.0106–0.0111) and the activation volume (28b3-41b3) suggest that the deformation kinetics is governed by the dislocation interactions with the ultrafine lamellae interface and twin boundaries.

Molecular Templates on Surfaces by Exploiting Supramolecular Chemistry in Langmuir–Blodgett Monolayers

AbstractAttaining precise control over molecular arrangements is of paramount importance for numerous applications in nanotechnology, particularly in constructing molecular templates to accurately immobilize target materials on surfaces. A strategic combination of supramolecular and interfacial chemistry may serve to build a well‐organized molecular network, enabling the subsequent location of target molecules on specific positions of a surface. A supramolecular complex (compound 1) comprised of a melamine unit forming hydrogen bonds with dendritic arms terminated in a coumarin unit is utilized, which readily undergoes photodimerization. The research demonstrates the formation of well‐organized Langmuir films of compound 1 which can be transferred on substrates at low surface pressures adopting a lying‐flat orientation. Upon irradiation of the pristine films at 365 nm the coumarin units undergo photo‐cross linking, leading to the formation of a compact photo‐crosslinked film. Incubation of these photo‐crosslinked films in a solution containing 1‐hexanethiol results in the withdrawal of the melamine and the chemisorption of two thiol molecules per each melamine unit. The nanopores created by the removal of the melamine core are attributed to the disruption of hydrogen bonds in compound 1 by the thiols. This precisely defined molecular network holds significant promise as a template for orchestrating the arrangement of functional materials on surfaces.

Effects of shell mold heating temperature on microstructures and freckle formation of single crystal superalloys

To study the effects of shell mold heating temperature on the microstructure and freckle formation of single crystal superalloys, the directional solidification experiment and simulation were conducted with designed stepwise specimens. The temperature field and morphology of mushy zone were analyzed. The results show that the primary and secondary dendrite arm spacings both decrease with the rise of shell mold heating temperature. This reduces the permeability of the liquid in the mushy zone and the width of the thermal-solutal convection channel, which reduces the formation tendency of freckles, the width of freckles and the number of dendritic fragments in freckled areas. In addition, with the increase of shell mold heating temperature, the cooling rate of liquid in the mushy zone increases, which reduces the cooling time of the melt in the mushy zone, weakens the breaking capability of liquid flow to the dendrite, and further reduces the tendency of freckle formation in single crystal superalloy castings.

Effect of Y Contents on the Microstructure, Mechanical Properties, and Corrosion Behavior of Biomedical Mg–0.5Zn Alloy

The effects of Y contents on the microstructure, mechanical properties, and corrosion resistance of biomedical Mg–0.5Zn alloy are investigated. In the results, it is shown that an increase in Y content leads to a growth in the amount of the second phase and a decrease in the spacing of the secondary dendrite arms. Additionally, the second phase changes from a uniformly dispersed point‐like shape to a semicontinuous reticular distribution. Meanwhile, the addition of Y obviously reduces the dendritic organization and this contributes to the improvement of mechanical properties. The corrosion resistance of the alloys increased first when Y content is 2 wt% at most, and then decreases in Mg–3Y–0.5Zn alloy. The gradual improvement of corrosion resistance in Mg–1Y–0.5Zn and Mg–2Y–0.5Zn is closely related to the formation of the compact corrosion layer including Y element, while the sudden drop corrosion resistance of Mg–3Y–0.5Zn alloy is mainly attributed to the presence of a great deal of semicontinuous long‐period stacked order and its excessive negative potential compared with Mg matrix, which leads to a severe pitting.

Influence of minor cerium addition on microstructure and fluidity of as-cast Al-Cu-Mn-Mg alloy

Al-Cu-Mn alloys are widely used to produce automobile components like cylinder heads and engine blocks because of their capability to retain excellent thermal and mechanical characteristics at high temperatures. However, the Al-Cu-Mn-based alloys demonstrate restricted fluidity, leading to casting defects such as shrinkage and incomplete filling. This research investigated the microstructure and fluidity of Al-4.7Cu-1.0Mn-0.5Mg (wt%) alloy with minor cerium (Ce) addition. The as-cast alloys predominantly comprise α-Al matrix, accompanied by the presence of Al2Cu, Al6Mn, and Al8Cu4Ce phases. The influence of adding Ce on the fluidity of the Al-4.7Cu-1.0Mn-0.5Mg alloy was investigated using a tri-spiral fluidity test mold in this research. The findings suggest that the addition of Ce within the range of 0.1 wt% to 0.5 wt% in the Al-4.7Cu-1.0Mn-0.5Mg alloy results in an enhancement in fluidity. Specifically, the alloy containing 0.4 wt% Ce exhibits a significant increase in fluidity distance, from 349.7 to 485.7 mm. This improvement can be attributed to the reduction in viscosity, the refinement of secondary dendrite arm spacing, and the modification of secondary phase particles. However, a higher concentration of Ce leads to a decrease in fluidity length, potentially due to the formation of Al8Cu4Ce.

New model for predicting homogenization kinetics of typical wrought superalloy

A new homogenization kinetics prediction model for wrought superalloys based on the concept of diffusion distance was proposed. The micro-segregation and homogenization kinetics of Ni-based wrought superalloy, GH4141, were systematically studied by using the quantitative electron prob X-ray micro-analyzer (EPMA) analyses. There is a discrepancy between the predicted homogenization kinetics by the residual segregation index model and the experimental measurement. Both the experiments and theoretical analyses reveal that the homogenization kinetics can be reasonably predicted by the diffusion distance model under 1D-diffusion condition, with considering the diffusion-direction factor that is usually ignored. The new model provides a new option for predicting the homogenization kinetics with only necessarily knowing the original dendrite arm spacing and diffusion coefficient.

Effect of local loading on microstructure and enhanced mechanical property of large complex castings prepared by Al–Si–Fe–Mn–Mg–Cu alloy during squeeze casting

Flywheel shells with a complex structure and large wall-thickness difference, as key components in heavy trucks, serve to connect the engine and transmission. Formability and mechanical performance control of such components should be taken into consideration. In this work, an Al–Si–Fe–Mn–Mg–Cu alloy was used to manufacture the flywheel shell via squeeze casting. The role of local loading on microstructure and mechanical property at thick-walled positions was investigated. Furthermore, the effect of the squeeze casting specific pressure and heat treatment on the microstructure and mechanical property of the Al–Si–Fe–Mn–Mg–Cu alloy flywheel shells was also analyzed. The results showed that at the thick-walled positions, local loading not only helped eliminate the solidification defects, but also refined the microstructure including α-Al grains and secondary dendrite arm spacing. With increasing the squeeze casting specific pressure from 24 MPa to 32 MPa, microstructure refinement and mechanical property enhancement of squeeze casting flywheel shells were obtained. After T6 heat treatment, the yield strength and ultimate tensile strength of flywheel shells were further increased to 261.8 and 318.4 MPa, respectively, owing to the formation of spherical eutectic Si phases and nano-sized β'', Q and S precipitates.

Effect of Al–5Ti–1B–La intermediate alloy on microstructure and mechanical properties of A356.2 aluminum alloy

This study delves into the effects of Al–5Ti–1B–1La intermediate alloy, a newly developed refinement agent, on the microstructure and mechanical properties of A356.2 aluminum-silicon alloy modified by Al–10Sr. The decomposition of Ti2Al20La, where La element was concentrated in the Al–5Ti–1B–1La intermediate alloy, hardly affected the conventional nucleation mechanism of TiAl3–TiB2; nonetheless, the La element significantly refined the dendritic arms of α-Al. Notably, the secondary dendrite arm spacing was reduced from 49 μm to 27 μm, when 0.025 wt% ∼0.2 wt% Al–5Ti–1B–1La intermediate alloy and 0.014 wt% Al–10Sr modifier was incorporated to the A356.2 aluminum alloy. Although the room-temperature ultimate tensile strength was increased only by 30 MPa, the elongation was remarkably improved from 10% to 26%. The hardness of the alloy was also enhanced from 75 HBW to 84 HBW. The experimental outcomes underscore the efficacy of minimal La element incorporation in enhancing the performance of Al–5Ti–1B intermediate alloy, and the findings are significant for improving the serviceability of automobile wheels made from A356.2 aluminum alloy. The method used in this study can also be employed to regulate the microstructure and enhance mechanical properties of other sub-eutectic aluminum-silicon alloys.

Effects of the synergistic addition of AlCrNiTi and Ce on the microstructure and mechanical properties of hypoeutectic Al-7Si alloy

A new strategy is proposed in this study to modify the microstructure of the Al-7Si alloy, which is widely employed in the aerospace and transportation sectors due to its lightweight, high specific strength, and specific modulus. The primary challenge of the Al-7Si alloy is its coarse microstructure, which undermines its mechanical properties. This research focuses on the effects of adding the AlCrNiTi master alloy and Ce to the Al-7Si alloy. The impact on both the microstructure evolution and the mechanical properties is examined, including analysis and discussion of the underlying mechanisms for refinement and strengthening. When the alloy was modified by 0.9 wt% of the AlCrNiTi master alloy and 0.1 wt% of Ce, there was a notable refinement of the α-Al phase, transforming it from a coarse dendritic structure to fine equiaxed grains. The addition of 0.9 wt% of the AlCrNiTi master alloy and 0.1 wt% of Ce can also reduce the secondary dendrite arm spacing (SDAS) to 5.9 μm. The eutectic Si phase underwent a significant transformation, changing from coarse flakes to fine granularity with rounded edges. Furthermore, CeSi2Ni2, Al3Ni intermetallic compounds, and nanoscale Al45Cr7 particles were observed in the modified Al-7Si alloy. Tensile tests showed that the addition of the inoculant in the Al-7Si alloy enhanced the ultimate tensile strength (UTS) from 173 MPa to 211 MPa and increased the elongation (El) from 7.9% to 14.1%.

Modeling coupled growth and motion of solid-air dendrite induced by convection in liquid hydrogen using phase-field lattice Boltzmann method

The safety hazard arising from the growth, condensation and accumulation of trace air in liquid hydrogen deserves attention. In order to predict the microstructural growth evolution and oxygen solute segregation distribution characteristics during solid-air dendrite motion induced by solution convection, a partially saturated bounce-back lattice Boltzmann coupled non-isothermal phase field method (PSLBM-PF) is proposed in this study. The partially saturated bounce-back lattice Boltzmann method (PSLBM) is employed to calculate the flow field and the forces and moments between the fluid and solid phases, and the phase field method (PF) is utilized for the computation of the growth of solid-air dendrites and the distribution of solute segregation. The motion of solid-air dendrites is determined by the momentum equation. The accuracy of the calculated interaction forces between fluid and solid phases was validated through the sedimentation process of circular particles in the liquid, and the capability of the present model to preserve the shape during solid-air dendrite motion (translational and rotational) was confirmed. Subsequently, this model was employed to investigate the growth and sedimentation motion of solid-air dendrites with different growth orientations in the solution. During dendrite settlement, the growth of the lower dendrite arms is promoted, while the settlement velocity and the solid phase fraction are almost unaffected by the growth orientation. Then, the differences in morphology evolution and solute distribution under conditions of forced convection for both stationary and motion are comparatively investigated, utilizing the free growth of solid-air dendrites under convection-free conditions as a reference. Finally, the model was utilized to study the growth of individual solid-air dendrites as well as translational and rotational motion under the action of shear flow. The presence of convection significantly alters the solute and temperature distributions at the solid-liquid interface, thereby influencing the dendrite growth process. The simulation results indicate that this model can predict the solid-air dendrites microstructural growth evolution and oxygen solute segregation distribution accompanying the convection and motion.

Directed energy deposition of PH 13–8 Mo stainless steel: microstructure and mechanical property analysis

Laser metal deposition (LMD) is of the directed energy deposition (DED) process which is widely used for producing large-scale, dense, and functional parts in the field of additive manufacturing (AM). This research work investigates the microstructure and mechanical properties of PH 13–8 Mo martensitic stainless-steel parts produced via LMD. The workshop trials were conducted using an LMD system collaborated with a robotic arm to deposit single-track thin walls and horizontal blocks. The microstructural characteristics of the additively manufactured parts were analyzed using an optical microscope. The mechanical properties were evaluated through hardness measurements and uniaxial tensile tests. The influence of energy density and powder deposition density on the characteristic geometry of straight walls was also investigated. The microstructural analysis showed that the microstructure consisted of columnar dendrites that grew epitaxially from the substrate, with primary austenite cells containing intercellular ferrite and martensite laths that were roughly parallel with the retained austenite. When the energy density increased from 43 to 86 J/mm2 (a doubling of energy density), there was an increase in secondary dendritic arm spacing (SDAS) by approximately 250% in the first layer and approximately 90% in the top layer. The difference in SDAS change between the first and top layers can be attributed to the difference in cooling rates experienced by each layer during the additive manufacturing process. Increasing powder deposition density from 0.5 to 1 g/min results in a decrease in porosity from 3% to less than 1% and an increase in strength from 800 to over 1000 MPa. The hardness of the deposits was found to range from 300 to 400 HV. This variation in hardness can be attributed to differences in microstructure resulting from changes in cooling rates at different heights.

Experimental study of SS316L, Inconel 625, and SS316L-IN625 functionally graded material produced by direct laser metal deposition process

Three types of walls were produced by the direct laser metal deposition (DLMD) process; SS316L, Inconel 625 (IN625), and SS316L-Inconel 625 FGM. The thin walls were deposited on an AISI 4130 austenitic steel substrate in five layers with a length of 2 cm. The solidification behavior, secondary dendrite arm spacing (SADS) value, chemical composition, and hardness of samples were studied. Microstructures were evaluated using optical microscopy (OM) images, scanning electron microscopy (SEM), EDS Line, EDAX, and Map analyses. OM and SEM images showed an acceptable bonding between the layers in all samples. The main solidification was equiaxed dendritic and columnar dendritic in most parts. The growth of dendrites was perpendicular to the substrate. Some dendrites grew epitaxially at the interface of two sequential layers. The standard deviation of SDAS value for SS316L, IN625, and SS316L-IN625 FGM was 0.63, 0.71, and 0.73, respectively. The lowest value of SDAS was obtained in layer one, while the highest value was obtained in layer five of the thin walls. The average SDAS values for SS316L, IN625, and SS316L-IN625 FGM were 4.40, 4.53, and 4.76 µm, respectively. Therefore, the difference between the SDAS values was not significant. EDAX and Map analyses showed that the segregation of Nb and Mo to the dendritic boundary and the formation of eutectic, secondary phases, and brittle Laves phases have occurred. Additionally, the segregation of Nb and Mo to the dendritic boundary in the SS316L-IN625 FGM sample was higher than SS316L and IN625 samples. The microhardness values oscillated significantly and decreased by moving away from the substrate (in the build direction). The microhardness values of different points of the SS316L-IN625 FGM walls were in the range of 218–278 HV. EDS line scan, microstructure, and microhardness analyses indicated the successful fabrication of the SS316L-IN625 FGM by the DLMD process.

Novel flat-top laser-aided cold metal transfer additive manufacturing for titanium alloy: Arc characteristics, microstructure, and tensile properties

In this paper, a novel flat-top laser-aided cold metal transfer additive manufacturing (F-LCAM) method is proposed for titanium alloys to restrict internal defects and anisotropy of mechanical properties in large-scale additive-manufactured titanium structures. The proposed method uses a flat-top laser to stabilise the drifting cathode spot and suppress the irregular shape of the weld deposit by promoting thermionic emission on the molten pool surface. Compared to the cold metal transfer additive manufacturing (CMT-AM) process, the auxiliary flat-top laser promotes the wettability of the molten pool and increases the contact angle of deposition from 95° to 142° in an F-LCAM sample. The non-destructive X-ray testing (NDT) results of multi-bead multilayer deposition showed that the defects caused by the pool weld bead morphology were effectively suppressed. Attributed to fluid flow in the melt pool enhanced by the flat-top laser, the dendritic arms were broken, columnar β grains in the F-LCAM sample were finer than in CMT-AM sample, and the aspect ratios of prior-β grains decreased from approximately 6 to 1. The F-LCAM sample exhibited a higher elongation and lower anisotropy than the CMT-AM sample. Defects were observed on the fracture surfaces of the CMT-AM vertical samples, which reduced the elongation of the CMT-AM samples to lower than that of the F-LCAM sample. The ultimate tensile strength, yield strength, and elongation of the multi-bead multilayer deposition met the standards of as-forged Ti6321 titanium alloy, indicating that the Ti6321 titanium alloy structure fabricated by the F-LCAM process has acceptable tensile properties for engineering applications.

Nickel-aluminide cladding on a steel substrate using dual wire arc additive manufacturing

In this study the nickel-aluminide intermetallic cladded on AISI 1010 steed using dual wire arc process. The nickel-aluminide is fabricated in situ through an arc provided by a gas tungsten arc welding process and changing aluminum wire feeding rate. The research findings reveal that at a constant Ni wire feeding rate of 450 mm/min, by decreasing the Al wire feeding rate lower than 800 mm/min, the instability of the melt pool prevents the formation of a uniform deposit on the substrate. Although deposition has been done at an Al wire feeding rate higher than 1600 mm/min, transverse cracks have formed in the clad layer. Increasing the aluminum wire feeding rate from 1000 to 1400 mm/min decreases the dendritic arm size from 9.2 ± 0.1 to 4.1 ± 0.3 μm. Although unreacted nickel is visible in the microstructure at the Al wire feeding rate of 1000 mm/min, at a high feeding rate (1400 mm/min), most of the microstructure contains AlNi and Ni3Al intermetallic compounds. With the rise in Al wire feeding rate from 1000 to 1400 mm/min, both yield strength and ultimate tensile strength increase from 521.45 ± 14.16 to 620.89 ± 16.08 MPa and from 762.11 ± 19.89 to 855.65 ± 21.54 MPa, respectively. Intriguingly, the clad layer's tensile toughness decreases from 26.51 ± 2.43 to 18.32 ± 2.56 MJ m−3. By increasing the wire feeding rate from 1000 to 1400 mm/min, the wear rate at room temperature, 500 °C, and 800 °C increases by 61.2, 45.7, and 44.3%, respectively.

A novel method for evaluating solidification cracking susceptibility of austenitic stainless steel using trapezoidal hot cracking test during laser welding

A novel evaluation method was developed for evaluating solidification cracking susceptibility of austenitic stainless steel using trapezoidal hot cracking test laser welding. By changing different chemical compositions and welding speeds, the critical restraint width was named and regarded as a new index to evaluate cracking susceptibility. First of all, the average critical restraint width of SUS310S, 316 and 302 was measured as 22.97 mm, 18.17 mm and 17.38 mm during laser welding at a speed of 1.0 m/min, respectability. Single phase austenite under mode A appeared in 310S while the other could form austenite and a small amount of ferrite based on mode FA, therefore, the solidification cracking susceptibility was 310S > 316 > 302. Then, the critical restraint widths of SUS310S and 304 had a tendency of decrease with increasing welding speed from 0.5 m/min to 1.0 m/min during laser welding. The lower heat input could decrease primary and secondary dendrite arm spacings, causing a reduction in the segregation degree. In addition, the fine dendrite along grain boundary of weld center could contribute to form zigzag interface which would be beneficial to interrupt the continuous residual liquid film. Thus, the solidification cracking susceptibility tended to decrease with an increase in laser welding speed from 0.5 m/min to 1.0 m/min. Above all, the developed evaluation method could improve the applicability, feasibility and progressiveness of hot cracking test.

Effect of Al-Sr-Y intermediate alloy on microstructure and mechanical properties of A356 alloy

In this experiment, an intermediate alloy (Al-3Sr-8Y) that can refine and modify A356 alloy simultaneously was developed, and the synergistic effect of Sr and Y on the microstructure and mechanical properties of A356 alloy was investigated. The results show that when the content of Al-3Sr-8Y intermediate alloy reaches 0.3 wt%, the morphology of α-Al dendrites is significantly refined and the secondary dendrite arm spacing (SDAS) was significantly reduced. Moreover, the morphology of eutectic Si transforms from acicular to small fibrous, and the average area and aspect ratio of eutectic Si decrease to 0.81 μm2, and 2.01. This change is caused by the twin plane re-entrant edge (TPRE) poisoning mechanism, where the addition of Al-3Sr-8Y can poison the intrinsic growth position of the Si phase, reduce the growth rate of the Si phase, promote isotropic growth, and achieve a highly branched morphology of the Si phase to form a fibrous structure. Due to the excellent synergistic effect of Sr and Y, the tensile strength and elongation of the alloy reached the maximum values of 303.5 MPa and 9.5% when 0.3 wt% Al-3Sr-8Y was added after heat treatment, which is an increase of 18.2% and 86.3% compared with the untreated A356 alloy, respectively.

Crystalline Microstructure, Microsegregations, and Mechanical Properties of Inconel 718 Alloy Samples Processed in Electromagnetic Levitation Facility

The solidification of Inconel 718 alloy (IN718) from undercooled liquid is studied. The solidification kinetics is evaluated in melted and undercooled droplets processed using the electromagnetic levitation (EML) technique by the temperature–time profiles and solid/liquid (S/L) interface movement during recalescence. The kinetics is monitored in real time by special pyrometrical measurements and high-speed digital camera. It is shown that the growth velocity of γ-phase (the primary phase in IN718), the final crystalline microstructure (dendritic and grained), and the mechanical properties (microhardness) are strongly dependent on the initial undercooling ΔT at which the samples started to solidify with the originating γ-phase. Particularly, with the increase in undercooling, the secondary dendrite arm spacing decreases from 28 μm to 5 μm. At small and intermediate ranges of undercooling, the solidified droplets have a dendritic crystalline microstructure. At higher undercooling values reached in the experiment, ΔT&gt;160 K (namely, for samples solidified with ΔT=170 K and ΔT=263 K), fine crystalline grains are observed instead of the dendritic structure of solidified drops. Such change in the crystalline morphology is qualitatively consistent with the behavior of crystal growth kinetics which exhibits the change from the power law to linear law at ΔT≈160 K in the velocity–undercooling relationship (measured by the advancement of the recalescence front in solidifying droplets). Study of the local mechanical properties shows that the microhardness increases with the increase in the γ″-phase within interdendritic spacing. The obtained data are the basis for testing the theoretical and computational of multicomponent alloy samples.