Master Alloy Research Articles

Microstructure and Mechanical Properties of Mg-Al-La-Mn Composites Reinforced by AlN Particles.

The Mg-Al-RE series heat-resistant magnesium alloys are applied in automotive engine and transmission system components due to their high-temperature performance. However, after serving at a high temperature for a long time, the Al11RE3 phase coarsened and even decomposed, while the Mg17Al12 phase grew and dissolved, which limits the service temperature of Mg-Al-RE series heat-resistant magnesium alloys to a maximum of 175 °C. In this study, a new preparation method for in situ AlN particles was presented. The AlN/Mg-4Al-4La-0.3Mn composites were prepared by a master alloy and casting method. The effects of various contents of AlN (0.5-3.0 wt.%) on the microstructure and mechanical properties of the Mg-4Al-4La-0.3Mn (AE44) alloy at room (25 °C) and high temperatures (150-250 °C) were investigated. Microstructure analysis revealed that the inclusion of AlN led to a reduction in both the grain size and second phase size in the AE44 alloy, while also improving the distribution of the second phase. The average grain size, Al11La3 phase, Al2La phase, and Al3La phase of the 2.0 wt.% AlN/AE44 composite were 135.7, 9.6, 1.9, and 12.6 μm, respectively, which were significantly lower than those of the AE44 matrix alloy (179.8, 12.6, 3.3, 17.8 μm). The refinement was attributed to the ability of AlN particles to serve as heterogeneous nucleation cores for α-Mg and, at the same time, impede the growth of the solid-liquid interface, eventually leading to grain refinement. With the increase in the AlN content, the mechanical properties of composites initially exhibited an increase at both room and high temperatures, followed by a subsequent decrease. When the AlN content was 2.0 wt.%, the composite exhibited optimal strength and plasticity matching. At room temperature, the TYS, UTS, and EL values of the 2.0 wt.% Mg-4Al-4La-0.3Mn composite were 96 MPa, 175 MPa, and 7.0%, respectively, which were increased by 26 MPa, 27 MPa, and 0.7% when compared with the base alloy. The TYS of the 2.0 wt.% Mg-4Al-4La-0.3Mn composite at 150 °C, 200 °C, and 250 °C were 17 MPa, 14 MPa, and 22 MPa higher than those of the matrix alloy, respectively. The main strengthening mechanisms were second phase strengthening, load transfer strengthening, and thermal mismatch strengthening. At elevated temperatures, AlN particles effectively pinned the grain boundaries, inhibiting their migration, and hindered dislocation climbing, resulting in excellent mechanical properties of the composites at high temperatures. This study contributes to the advancement of in situ AlN particle preparation methods and the exploration of effects of AlN on the properties and microstructure of Mg-Al-RE alloys at high temperatures (150-250 °C).

Composition and Structure of Surface Layer in Composite Castings from Gray Cast Iron Formed Using Chromium-Ferroboron Master Alloys

Composition and Structure of Surface Layer in Composite Castings from Gray Cast Iron Formed Using Chromium-Ferroboron Master Alloys

Hot Deformation Constitutive Analysis and Processing Maps of Ultrasonic Melt Treated A5052 Alloy.

Hot deformation constitutive analysis and processing maps of ultrasonic melt treated (UST) A5052 alloy were carried out based on a hot torsion test in this study. The addition of the Al-Ti master alloy as a grain refiner with no UST produced a finer grain size than the UST and pure Ti sonotrode. The Al3Ti phase particles in the case of the Al-10Ti master alloy acted as a nucleus for grain refinement, while the Ti atoms dissolved in the melt from the sonotrode were considered to have less of a grain refinement effect, even under UST conditions, than the Al3Ti phase particles in the Al-Ti master alloy. The constitutive equations for each experimental condition by torsion test were derived. In the processing maps examined in this study, the flow instability region was not present under UST in the as-cast condition, but it existed under the no UST condition. The effects of UST examined in this study are considered as (i) the uniform distribution of Ti solutes from the sonotrode and (ii) the reduction of pores by the degassing effect. After the homogenization heat treatment, most instability regions disappeared because the microstructures became uniform following the decomposition of intermetallic compounds and distribution of solute elements.

Study on microstructure and refining effect of deformed Al-4.5Er-1Zr-1.5Ti master alloy

The microstructure and grain refinement of Al-4.5Er-1Zr-1.5Ti master alloy were analyzed by the refinement experiment, OM, SEM and XRD. The results show that the grain size of pure aluminum is reduced from 14,000μm to 202μm by Al-4.5Er-1Zr-1.5Ti master alloy, which is mainly due to the nucleation promoted by Ti2Al20Er, Al3Er and Al3Ti. Plastic deformation further improves the refining effect of the material by improving the primary phase size, and the Al-4.5Er-1Zr-1.5Ti −2ARB can refine the pure aluminum from 202 mμm to 150μm, and the refinement was increased by 25.7 %. The master alloy showed a better refinement effect in Al-5Cu alloy than pure aluminum, with a grain size of 92μm and a refinement improvement of 97.8 %.

Enhanced Grain Refining Effect of Mg–Zr Master Alloy on Magnesium Alloys via a Synergistic Strategy Involving Heterogeneous Nucleation and Solute-Driven Growth Restriction

Enhanced Grain Refining Effect of Mg–Zr Master Alloy on Magnesium Alloys via a Synergistic Strategy Involving Heterogeneous Nucleation and Solute-Driven Growth Restriction

Rare Earth Chlorides in Low-Hydration Magnesium Chloride Electrolysis: Mechanistic Insights

During the molten salt electrolysis of magnesium production, water in the magnesium chloride (MgCl2) feedstock poses significant interference, reducing the current efficiency. Employing rare earth chlorides (RECl3) to assist in dehydrating MgCl2 and producing Mg-RE master alloys emerges as an effective strategy. This study investigated the transformation process in the hydrolysis reaction of low-hydrate MgCl2 within the molten salt, examining the electrochemical activity of its hydrolysis products using Cyclic voltammetry (CV). Additionally, a thermodynamic analysis of the reaction between hydrolyzate MgO and RECl3 was performed at electrolysis temperatures. By integrating CV and Square wave voltammetry (SWV) with X-ray diffraction (XRD) analysis, the study explored the alterations in the electrochemically active components of the molten salt system following the addition of RECl3 to the KCl-NaCl molten salt containing MgO.

Insights into the effects of La on the grain refinement and mechanical properties of Al-Ti-C intermediate alloy and pure Al: A first-principle study and experimental investigation

This paper employs the self-propagating high-temperature synthesis (SHS) to prepare Al-Ti-C master alloys and explores the effects of integrating the rare earth element lanthanum to create Al-Ti-C-La composites. This research focuses on the microstructural changes in both the master alloy and pure aluminum, which aimed to elucidate the mechanisms that enhance grain refinement and resistance to grain refinement fading. The analysis reveals that when Al-Ti-C-La master alloys are incorporated into molten Al, the predominant structures formed include an Al matrix, rod-like Al3Ti phases, and TiC particles, alongside AlLa phases and substantial Al20Ti2La compounds. The grain refining capability of Al-Ti-C-La master alloys is significantly exceeds that of the Al-Ti-C master alloys. The addition of La markedly reduces the settling of TiC particles, thereby granting the Al-Ti-C-La master alloys excellent resistance to grain refinement fading. The newly formed Al20Ti2La phase plays a crucial role in refining the aluminum matrix, with metallic bond characteristics present on the side towards the Al matrix at the Al20Ti2La/Al interface and distinct covalent bond characteristics on the Al20Ti2La side. Moreover, the Al20Ti2La (110)/Al (110) interface exhibits the highest interfacial adhesion energy and stronger covalent bond features. Consequently, α-Al is prone to heterogeneously nucleate on the Al20Ti2La phase via the Al20Ti2La (110)/Al (110)-HCP orientation, which refines the grains of the aluminum matrix, ultimately enhancing the performance of aluminum-based alloys.

L12 nanoparticle-strengthened CoNi-based superalloy with ultrahigh yield stress developed using CALPHAD method

In this study, a Co-30Ni-10Ti-2Ta-3Al (30Ni3Al) alloy with high γ′ phase dissolution temperature (1215°C), excellent mechanical properties, and low density (8.46 g/cm3) was developed based on the thermodynamic database of Co-based high-temperature alloys established by our group. Compositional design and microstructure control were achieved through the utilization of thermodynamic phase diagrams and phase fractions. It is found that the addition of 2 at.% Ta significantly improves the γ′ phase fraction and solvus while maintaining a suitable working window. However, a rafting trend of γ′ phase was observed as heat treatment for a long time at 750°C. By introducing 3 at.% Al and 30 at.% Ni into the optimized Co-10Ti-2Ta master alloy, the rafting of the γ′ phase was effectively suppressed. Benefiting from the fine, stable, high volume fraction γ′/γ microstructure, the 30Ni3Al alloy demonstrates compressive yield strengths of approximately 1487±7 MPa and 1319±13 MPa at room temperature and 600°C, respectively. The superb mechanical property at high temperatures can be attributed to the work-hardening effect resulting from the interactions of superattice stacking faults in γ′ phase.

〈111〉-orientation growth of Tb-Dy-Fe alloys induced by high magnetic fields during directional solidification

The 〈110〉 and 〈112〉 directions are the preferred growth directions of the magnetic phase in Tb-Dy-Fe alloys, but the 〈111〉 direction is the easy magnetization axis direction, and the 〈111〉-oriented alloy exhibits superior magnetostrictive behavior. In this study, Tb-Dy-Fe alloys with 〈111〉 orientation were prepared by directional solidification (i.e., the master alloy was completely melted) under high magnetic fields. The competition between the preferred growth direction and the easy magnetization direction was resolved, leading to enhanced magnetostrictive properties. During the initial solidification stage, the magnetic torque induced the 〈111〉 orientation in the magnetic phases generated by direct precipitation of the liquid phase and pseudo-eutectic reactions to rotate in the direction of the magnetic field. In the subsequent competitive growth process, 〈111〉-oriented grains grew parallel to the magnetic field direction under the influence of magnetocrystalline anisotropy energy. This work enriches the theory of magnetic orientation during directional solidification, providing novel insights into the preparation of highly oriented functional materials.

Grain Refining Efficiency of Al-V-B Master Alloy in A356.2 Alloy Under Different Inoculated Temperatures and Holding Times

Grain Refining Efficiency of Al-V-B Master Alloy in A356.2 Alloy Under Different Inoculated Temperatures and Holding Times

Deposition of Fe-doped CdS films by spray pyrolysis from various precursors

Iron-doped cadmium sulfide films (Fe–CdS) were produced by spray pyrolysis using iron nitrate, chloride and sulfate as iron precursors. Based on experimental analysis data and thermodynamic calculations, it was found that the composition, uniformity and surface morphology of the films significantly depend on the nature of the iron precursor. It has been found that all synthesized Fe–CdS films can be used as master alloys for the manufacture of Fe:ZnSe laser elements.

Zr as an Alternative Grain Refiner in the Novel AlSi5Cu2Mg Alloy

Al-Si-Cu-Mg alloys are among the most significant types of aluminum alloys, accounting for 85–90% of all castings used in the automotive sector. These alloys are used, for example, in the manufacturing of engine blocks and cylinder heads due to their excellent specific strength (ratio of strength to specific weight) and superior castability and thermal conductivity. This study investigated the effect of using Zr as an alternative grain refiner in the novel AlSi5Cu2Mg cylinder head alloy. The microstructure of this alloy could not be refined via common Al-Ti-B grain refiners due to its specifically designed chemical composition, which limits the maximum Ti content to 0.03 wt.%. The results showed that the addition of Zr via the AlZr20 master alloy led to a gradual increase in the solidus temperature and to the grain refinement of the microstructure with the addition of as little as 0.05 wt.% Zr. The addition of more Zr (0.10, 0.15, and 0.20 wt.%) led to a gradual grain refinement effect for the alloy. The presence of Zr in the AlSi5Cu2Mg alloy was reflected in the formation of Zr-rich intermetallic phases with acicular morphology. Such phases acted as potent nucleants for the α-Al grain.

Investigation of Modifying Alloying Elements in High-Pressure Injection Casting Eutectic Al-Si Alloys

In the study, the mechanical properties of aluminum alloys produced by the injection molding method, especially using Strontium and Titanium metals, were optimized without being subjected to cold forming. Mechanical tests were applied to the alloys produced by the high-pressure casting technique, and their strength, hardness, and microstructure were examined. Optical and SEM microscopy examinations investigated grain structures. Within the scope of the study, AlTi5B1 master alloy and AlSr10 master alloy were added to the pure AlSi10 (Fe) alloy in 5 different compositions. AlTi5B1 master alloy added to pure AlSi10(Fe) alloy significantly increased the hardness by reducing the grain size. Si modification took place with the addition of AlSr10 master alloy, and it was observed that the obtained weight ratios of 150ppm, 300ppm, and 450ppm Sr increased the hardness proportionally by 2.5 HB each. With the increase in Ti and Sr master alloys added, a significant increase was observed in tensile and yield strengths and % elongation rates. In the compression test, the percentage (%) deformation elongation, the reduction of the grain structure of the material by the added Ti and Sr elements, and the transformation of the eutectic silicon into a spherical structure absorbed the applied Fm force. This led to an increase in strength, and while the permanent deformation elongation decreased as the weight of Ti increased, it was observed that the permanent deformation elongation decreased proportionally with each added amount of 150 ppm Sr. The addition of the Ti element reduced the grain size by shrinking the α-Al dendrites, but it did not affect the eutectic Si.

Research on directional solidification combined with electron beam melting and refining for recycling of FGH4096 alloy scraps

The constraints of traditional manufacturing techniques have led to the generation of a considerable amount of waste superalloy, causing substantial resource wastage. The primary concern with waste superalloys lies in the excessive presence of inclusions and impurity elements, rendering them unsuitable for further utilization. This study proposes the use of directional solidification combined with electron beam melting and refining (EBMR) to prepare FGH4096 superalloy ingots (Φ120 mm), which offers a promising approach to produce large-sized powder superalloy master alloy ingots with high-purity and high homogeneity. It is found that the secondary dendrite arm spacing and the size of the γ’ phase in the alloy are significantly reduced after EBMR treatment. The concentration of O and N can be decreased to 5.7 and 0.6 ppmw, respectively. The size of inclusion can be reduced below 8.69 μm and the inclusion numbers reduce by over 50 % compared with both conventional ingots. A droplet transfer mode and melt convection mode mechanism have been proposed, which accurately predicts the melting temperature and melt flow. A quantitative study is conducted on the influence of inclusion density, the contact angle between inclusions and melt, and the surface tension of the melt on capillary forces. The results indicate that the capillary forces between inclusions in the melt range from 1.8 × 10−19 N and 1.9 × 10−17 N. Furthermore, the collision-aggregation behavior of inclusions in the melt is discussed, and an estimate of the tendency of inclusion collision-aggregation is provided. The enrichment of inclusions in the EBMR ingot is primarily the result of turbulent collision. The Marangoni effect and the extremely high surface temperature of the melt promote the collision and agglomeration of inclusions, causing them to accumulate rapidly at the melt surface. Moreover, the thorough removal of inclusions through the decomposition and dissolution process of the electron beam offers theoretical backing for the preparation of superalloys through electron beam melting and high-purity refining.

Analysis of Chemical, Microstructural and Mechanical Properties of a CuAlBe Material Regarding Its Role as a Non-Sparking Material.

We developed and analyzed a novel non-sparking material based on CuAlBe for applications in potentially explosive environments. Using a master alloy of CuBe, an established material for anti-sparking tools used in oil fields, mines, or areas with potentially explosive gas accumulations, and pure Al, we used an Ar atmosphere induction furnace to obtain an alloy with ~10 wt% Al and ~2 wt% Be percentages and good chemical and structural homogeneity. The new material was tested in an explosive gaseous mixture (10% H2 or 6.5% CH4) under extremely strong wear for 16,000 cycles, and no hot sparks capable of igniting the environment were produced. The material was used in the form of hot-rolled plates obtained from melted ingots. The experimental results reflect the use of a suitable material for non-sparking tools. This material has good deformability during hot rolling, abnormal grain growth during deformation under heat treatment and special thermo-mechanical processing, and no high chemical composition variation. Additionally, there are slightly different corrosion resistance and mechanical properties between the melt and hot-rolled state of CuAlBe material. Through hot rolling, the material's corrosion resistance increased, reducing the chances of generating sparks capable of causing explosions.

From bulky Si to porous medium entropy alloy: Enabling highly efficient Li storage via the simultaneous reconstruction of microstructure and component

We show here that the Li-storage performance of Si anode can be substantially improved by engineering a multilevel nanoporous SiGeTiZnCuAl medium entropy alloy (NP-MEA). The NP-MEA is directly engineered through a corrosion-driven phase and structure simultaneous reconstruction by partially etching Al and Zn from the multi-element master alloy. The unique multi-elemental interactions can revolutionize the chemical microenvironment, and thus stabilize the structure and impel the transportation of the electrons and ions. The metallic sponge offers multilevel pore channels for electrolyte permeation and ample space for volume change accommodation, abundant accessible active sites for lithiation/delithiation, as well as the rigid skeleton for expediting the electron transportation and stabilizing the structure. Benefiting from the synergy of component and structure, the NP-MEA delivers a high reversible capacity of 646.1 mAh g−1 after 500 cycles at a current density of 2 A g−1.

The effect of Cu–8%P master alloy, SIMA process, thixoforming, and heat treatment on the microstructure and mechanical properties of Al–20%Mg2Si composite

In the present research, the effect of thixoforming and age-hardening heat treatment on the microstructure and mechanical properties of un-modified and modified Al–20%Mg2Si composites produced through the strain-induced melt activation (SIMA) process has been investigated. This method showed promising potential for manufacturing the ideal microstructure, achieving globular grains, and enhancing mechanical properties. Quantitative analysis has revealed that adjusting the semi-solid heat treatment parameters to a temperature of 570 °C and a holding time of 25 min optimizes the globular α-Al grains and Mg2Si particles, achieving the size of 20.62 μm and 66.71 μm and the shape factor of 0.81 and 0.83 for Mg2Si particles and α-Al grains, respectively. The yield strength of the modified Al–20%Mg2Si composite increased by 23.67% and the ultimate tensile strength increased by 21.20%, compared to the un-modified specimen. Both composites underwent the thixoforming process, illustrating the ultimate tensile strength and elongation of 93.68 MPa and 4.32% for the original composite and 138.86 MPa and 7.29% for the modified composite. The modified Al–20%Mg2Si composite was subjected to the effective combination of thixoforming and age-hardening. According to the tensile test results, the yield strength, ultimate tensile strength, elongation, and toughness raised by 138.72%, 140.92%, 267.70%, and 471.12%, respectively, compared to the as-cast specimen. Moreover, its impressive hardness of 125.1HB contributes to its overall performance.

Genetic behavior of Al-Sr-Ti-C master alloy from casting to continuous rheo-extrusion and its refinement and modification effects on A356 alloy

Genetic behavior of Al-Sr-Ti-C master alloy from casting to continuous rheo-extrusion and its refinement and modification effects on A356 alloy

Smelting characteristics of nickel‑chromium‑manganese bearing prereduced pellets for the preparation of nickel saving austenite stainless steel master alloys

Nickel saving austenite crude stainless steel master alloys were innovatively produced by smelting of nickel‑chromium‑manganese bearing prereduced pellets in an effective and economical way. The thermodynamics analysis and systematic process mineralogy were also conducted to further reveal the smelting characteristics of prereduced pellets and the related enhanced mechanism. The results showed that the preferable stainless steel master alloys with 66.29% Fe, 4.21% Ni, 17.28% Cr, 6.53% Mn and 4.76% C can be prepared from the nickel‑chromium‑manganese bearing prereduced pellets with a corresponding recovery of valuable metals more than 95%. Furthermore, during the enhanced smelting process, the optimization of slag types can further realize the phases transformation from high-melting-point enstatite and forsterite to low-melting-point diopside and monticellite to obtain a decreased smelting temperature and viscosity of slag. The smelting duration and the alloy grain included in the smelting slag were both obviously decreased, resulting in an improved smelting performance.

Insights into the microstructure evolution and wear resistance of Nano-TiC particles reinforced High-Cr hot work die steel

The current study innovatively proposed to prepare TiC nanoparticles reinforced high-Cr hot work die steels through an aluminum master alloy. The influences of TiC nanoparticles on the microstructure and wear resistance of high-Cr hot work die steels were thoroughly investigated. It was found that the addition of nanoparticles refined the pro-eutectoid ferrite in the as-cast condition, and the granular pearlite in the isothermal spheroidized condition, respectively. After receiving the quenching and tempering heat treatment, the size of lath martensite, retained austenite and nanosized precipitates were reduced. The TiC nanoparticles were used as heterogeneous cores to improve the nucleation rates of austenite and ferrite during phase transformation. The finer grains with more grain boundaries and nanoparticles refined the size of tempered microstructure of high-Cr hot work die steels. In ball-on-plate reciprocating sliding wear tests, it was found that the presence of TiC nanoparticles enhanced the wear resistance of high-Cr hot work die steels under various test conditions. The nanoparticles increased the strength of the substrate and inhibited the formation of cracks. More grain boundaries and nanoparticles hindered the migration of dislocations, which resulted in less plastic deformation. Also, the nanoparticles could partially withstand the external load during the relative motion. The results obtained in this research provide applicable values for optimizing the strength-ductility and tribological performance of hot work die steels.