Alloy Heat Research Articles

Rapid L-PBF printing of IN718 coupled with HIP-quench: A novel approach to manufacture and heat treatment of a nickel-based alloy

There has been a growing interest in additive manufacturing in recent years, with researchers actively working on improving component quality through adjustments to printing parameters, lead time, and productivity. Rapid L-PBF printing has emerged as an attractive approach to expedite component manufacturing. However, employing a rapid building strategy may lead to additional internal flaws, which can be addressed during a Hot Isostatic Pressing (HIP) cycle. In this study, Inconel 718 was L-PBF printed using two distinct strategies: one involving the creation of a dense 1 mm shell with loosely packed powders in the core and the other utilizing different sets of printing parameters for the shell and core, respectively. These strategies resulted in a 60% and 45% printing time reduction, respectively, compared with the time requirement for printing same-size cubic samples with optimized parameters. Additionally, full densification and porosity elimination were achieved through a HIP-quench approach, obviating the need for further heat treatment. The study presents the final microstructures and retained flaws, along with assessing the degree of recrystallization via EBSD analysis and evaluating mechanical properties using hardness measurements and compression tests.

Impact of in-process cooling and tool rotation speed on the mechanical and microstructural characteristics of friction stir processed AA2024

Despite significant grain size refinement, friction stir processing (FSP) of heat-treatable aluminum alloys is found to degrade the alloys of strength and hardness qualities. The drop in strength brought on by coarsening or the dissolution of the strengthening precipitate(s) could not be made up for by the improvement in strength brought about by the refinement of grain size following FSP. In order to get around this, the current work looks into a practical method of heat rejection from the FSP zone in addition to grain size refinement during FSP of AA2024 to regulate the precipitate evolution. Under natural cooling, air cooling, and CO2 cooling conditions, friction stir processing (FSP) was used to change the microstructure of Solutionized AA2024 at three distinct rotation speeds of 750, 1180, and 1500 rpm (fixed traverse speed of 50 mm/min). The microstructural evolution (through optical microscopy and SEM) and mechanical properties of FSP samples under different conditions of rotation speed and cooling and their differences were mainly discussed. All the FSP samples have a higher Vickers hardness than the base metal (minimum variation of 16.79% and maximum variation of 41.05%). The maximum hardness, yield strength, tensile strength, and elongation have been obtained under air cooling conditions and a rotation speed of 1180 rpm, which is a result of the simultaneous and effective effect of grain boundary strengthening and precipitation hardening.

Reverse ε→γ transformations of temperature-induced and stress-induced martensites in Fe–Mn–Si alloys with shape memory effect

In this work we argue that the reverse martensitic transformation (MT) of the stress-induced martensite (SIM) of Fe–Mn–Si-based alloys for moderate prestrains occurs in essentially thermoelastic-like way, in contrast to non-thermoelastic MT of temperature-induced martensite (TIM). We compare, using a number of complementary experimental techniques, the temperatures and the kinetics of the reverse ε→γ martensitic transformation of SIM and TIM for commercial and model Fe–Mn–Si alloys after various thermomechanical treatments. We claim that two studied phenomena are generic in Fe–Mn–Si-based alloys of different compositions and microstructure: first, opposite to the conventional effect of stabilization of martensite by prestrain, the reverse MT during heating of alloys prestrained in bending and tension starts well below (up to 100 K) the start temperature of the reverse MT for the TIM of the same alloy. The difference between engineering temperatures of the start of the reverse transformation, As, for SIM and TIM reaches ca. 50 K, pointing to a need to consider different As for TIM and SIM, AsTIM and AsSIM. Second, the reverse transformations of TIM and SIM show very different kinetics. The reverse MT of SIM is diffuse over the temperature range exceeding 100 K. The reverse MT of TIM, on the contrary, is well localized within the temperature range of ca. 20 K. The experimental observations can be interpreted assuming that, due to the differences in the formation mechanisms of SIM and TIM, the latter shows non-thermoelastic behaviour, whereas the SIM shows similarities with the thermoelastic martensites stabilized by prestrain.

New quaternary eutectic Al-Cu-Ca-Si system for designing precipitation hardening alloys

The aluminum corner of the previously unexplored quaternary eutectic Al-Cu-Ca-Si system promising for the design of new heat treatable alloys have been studied using thermodynamic modeling and experimental techniques. The experimental data have revealed the presence in equilibrium of a previously undescribed quaternary compound identified as a strict stoichiometric Al2CaSiCu phase with a tetragonal I4/mmm structure (Pearson symbol: tI10) and the lattice parameters a = 4.04 Å and c = 11.00 Å. The phase has a density of 3.36 g/cm3 and a microhardness of 335 Hv. In accordance with the suggested structure of the phase diagram, its region that can be promising for the design of heat treatable alloys contains three (Al)+Al2Cu+Al2CaSiCu, (Al)+Al2Si2Ca+Al2CaSiCu and (Al)+Al2Cu+Al2Si2Ca quasi-ternary sections and two (Al)+Al2Cu+Al2Si2Ca+Al2CaSiCu and (Al)+Al2Cu+Al2CaSiCu+Si four-phase fields. Analysis of the precipitation hardening response for the new quaternary Al-5 wt%Cu-Ca-Si alloys suggests that it is not inferior (the obtained peak hardness is ∼125 Hv) to that for the alloys Al-5 wt% Cu (∼120 Hv) and Al-4 wt%Si-5 wt%Cu (∼125 Hv) based on the conventionally used systems. However, to obtain noticeable hardening at aging, the content of silicon should be at least 1.1–1.2 times higher than that of calcium. A comparative hot tearing susceptibility (HTS) study revealed that the new heat treatable Al-5 wt%Cu-Ca-Si alloys have higher hot tearing resistances (HTS ∼16 mm according to a pencil probe) than that of the Al-5 wt%Cu base alloy (HTS >16 mm).

Microstructural and mechanical analysis of heat-treated Zn-Al alloy and Zn-Al/ZrB2 composites

This study explores the impact of heat treatment on Zn-Al alloy and Zn-Al/ZrB2 composites. Specifically, heat treatment at 250 °C for 3 h resulted in a significant refinement of grain structure and notable hardness improvement, showcasing an optimal combination of microstructural and mechanical properties. However, higher temperatures led to increased grain size and reduced hardness for both alloy and composites. These findings offer promising insights for optimizing processing parameters, enhancing the performance of Zn-Al based composites in critical engineering applications.

Effect of natural aging by multifunction cavitation on plane bending fatigue behaviour of heat-treatable Al-Si7Mg aluminum alloys and its fatigue strength estimation

The effect of natural aging by multifunction cavitation (MFC) on the fatigue behaviour of heat-treatable Al-Si7Mg aluminum alloys was examined. Surface observation and plane bending fatigue tests were conducted for the MFC-treated aluminum alloys at a stress ratio, R, of −1. The hardness of aluminum alloy without T6 treatment was significantly increased by MFC due to both the work hardening and natural aging. MFC treatment improved the fatigue lives and the fatigue strength at N = 107 cycles of aluminum alloys due to the generation of compressive residual stress and increasing the surface hardness; however, surface pits were large enough to easily nucleate an initial fatigue crack. In addition, the fatigue strength at N = 107 cycles of MFC-treated aluminum alloys can be estimated considering the residual stress, pit size and surface hardness.

Design, fabrication and experimental verification of a drag sail based on thermal-driven controllable bi-stable shape memory polymer composite booms

Deployable drag sails are used for passively deorbiting defunct satellites and other spacecraft. Designing the deployable boom is the main challenge in this technology. We present a bi-stable shape memory polymer composite (Bi-SMPC) boom with high stiffness, a high unfolding/folding ratio, and consistent roll-out deployment. It was designed and fabricated by a strategy of controlling the gradual release of elastic energy stored in a bi-stable composite structure through thermal-driven SMP matrix. Two heating layer strategies were investigated experimentally to determine the optimal driving layer and driving parameters. Based on these parameters, verification tests of a four-stage deployment Bi-SMPC boom were conducted. Meanwhile, a proof-of-concept prototype of a four-stage deployment drag sail based on the Bi-SMPC booms was designed and fabricated. Tests were conducted to verify the effectiveness of the drag sail deployed by the booms. It was found that SMPs can effectively control the deployment of bistable composite structures. The nickel-chromium alloy heating layer offers a more uniform driving temperature field compared to carbon fiber. The drag sail can be deployed successfully under the driving of four Bi-SMPC booms.

Investigating the Impact of Friction Stir Processing on the Hydrogen Embrittlement in AA6082-T6 Heat-Treatable Aluminum Alloy

This study investigates the impact of friction stir processing (FSP) on the hydrogen embrittlement (HE) in AA6082-T6 heat-treatable aluminum alloy. The effects of different number of FSP passes and different hydrogen cathodic charging (HCC) conditions on the material’s response to HE are examined through comprehensive mechanical testing, microhardness analysis, and microstructural characterization. The results revealed that FSP leads to a decrease in yield strength, ultimate tensile strength, and microhardness, accompanied by an increase in energy absorption. The introduction of hydrogen through HCC significantly reduces mechanical properties, particularly in non-FSPed specimens. Notably, specimens with 8 FSP passes exhibit an interesting behavior with a slight increase in energy absorption and microhardness values after HCC. Microstructural analysis shows that FSP refines the microstructure, resulting in enhanced resistance to hydrogen-induced blistering effects. These findings contribute to the understanding of hydrogen embrittlement in FSPed aluminum alloys, providing insights for developing surface-modified materials suited for hydrogen-rich applications.Graphical

Heat affected zone liquation cracking evaluation on FeMnAl alloys

ABSTRACT FeMnAl steels are currently generating a lot of interest with potential applications for structural parts in armored vehicles due to their lower density and outstanding mechanical properties. Despite the extensive mechanical performance and heat treatment exploration of this alloy class, further weldability investigation is required for future large-scale deployment. In the present study, the liquation cracking of four heats of cast FeMnAl alloys was investigated by the spot-Varestraint technique. The study focuses primarily on the effect of the major elements of the FeMnAl system: C, Mn and Al. Optical and electron microscopy were employed to investigate the microstructural features, and CALPHAD was employed to aid the discussion regarding the alloy’s composition differences and their effect on the liquation cracking susceptibility. The study was able to identify that compositions with the higher Mn, C, and lower Al presented the highest liquation cracking susceptibility. Conversely, composition presenting lower Mn, C, and Al showed the most resistant behavior. Furthermore, lower Al content promoted a fully-γ microstructure at low temperatures, which encouraged the appearance of longer cracks as a γ-matrix is more susceptible to HAZ cracking than a fully ferritic (α) or duplex (α + γ) microstructure.

Nano-Sized Al2O3-Gr Reinforced Al7075 Hybrid Composite: Impact of Cooling Agents on Mechanical, Wear, and Fracture Behavior.

Aluminum metal cast composites (AMCCs) are frequently used in high-tech sectors such as automobiles, aerospace, biomedical, electronics, and others to fabricate precise and especially responsible parts. The mechanical and wear behavior of the metal matrix composites (MMCs) is anticipated to be influenced by the cooling agent's action and the cooling temperature. This research paper presents the findings of a series of tests to investigate the mechanical, wear, and fracture behavior of hybrid MMCs made of Al7075 reinforced by varying wt % of nano-sized Al2O3 and Gr and quenched with water and ice cubes. The heat-treated Al7075 alloy hybrid composites were evaluated for their hardness, tensile, and wear behavior, showcasing a significant process innovation. The heat treatment process greatly improved the hybrid composites' mechanical and wear performance. The samples quenched in ice attained the highest hardness of 119 VHN. There is a 45.37% improvement in the hardness of base alloy with the addition of 3% of Al2O3 and 1% of graphite particles. Further, the highest tensile and compression strengths were found in the ice-quenched 3% Al2O3 and 1% graphite hybrid composites with improvements of 34.2 and 48.83%, respectively, compared to the water-quenched base alloy. Under the samples quenched in ice, the mechanical and wear behavior improved. The tensile fractured surface showed voids, particle pullouts, and dimples. The worn-out surface of wear test samples of the created hybrid composite had micro pits, delamination layers, and microcracks.

Improved Thermal Stability of Al-Si Alloy Coated Steel Sheet with Cr Thin Film Deposition

We investigated the effect of Cr thin film deposition on the thermal stability and corrosion resistance of hot-dip aluminized steel. A high-quality Cr thin film was deposited on the surface of the Al-9 wt. % Si-coated steel sheets by physical vapor deposition. When the Al-Si coated steel sheets were exposed to a high temperature of 500℃, Fe from the steel substrate diffused into the Al-Si coating layer resulting in discoloration. However, the highly heat-resistant Cr thin film deposited on the Al-Si coating prevented diffusion and surface exposure of Fe, improving the heat and corrosion resistances of the Al-Si alloy coated steel sheet.

The Influence of Precipitated Particles on the Grain Size in Cold-Rolled Al-Mn Alloy Foils upon Annealing at 100-550 °C.

The Al-Mn alloy heat exchanger fin production process includes a brazing treatment at s high temperature of 600 °C, in which coarse grains are preferred for their high resistance to deformation at elevated temperatures by decreasing the grain boundary sliding. In this study, Al-1.57Mn-1.57Zn-0.58Si-0.17Fe alloy foils cold rolled by 81.7% (1.1 mm in thickness) and 96.5% (0.21 mm in thickness) were annealed at 100-550 °C for 1 h to investigate their recrystallization behavior, grain sizes, and precipitates by increasing the annealing temperature, using micro-hardness measurement, electron back-scattered diffraction (EBSD), scanning electron microscopy (SEM), and transmission electron microscopy (TEM) techniques. The micro-hardness results showed that the recrystallization finishing temperatures for the two samples were almost the same, 323 ± 2 °C. The EBSD results showed that when the annealing temperature decreased from 550 to 400 °C, the recrystallized grain sizes of the two samples were nearly identical-both increased slightly. Further decreasing the annealing temperature from 400 to 330 °C caused the grain sizes to increase more, with the thinner foil sample having a more significant increase. The SEM and TEM observations showed that the micron-sized primary-phase remained unchanged during the annealing process. The nano-sized secondary phase precipitates formed during the hot-rolling process experienced a coarsening and dissolving process upon annealing. The particle size of the secondary phase increased from 32 nm to 44 nm and the area fraction decreased from 4.2% to 3.8%. The nucleation analysis confirmed that the large primary-phase could act as a nucleation site through particle stimulated nucleation (PSN) mode. The relatively dense secondary phase precipitates with small sizes at lower temperatures could provide higher Zener drag to the grain boundaries, leading to fewer nuclei and thereafter coarser grains. The coarsening of the recrystallized grains in the foils could be implemented through thickness reduction and/or precipitation processes to form densely distributed nano-sized precipitates.

Thermal effects on wear behavior of additively manufactured NiTi shape memory alloys

NiTi alloys fabricated by laser powder bed fusion (LPBF) additive manufacturing technology not only address the compositional instability resulting from complex processes but also solve the challenges of difficult machining of intricate aerospace structures. However, there are very few reports on the wear behavior of LPBF-NiTi alloys. In the present work, the effects of microstructure and thermal treatment, including heat treatment and frictional heat, on the wear behavior of LPBF-NiTi alloy and 100Cr6 ball were analyzed through a series of tribological experiments with different sliding speeds. As the average sliding speed increases (0.079–0.216 m/s), the wear rate of the as-built and heat-treated samples tends to decrease in the range of 2.69 × 10−3–0.97 × 10−3mm3/m. Although the heat-treated LPBF-NiTi alloy is 46 % harder than the as-built alloy is, the latter has a higher toughness (505 MJ/m3) and greater transformation strain of SIM (0.097). This leads to a coupling effect of heat treatment and sliding speed on the wear resistance. In addition, the wear track morphologies under different sliding speeds are asymmetric due to the 24% greater acceleration at the far end from the motor and the 2.15 mm deviation between the maximum speed position and the geometric center of the track. The wear modes of the as-built and heat-treated samples included adhesive, abrasive and delamination wear. Moreover, the wear morphologies and dominant wear modes change with the frictionally caused heat release induced by the sliding speed.

Ізотермічне гартування залізовуглецевих сплавів, суміщене з їх виливанням

Isothermal hardening (Austempering) of iron-based alloys with medium and high carbon content, which creates a metallic structure called bainite, is used to increase the strength and impact toughness of the metal. The parts are heated to a temperature approximately 200-300 °C below the solidification temperature of the metal, then cooled (hardened) fairly quickly to the temperature of the beginning of the bainite transformation, avoiding the martensitic transformation, and kept for a time sufficient to obtain the given bainite microstructure. IG is particularly advantageous for castings from high-strength cast iron (HC), adding to the high foundry performance of the growth of the mechanical characteristics of this alloy to the level of steel strength at a lower cost, density and energy consumption of HC casting compared to steel. The article examines methods of heat treatment of castings removed in a hot austenitic state from a sand mold, as a type of heat treatment of iron-carbon alloys combined with their casting. For this, casting according to gasification models was used, in which, due to the high fluidity of the dry sand of the casting mold, it is not difficult to remove hot castings from the mold for tempering. A number of IG methods previously patented by the FTIMS Institute of the National Academy of Sciences of the Russian Academy of Sciences have been supplemented by a new method of such hardening in a dosed amount of water, taking into account the effect of its film boiling. The new method includes the calculation of the optimal mass of quenching liquid - water with the aim of heating this mass of water to its boiling point at the time of cooling of the casting to the given temperature of the bainite transformation of the metal. The method saves the quenching liquid, simplifies the control of the duration of cooling, during which it allows the transportation of castings between the foundry and heat-treatment sections, which, in general, saves time, energy resources and the area of the workshop for obtaining heat-treated castings. Keywords: isothermal hardening, heat treatment, castings, austenite, lost foam casting.

Dry milling of stir-cast and heat-treated EV31A magnesium alloy: An experimental investigation based on the multi-criteria optimization method

The purpose of this study is to examine the impact of various milling parameters and sample preparation methods on the end-milling of EV31A Mg alloy under as-cast, T4, and T6 heat-treated conditions. The test specimens were prepared through stir-casting and heat-treated according to T4 and T6 conditions. The CNC vertical milling machine with the HSS tool was used for the end-milling process based on Taguchi's L9 orthogonal array. Three levels of variation are applied to the process parameters, including spindle speed (S), feed rate (f), depth of cut (d), and test specimen (as-cast, T4, and T6 EV31A). The parameters of surface roughness (Ra, Rz, Sa, Sz), the rate of material removal (MRR), and the cutting force (Fr) were similarly measured. For surface roughness, optical profilometry was used, while the weight loss method and dynamometer were employed, respectively, to assess MRR and Fr. In order to improve the process parameters, TOPSIS (techniques order preferences by similarity to ideal solution) is employed. This method reduces several responses to a single measurable response (the closeness coefficient). S = 1500 rpm, f = 150 mm/min, and aP = 1.5 mm are the ideal process parameters to achieve the maximum closeness coefficient (Ci) of 0. 917129 under as-cast circumstances. Furthermore, analysis of variance (ANOVA) verifies that sample preparation methods of 24.59 % and depth of cut of 38.19 % significantly impact response characteristics.

Research Progress on Thermal Conductivity of High-Pressure Die-Cast Aluminum Alloys

High-pressure die casting (HPDC) has been extensively used to manufacture aluminum alloy heat dissipation components in the fields of vehicles, electronics, and communication. With the increasing demand for HPDC heat dissipation components, the thermal conductivity of die-cast aluminum alloys is paid more attention. In this paper, a comprehensive review of the research progress on the thermal conductivity of HPDC aluminum alloys is provided. First of all, we introduce the general heat transport mechanism in aluminum alloys, including electrical transport and phonon transport. Secondly, we summarize several common die-cast aluminum alloy systems utilized for heat dissipation components, such as an Al–Si alloy system and silicon-free aluminum alloy systems, along with the corresponding composition optimizations for these alloy systems. Thirdly, the effect of processing parameters, which are significant for the HPDC process, on the thermal conductivity of HPDC aluminum alloys is discussed. Moreover, some heat treatment strategies for enhancing the thermal conductivity of die-cast aluminum alloys are briefly discussed. Apart from experimental findings, a range of theoretical models used to calculate the thermal conductivity of die-cast aluminum alloys are also summarized. This review aims to guide the development of new high-thermal-conductivity die-cast aluminum alloys.

High-Throughput Extraction of Phase–Property Relationships from Literature Using Natural Language Processing and Large Language Models

Consolidating published research on aluminum alloys into insights about microstructure–property relationships can simplify and reduce the costs involved in alloy design. One critical design consideration for many heat-treatable alloys deriving superior properties from precipitation are phases as key microstructure constituents because they can have a decisive impact on the engineering properties of alloys. Here, we present a computational framework for high-throughput extraction of phases and their impact on properties from scientific papers. Our framework includes transformer-based and large language models to identify sentences with phase-property information in papers, recognize phase and property entities, and extract phase-property relationships and their “sentiment.” We demonstrate the application of our framework on aluminum alloys, for which we build a database of 7,675 phase–property relationships extracted from a corpus of almost 5000 full-text papers. We comment on the extracted relationships based on common metallurgical knowledge.

Effect of Mn/Ag Ratio on Microstructure and Mechanical Properties of Heat-Resistant Al-Cu Alloys.

This paper mainly investigated the effect of the Mn/Ag ratio on the microstructure and room temperature and high-temperature (350 °C) tensile mechanical properties of the as-cast and heat-treated Al-6Cu-xMn-yAg (x + y = 0.8, wt.%) alloys. The as-cast alloy has α-Al, Al2Cu, and a small amount of Al7Cu2 (Fe, Mn) and Al20Cu2 (Mn, Fe)3 phases. After T6 heat treatment, a massive dispersive and fine θ'-Al2Cu phase (100~400 nm) is precipitated from the matrix. The Mn/Ag ratio influences the quantity and size of the precipitates; when the Mn/Ag ratio is 1:1, the θ'-Al2Cu precipitation quantity reaches the highest and smallest. Compared with the as-cast alloy, the tensile strength of the heat-treated alloy at room temperature and high temperature is greatly improved. The strengthening effect of the alloy is mainly attributed to the nanoparticles precipitated from the matrix. The Mn/Ag ratio also affects the high-temperature tensile mechanical properties of the alloy. The high-temperature tensile strength of the alloy with a 1:1 Mn/Ag ratio is the highest, reaching 135.89 MPa, 42.95% higher than that of the as-cast alloy. The analysis shows that a synergistic effect between Mn and Ag elements can promote the precipitation and refinement of the θ'-Al2Cu phase, and there is an optimal ratio (1:1) that obtains the lowest interfacial energy for co-segregation of Mn and Ag at the θ'/Al interface that makes θ'-Al2Cu have the best resistance to coarsening.

Development of an Alternative Heat Treatment to the Traditional T6 Heat Treatment of AlSi10Mg Alloy Produced by Additive Manufacturing

Development of an Alternative Heat Treatment to the Traditional T6 Heat Treatment of AlSi10Mg Alloy Produced by Additive Manufacturing

Magnetic properties, phase diagram and low-temperature specific heat of Ni50Mn50-xSbx alloys

This study examines the magnetic properties and temperature-composition phase diagram of the Ni50Mn50-xSbx alloys. The addition of Sb into the antiferromagnetic Ni50Mn50 alloy introduces ferromagnetic interaction, resulting in a sudden decrease in the Néel temperature. The characteristic regions of ferromagnetic (FM) and antiferromagnetic (AFM) interactions were determined on temperature-composition phase diagram, as well as compositional dependence of Néel temperature was computed. Increase of Sb content gives rise to an interplay between AFM and FM interactions, leading to the emergence of a spin glass-like state. We identified six distinct magnetic phases in the Ni50Mn50-xSbx system, encompassing AFM, paramagnetic, and FM martensite, as well as spin glass, and paramagnetic and FM austenite. Importantly, this behavior may extend to other Ni50Mn50-xZx (Z = In, Sn) alloys, where addition of Z elements leads to the introduction of FM interaction. Moreover, a significant impact of magnetic ordering on low-temperature specific heat is demonstrated. Neglecting the magnetic contribution in ferromagnetic phase leads to the overestimation of electronic specific heat coefficient by factor of 2.