Microstructure Of Alloy Research Articles

Improving strength-conductivity synergy of Al-Cu-(Sn/Er) alloy with nanoscale substructure

As a conductive material for power transmission, Al-Cu alloy is widely used in power engineering, microelectronics and other fields. In view of the contradiction between the conductivity and strength of aluminum alloy, Sn and Er elements were selected to micro-alloy Al-Cu alloy. Al-Cu, Al-Cu-Sn and Al-Cu-Sn-Er alloys were prepared by near-liquidus casting. After solution treatment, it was subjected to three-stage alternating process of rolling and aging. The effects of micro-alloying and alternating process on the microstructure and properties of Al-Cu alloy were studied. The results show that the precipitated phase Al2Cu of Al-1.12 Cu alloy is rod-shaped after the first-stage process, and the average size is about 278±87 nm. The precipitated phases in the Al-Cu-Sn alloy are Al2Cu (average size of about 206±79 nm) and nano-sized β-Sn particles. The fine β-Sn nanoparticles in the Al-Cu-Sn-Er alloy heterogeneously nucleated on Al8Cu4Er (average size of about 167±45 nm), making Al8Cu4Er grow into particles. After secondary processing, stacking faults (SFs) appeared in the substructures of the three alloys, and the precipitated phases were further refined. The size of most precipitated phases in Al-1.13Cu-0.12Sn and Al-1.01Cu-0.15Sn-0.22Er alloys is reduced to nanometer level. After the three-stage process, some of the Al2Cu precipitates in the Al-Cu alloy are also refined to the nanometer level, and the precipitates in the other two alloys are all refined to the nanometer level. Nanotwins also appear in Al-1.01Cu-0.15Sn-0.22Er alloy. The tensile strength of Al-1.13Cu-0.12Sn and Al-1.01Cu-0.15Sn-0.22Er alloys after three-stage alternating process is 303 MPa and 327 MPa, respectively. The elongations are 21.6 % and 23.3 %, respectively. The relative conductivity was 61.7 %IACS and 59.8 %IACS, respectively. The synergistic effect of microalloying of Sn and Er elements and three-stage alternating processing technology not only reduces the size of precipitates and twins in the alloy to the nanometer level, but also adjusts the distribution of dislocation tangles and stacking faults (SFs), improves the substructure configuration, and improves the mechanical and electrical properties of conductive aluminum alloys.

A study on the machinability of DMLS In718 alloy using an electro-spark machining process

ABSTRACT The direct metal laser sintering process is used to develop the nickel base superalloy DMLS In718 for the experimentation. The DMLS In718 alloy is evaluated to ensure the metallurgical qualities and mechanical properties. Microstructure of the DMLS In718 alloy is anisotropic in nature and the hatch bands are clear to infer. The hardness of the DMLS In718 is 275 Hv which equivalent to the commercially available inconel718 material. the mechanical strength and density of the DMLS In718 alloy is justifiable to the commercial material. The machining studies are performed with electro spark erosion process to report on surface quality, kerf taper and material removal rate. the minimum pulse on time has produced a fine surface quality compared to the maximum process condition. The surface topography in terms of oxide scale and recast layers are identified during to inefficient process conditions. This paper was an opportunity to deliberate the machining quality of the wire electro spark process.

Microstructure and Mechanical Properties of Thick-Walled WE43A Alloy Fabricated by Wire Arc Additive Manufacturing

Microstructure and Mechanical Properties of Thick-Walled WE43A Alloy Fabricated by Wire Arc Additive Manufacturing

Effect of thermomechanical processing on mechanical properties and the microstructure of binary Al-Ce alloy

A new generation of Al alloys based on the Al-Ce system, with microstructure and properties weakly sensitive to elevated temperatures, is being developed for applications such as thermal engine blocks and supersonic aircraft fuselage components. Cast Al-Ce binary alloys with 4, 10 and 16 wt% Ce were produced by slab casting and further processed by extrusion. Extrusion produces a highly refined microstructure resulting in a twofold increase in strength (tensile strength of 228 MPa at room temperature). We show that the Al-10Ce is highly stable (more than 99 % strength retention after 300 °C 100 h exposure), far superior to high temperature grade Al alloy AA2618. The extruded Al-10Ce also shows a room temperature ductility of more than 20 %, with a fracture toughness of 55.42 kJ/m2 that does not degrade after high temperature exposure (97.6 % toughness retention after 300 °C 100h exposure). Results from testing at different temperatures are also reported.

Effect of Rare Earth Y on the Microstructure, Mechanical Properties and Friction of Sn-Babbitt Alloy

Babbitt alloy is a bearing material with excellent properties, including good anti-friction wear resistance, embeddedness, corrosion, and compliance, as well as sufficient bearing capacity. However, with the development of engines to have high speed and heavy load, the use of Babbitt alloy as a bearing material exposes its weaknesses of low bearing capacity, insufficient fatigue strength and a sharp decline in mechanical properties with an increase in working temperature. Therefore, its application scope is gradually narrowed and subject to certain limitations. Improving the tensile strength and wear resistance of tin-based Babbitt alloy is of great significance to expanding its application. In this study, tin-based Babbitt alloy was taken as the main research object; the particle size, microstructure, mechanical properties, and friction were systematically studied after the single addition of Y-Cu composite in tin-based Babbitt alloy liquid. The wear performance and the strengthening, toughening and wear mechanisms of tin-based Babbitt alloy were investigated under the action of Y in order to prepare a high-performance tin-based Babbitt alloy for bimetallic bearing. It was found that when rare-earth Y was added to the Babbitt alloy body, the wear properties were greatly improved.

Improved wear and corrosion resistance of magnesium AZ80 alloy prepared by laser surface remelting

Laser surface remelting (LSR) is a laser-based surface treatment method. In the LSR process, microstructural defects such as cracks and porosity are suppressed in addition to grain refinement, and the mechanical properties are improved. The present research investigated the effects of LSR parameters on the microstructure, wear, and corrosion behavior of Mg AZ80 alloy. The results showed that in LSR, the coarse-grained (29.8 μm) structure of AZ80 was transformed into a fine-grained structure (3.1 μm) with no microstructural defects. The evaporation of Mg during LSR and the formation of Al-rich and Mg-poor phases are the most important challenges in the surface treatment of AZ80. This limitation was solved by optimizing the LSR parameters, which included a gas flow rate of 2 L min−1, pulse duration of 3 ms, scanning speed of 3 mm s−1, pulse frequency of 8 Hz, and heat input of 64 J mm−1. The prevention of Mg evaporation was associated with the elimination of porosity and cracks, reducing of the solidification range, and uniform distribution of β-Mg17Al12 precipitation phases in α-Mg refined grains. The tribological behavior of the laser-treated region showed that the COF, depth of the wear scar, wear rate, and wear volume loss were reduced by 18%, 48%, 37%, and 66%, respectively, compared to AZ80. This result is attributed to the refinement of α-Mg grains and the uniform distribution of β-Mg17Al12 in the laser-treated region. The results of the polarization curves of the corrosion test in 3.5 wt% NaCl solution showed that the optimal laser-treated region with the lowest corrosion current density (34.68 × 10−6 μA.cm−2) and highest self-corrosion potential (1.425 V) exhibited the highest corrosion resistance. A slight change in the breakdown potential current slope in the laser-treated region indicates the formation of a protective film on the surface after the completion of LSR, which increases corrosion resistance.

Magnetic hysteresis of Sm1-x Gdx Co3 Cu2 alloys

The paper presents the results of a comprehensive study of the hysteresis characteristics of Sm1−𝑥Gd𝑥Co3Cu2 alloys (x=0.1–0.9), considering their actual microstructure. It is shown that in the as-cast state, all alloys in the series are significantly heterogeneous and contain inclusions of up to three phase components. Hightemperature annealing at 1050∘C for 4 hours enables modifying the microstructure of the original alloys, however, a single-phase state was only achieved for alloy samples with 𝑥 = 0.1. The high-coercivity state of the samples is provided by a regular microstructure and is implemented through the pinning mechanism. The maximum coercive force of 0.94 T was achieved on the Sm0.4Gd0.6Co3Cu2

Influence of multiple friction stir welding passes on the microstructure and mechanical properties of AA2024 age-hardened aluminum alloy

Friction stir welding (FSW) is a promising joining process for age-hardened aluminum alloys. However, when the process is used for welding age-hardened aluminum alloys, the hardness and joint efficiency are poor mainly because the strengthening precipitates become incoherent and/or get dissolved during the welding process. In this novel work, efforts have been made to enable the reprecipitation of the strengthening precipitates using multi-pass FSW. After producing FSW welds on AA2024 alloy, the welds have been processed by the same tool and at the same parameters several times to facilitate the reprecipitation of strengthening precipitates. As the precipitation kinetics of age-hardened aluminum alloys are temperature-dependent, a thermal imaging camera was utilized to record the temperature history during welding and subsequent cooling of the welded plates. The metallurgical examination of welded samples was carried out using optical microscopy, Scanning Electron Microscope (SEM), energy dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD), and microhardness test. It was observed that grain refinement occurs continuously due to dynamic recrystallization and severe plastic deformation up to the third FSW pass, after which there is no significant change in grain size. Generally, the microhardness value was higher in the stir zone than the heat-affected zone (HAZ), and the hardness in the stir zone increased after 4 passes of FSW. SEM images show clusters of incoherent precipitates, fragmentation, precipitate dispersion, dissolution, and reprecipitation of precipitates during each subsequent pass. The identification of the precipitates was carried out using EDS and XRD analysis.

Influence of Ag and Zn on the Microstructure and Properties of Sn-40 Bi Alloy for Improved Soldering Applications

Influence of Ag and Zn on the Microstructure and Properties of Sn-40 Bi Alloy for Improved Soldering Applications

Titanium Alloy Ti-6Al-4V Electrochemical Dissolution Behavior in NaNO3 and NaCl Solutions at Low Current Density

Jet electrochemical micromilling (JEMM) exhibits significant potential for high-efficiency and high-quality machining of titanium alloy microstructures. However, during the JEMM process, the machined surface of the workpiece inevitably experiences stray current attacks at low current levels. Due to the formation of a dense passive film on the surface of the titanium alloy under electrochemical action, stray corrosion occurs on the machined surface. Hence, the electrochemical dissolution behavior of titanium alloys at low current densities directly impacts both machining efficiency and quality. This study first analyzed the effects of electrolyte composition and current density on the transpassive potential, breakdown of the passive film, current efficiency, and the dissolved surface on Ti-6Al-4V. The transpassive potential and electrochemical impedance of Ti-6Al-4V were found to be lower in NaCl solution than in NaNO3 solution. In addition, lower current densities enabled higher current efficiency and resulted in a more uniform and flat dissolution surface. Subsequent experiments used these two solutions for JEMM of complex-shaped microstructures on Ti-6Al-4V. The findings demonstrated that, compared to the NaNO3 solution, the use of NaCl solution increases the material removal rate by approximately 30%, enhances the aspect ratio by about 26%, and reduces surface roughness by roughly 58%. This indicates that employing NaCl solution can lead to superior machining efficiency and quality.

Microstructure and Texture Evolution of Ti65 Alloy during Thermomechanical Processing

Microstructure and Texture Evolution of Ti65 Alloy during Thermomechanical Processing

SLM Magnesium Alloy Micro-Arc Oxidation Coating

In this study, we utilized Selective Laser Melting (SLM) technology to fabricate a magnesium alloy, and subsequently subject it to micro-arc oxidation treatment. We analyzed and compared the microstructure, elemental distribution, wetting angle, and corrosion resistance of the SLM magnesium alloy both before and after the micro-arc oxidation process. The findings indicate that the SLM magnesium alloy exhibits surface porosity defects ranging from 2% to 3.2%, which significantly influence the morphology and functionality of the resulting film layer formed during the micro-arc oxidation process. These defects manifest as pores on the surface, leading to an uneven distribution of micropores with varying sizes across the layer. The surface roughness of the 3D-printed magnesium alloy exhibits a high roughness value of 180 nanometers. The phosphorus (P) content is lower within the film layer compared to the surface, suggesting that the Mg3(PO4)2 phase predominantly resides on the surface, whereas the interior is primarily composed of MgO. The micro-arc oxidation process enhances the hydrophilicity and corrosion resistance of the SLM magnesium alloy, thereby potentially endowing it with bioactivity. Additionally, the increased surface roughness post-treatment promotes cell proliferation. However, certain inherent defects present in the SLM magnesium alloy samples negatively impact the improvement of their corrosion resistance.

Understanding of additively manufactured material cyclic behavior at the grain scale by neutron diffraction and crystal plasticity modeling

Additive manufacturing (AM) offers distinct advantages in terms of complexity, reduced material waste, and shorter production times. However, the microstructures of AM alloys differ significantly from conventionally manufactured ones, and their impact on grain behavior remains uncertain. This study employs neutron diffraction, coupled with Crystal Plasticity Finite Element (CPFE) modeling, to investigate microstructural effects on cyclic behavior in 316L LPBF alloys. Neutron diffraction provides high-resolution strain and stress data at the polycrystalline level during loading, offering valuable insights into grain behavior. The CPFE model is initially validated at the grain scale using neutron diffraction, demonstrating its ability to predict local mechanical behavior in additively manufactured materials. This methodology holds promise for broader applications in various AM alloys, particularly when macroscopic identification of mechanical behavior is insufficient. Furthermore, the comparison between neutron diffraction and CPFE predictions allows to identify the influence of dendrites and dislocation substructures on the mechanical behavior at the grain scale. Notably, the micromechanical anisotropy resulting from dislocation organization along dendritic structures with specific orientations is highlighted. This study shows that despite the observed anisotropy, experimental measurement of intragranular strain distribution are correctly captured with a quantification of the deviation observed on some specific orientations due to the above cited microstructure sub-structures.

Influence of different wrought processes on the microstructure and texture evolution in AZ31 magnesium alloy

AZ31 magnesium alloys were deformed by five wrought processes (forging, rolling, extrusion, equal-channel-angular-extrusion (ECAE), and caliber rolling) under the condition of an introduced equivalent plastic strain of approximately 1.5 at 573 K. The strain components induced by these wrought processes were computed using the finite element method (FEM). By combining the calculation results with the microstructure observations, the texture and microstructure evolution were discussed from the viewpoint of the strain state. The FEM showed that approximately the same equivalent strain was induced at the center of the alloys where observations were performed. Therefore, as the values of the equivalent plastic strain were fixed in all wrought processes, the effect of the strain component could be compared. The forged and rolled alloys had an intensive basal texture perpendicular to the compression and normal directions, respectively. In the others, a basal fiber texture parallel to the material flow direction was observed. These basal textures were oriented perpendicular to the compressive strain, and their intensities strengthened with an increase in the strain component. The microstructure became more refined and homogenized as the magnitude of the minimum principal strain decreased. This decrease corresponds to the transition of the deformation mode from the uniaxial compression mode to the multidirectional deformation mode as long as the same equivalent strain is induced. This result demonstrates that the microstructure obtained through dynamic recrystallization depends on the deformation mode, separately from the effect of the conventionally reported equivalent plastic strain.

Preparation and Characterization of Ni-Mn-Ga-Cu Shape Memory Alloy with Micron-Scale Pores

Porous Ni-Mn-Ga shape memory alloys (SMAs) were prepared by powder metallurgy using NaCl as a pore-forming agent with an average pore size of 20–30 μm. The microstructure, phase transformation, superelasticity, and elastocaloric properties of the porous alloys were investigated. The prepared porous alloy had a uniform pore distribution and interconnected microchannels were formed. Cu doping can effectively improve the toughness of a porous alloy, thus improving the superelasticity. It was found that porous Ni-Mn-Ga-Cu SMAs have a flat stress plateau, which exhibits a maximum elongation of 5% with partially recoverable strain and a critical stress for martensite transformation as low as about 160 MPa. In addition, an adiabatic temperature change of 0.6 K was obtained for the prepared porous alloy at a strain of 1.2% at about 150 MPa. This work confirms that the introduction of porous structures into polycrystalline Ni-Mn-Ga SMAs is an effective way to reduce costs and improve performance, and provides opportunities for engineering applications.

Influence of heat treatment temperature on grain structures and properties of a Ni-based superalloy fabricated via selective laser melting

This paper investigated the grain structures and mechanical properties of GH3625 alloy fabricated by Selective Laser Melting （SLM）technology at different heat treatment temperatures. GH3625 alloy samples were fabricated using SLM and subjected to heat treatment at different temperatures. Microstructural characterization was conducted using Optical Microscopy (OM), Scanning Electron Microscopy (SEM), and Electron Backscatter Diffraction (EBSD). Tensile tests were also performed to evaluate the mechanical properties. It was found that the heat treatment temperature significantly affects the microstructure of SLM-fabricated GH3625 alloy. As the temperature increases from 950°C to 1100°C, the grains gradually become uniform equiaxed morphologies with weakened grain preferred orientation, increased grain size, reduced average misorientation, and increased proportion of high-angle grain boundaries. The transformation of microstructure leads to a decrease in tensile strength and an increase in plasticity of the alloy. Samples treated at 950°C have higher tensile strength,while at 1100°C exhibits higher plasticity. The study shows that by controlling the heat treatment temperature, the grain size, grain boundary characteristics, and dislocation density of SLM GH3625 alloy can be adjusted, thereby affecting the mechanical properties of the alloy, providing important technical support for its application in high-performance fields.

Correlation of microstructure and magnetic softness of Si-microalloying FeNiBCuSi nanocrystalline alloy revealed by nanoindentation

Abstract Compared to the commercial soft-magnetic alloys, the high saturation magnetic flux density (B s) and low coercivity (H c) of post-developed novel nanocrystalline alloys tend to realize the miniaturization and lightweight of electronic products, thus attracting great attention. In this work, we designed a new FeNiBCuSi formulation with a novel atomic ratio, and the microstructure evolution and magnetic softness were investigated. Microstructure analysis revealed that the amount of Si prompted the differential chemical fluctuations of Cu element, favoring the different nucleation and growth processes of α-Fe nanocrystals. Furthermore, microstructural defects associated with chemical heterogeneities were unveiled using the Maxwell-Voigt model with two Kelvin units and one Maxwell unit based on creeping analysis by nanoindentation. The defect, with respect to a long relaxation time in relaxation spectra, was more likely to induce the formation of crystal nucleus that ultimately evolved into the α-Fe nanocrystals. As a result, Fe84Ni2B12.5Cu1Si0.5 alloy with refined uniform nanocrystalline microstructure exhibited excellent magnetic softness, including a high B s of 1.79 T and very low H c of 2.8 A/m. Our finding offers new insight into the influence of activated defects associated with chemical heterogeneities on microstructures of nanocrystalline alloy with excellent magnetic softness.

Exploring wear, corrosion, and microstructure in PEO coatings via laser surface treatments on aluminum substrates

The inadequate resistance to corrosion and wear of Al-based alloys is a major hindrance to their extensive use. Plasma electrolytic oxidation (PEO), a common and efficient coating technique, creates an oxide coating similar to ceramic on the surface of Al-based alloys, thereby improving their ability to withstand corrosion and wear. Studies have shown that PEO treatment can significantly enhance the short-term corrosion and wear resistance of Al-based alloys. To improve the long-term corrosion resistance of PEO coatings, researchers are now exploring the combination of laser processes with the PEO process. Laser processing is a simple yet efficient technique known for its flexibility, precision, and control. Various laser procedures are recognized for their ability to improve the resistance to wear and corrosion of PEO coatings applied on Al substrates and their alloys. Laser melting procedures have the capability to standardize and modify the microstructure of aluminum-based alloys. This review focuses on enhancing the anti-corrosion and anti-wear properties of aluminum alloys through the integration of laser surface treatments with PEO technology.

Effect of heat treatment on the microstructure and mechanical properties of AZ91D magnesium alloy fabricated via GTA wire arc additive manufacturing

This study aims to address elemental segregation and poor mechanical properties in as-deposited AZ91D magnesium alloy fabricated via wire arc additive manufacturing through heat treatment. Three distinct heat treatments are investigated: solution treatment (T4), artificial aging treatment (T5), and a combination of solution and aging treatment (T6). Microstructural analysis reveals equiaxed grains in all samples. In the T4 state, the eutectic phase along grain boundaries dissolvs into the matrix, reducing elemental segregation but increasing grain size. In the T5 state, elemental segregation is further reduced; however, due to the relatively low aging temperature, the microstructural features of the as-deposited state are largely retained. In the T6 state, solution treatment increases grain sizes, and the uneven distribution of the reprecipitated β phase leads variations in mechanical properties between vertical and horizontal directions. Compared to the as-deposited state, the T6 treatment achieves a synergistic improvement in both strength and ductility. The ultimate tensile strength increases to 262.3 MPa, and the elongation rises to 13.8%, representing improvements of 12.5% and 32.7%, respectively, compared to the as-deposited values of 233.2 MPa and 10.4%.

Inducing columnar-to-equiaxed transition by gradient impediment-flow optimization mechanism: The inheritance chain of solidification

Optimization of the metal solidification microstructure is a long-standing topic. It is the initial and critical guarantee of fabricating high performance metal materials, especially in the context of external field control, for example, for electromagnetic fields. However, tailoring the final solidification microstructure is extremely difficult because its mechanism is a long process inheritance chain which can be hardly observed by experiments. In this study, systematically simulations of the continuous casting using an electromagnetic swirling flow nozzle (EMSFN) was made to clarify this inheritance chain. It was newly found that a relatively uniform flow field inherited from a magnetic field generates a gradient impediment-flow optimization mechanism (GIFO), which is beneficial for both columnar-to-equiaxed transition (CET) and grain refinement. Specifically, 600 A increases the superheat dissipation, and the temperatures of the solidification front at 200 mm and 400 mm below the meniscus are increased by 15.47 K and 12.27 K, respectively, and the temperature gradient is decreased by 17.3 % and 22.8 %. The concentration gradient at the solidification front decreased by 89.9 %, 31.1 %, and 51.3 % at 200 mm, 400 mm, and 650 mm below the meniscus, respectively. Coupled changes in the temperature and concentration gradients impede dendritic growth and promote equiaxed grain nucleation. In addition, more equiaxed grain nuclei are transported to the forefront of the growing dendrite when the molten steel rotates and is transported from the inner to the outer regions. According to the simulation, the experimental validation proved that electromagnetic swirling flow nozzle was a convenient method for promoting this mechanism. It can optimize the solidification structure of Grade 70 carbon spring steel continuous casting billets with an increase of 21.26 % in the equiaxed grain ratio extremely low carbon segregation, and improved mechanical properties. This newly found mechanism can be considered as a generic theory for optimizing the solidification microstructure of alloys, which can guide the process design of various external field control technology.