Solidification Behavior Research Articles

Immobilization of arsenic wastes and retardation effect on cement hydration: Experimental and molecular dynamic analysis

AbstractThis work was designed to investigate the influence of arsenic dosage, variety on the mechanical properties, hydration, and solidification from the perspective of Portland cement (PC) performance evolution. The results demonstrate that using PC could solidify the arsenic wastes effectively, with arsenic leaching concentrations consistently below 5 mg/L. Arsenic wastes retard cement hydration, leading to a slower rate of hydrates formation, disrupting the calcium silicate hydrate (C–S–H) stacking structure, and thus detrimental to strength development especially at early age. The adverse effect is highly dependent on the arsenic variety. The insoluble calcium arsenate exhibits the least impact, while the arsenates show the largest challenging to immobilization due to the instability of hydrates. Molecular dynamic simulation indicates that arsenic can be chemically immobilized with Ca2+, and be physically adsorbed onto the positively charged C–S–H by forming As‐O···Ca···Si‐O units, accompanied by a significant reduction in adsorption energy by 46.5%. The arsenic solidification behavior provides a basis for the resource utilization of arsenic wastes in cementitious materials.

A novel age-hardenable austenitic stainless steel with superb printability

Precipitation-hardened high strength alloys, such as nickel-based alloys, aluminum alloys and stainless steels, are susceptible to hot cracking during 3D printing. This issue is typically mitigated by reducing solute segregation or promoting columnar-to-equiaxed transition. Here, we demonstrate an alternative approach by increasing segregation solutes, especially Ti element, to reduce hot cracking during laser powder bed fusion (L-PBF) additive manufacturing of a new austenitic stainless steel (ASS). Enhanced segregation triggers peritectic-like reactions at cell/grain boundaries, forming multiple phases that bridge FCC dendrites. As a result, the new ASS exhibited excellent printability across a broad range of processing parameters. The as-built (AB) steel displayed a heterogeneous columnar grain microstructure with fine L21/BCC/C14 precipitates partially decorating cell structures, achieving a yield strength (σ0.2) above 690 MPa and uniform elongation (εu) beyond 17.5%. The epitaxial growth of the columnar grains was frequently interrupted by puddles of fine grains, leading to near-isotropic tensile properties. Following isochronal annealing at temperatures between 600 to 1150 °C for two hours, the AB steel underwent varying degrees of microstructure evolution, resulting in a broad range of mechanical properties (σ0.2 from 300 to 1460 MPa and εu from 59.5% to 7.6%). This high strength is attributed to the formation of the L21/σ/η multiple phases at cell and grain boundaries, in combination with coherent L12-ordered (γ') nanoparticles precipitated within cell interiors during aging. This study explored that compositional design leveraging the unique solidification behavior of the L-PBF process can produce hierarchical-structured stainless steels with excellent printability and tunable mechanical performance.

Selective Growth of Nb-Fe-B Intermetallic Compounds for the Direct Separation of Rare Earths Based on Manipulating Liquation

Since the primary goal of industrialization has changed to carbon neutrality, the importance of rare earths (REs) has increased due to their criticality in green industries. The attainment of sustainable resources via green production processes is necessary due to the increasing need for REs. Liquid metal extraction is regarded as a leading technology for supporting the sustainability of resources based on the selective reactivity between REs and extractants. However, this process requires multiple stages, including pretreatment, extraction and separation, which are considered bottlenecks in industrialization. In this work, reverse selectivity is applied instead of conventional liquid metal extraction (c-LME) for the direct separation of REs in a single stage. Niobium (Nb) is selected because of its thermodynamic properties for enhancing the selectivity of the reactions between the extractant and other elements, excluding REs. The process is thermodynamically designed for liquation systems, and it reflects the interactions between the extractant and magnets. The solidification behavior based on the selective growth of phases without REs is shown with variations in the composition and cooling rate to confirm the kinetics. The composition prevents the formation of RE-Fe intermetallic compounds, and excess Nb is considered a bottleneck for separating REs. In addition, the cooling rate influences the agglomeration of RE as a layer. Because of the manipulation of the liquation, 92.89% of the REs are successfully separated in the form of accumulated layers. This effective process for the direct separation of REs is verified through thermodynamic and experimental assessments. Overall, this investigation can provide new guidelines for the construction of a circular economy after improving the energy efficiency of this system in future research.

Polymetallic red mud direct materialization strategy towards zero waste emission: Electromagnetic wave absorption conversion and sodium solidification

Red mud is an industrial hazardous alkaline solid waste, whereas it is rich in polymetallic components showing a high comprehensive utilization value. Direct materialization of red mud towards zero waste emission is a more reasonable and environmentally friendly strategy. In this work, a novel materialization approach of red mud via converting the polymetallic constituents into functional ferrite material by phase reconstruction with MnO2 was proposed. The mineral phase reconstruction, microstructure evolution, reaction interface observation, electromagnetic property, and the materialization conversion mechanism were investigated. It was found that the complicated phases in red mud were transferred to simple forms including the magnetic ferrites (Ca/Na/Al/Ti-bearing Mn ferrite) and weakly magnetic silicates ((Na,Al,Ca)2SiO3) after phase reconstruction. The reconstructed red mud after sintering at 1200 ℃ for 120min in air atmosphere had satisfactory electromagnetic property. Magnetism study demonstrated the soft magnetic property with maximum saturation magnetization of 34.22emu/g and coercivity of only 7.0Oe. Compared with the original red mud, effective electromagnetic wave absorption with reflection loss (RL) values of the reconstructed red mud below -20 dB were satisfied across a wider frequency bandwidth of 5-18GHz, and the minimum RL value was lower as -32.4dB with a thinner veneer thickness of 15mm, highlighting its excellent electromagnetic wave absorption performance. Moreover, Na solidification behaviors indicated that Na was solidified in the sintered product, which can reduce the possible environmental hazards of red mud alkalinity. The novel materialization treatment with zero waste emission exhibits a favorable application prospect with a large red mud batching ratio about 50wt%.

Effect of Swirling Flow Submerged Entry Nozzle on Solidification and Macrosegregation Behavior of a Round Bloom with Mold and Final Electromagnetic Stirring

Effect of Swirling Flow Submerged Entry Nozzle on Solidification and Macrosegregation Behavior of a Round Bloom with Mold and Final Electromagnetic Stirring

Simulation and experimental investigation of grain structure, residual stress,γ′ phases in single crystal blade

Ni-based superalloy turbine blades have been required components in contemporary aero-engine. Knowing the solidification behavior, residual stress at grain defects, and microstructure of directionally solidified turbine blades is a required condition to improve the service performance of directionally solidified turbine blades. Firstly, the temperature field evolution of the blade under the withdrawal rate of 3 mm/min was studied. The deviations in temperature distribution in the high-rate solidification (HRS) procedure, particularly near the platform, can lead to transformations in the mushy zone, potentially resulting in solidification defects. Secondly, the grain growth of hollow turbine blades was calculated using the cellular automaton-finite factor method. The simulated grain framework was essentially consistent with experimental results. A method of process bar addition based on physical field distribution is also proposed. This method involves designing a combination of one Y-shaped and two I-shaped rods to decrease the cooling rate of blade edges and eliminate stray grains (SG). Then, the residual stress distribution at the locations of stray grains and low-angle grain boundaries (LAGBs) was analyzed before and after the addition of process bars. Finally, discussions were held regarding the distribution of γ′ phases in grain defects and blades.

Study on the Interaction Dynamics of Magnesium and Molten Cast Iron: A Chill Casting Perspective

AbstractThis study presents a reassessment of the role of magnesium in the production process of cast iron. Through detailed experimentation involving an interrupted reaction process employing a chill casting approach in a copper mold, several reaction products that emerged during the high-temperature interaction between magnesium and cast iron were thoroughly examined. Two cast irons with different chemical compositions, notably different sulfur contents, were used to describe the contribution of magnesium during desulfurization and nodularization. The designed approach successfully revealed that rapid deoxidation and desulfurization reactions of cast iron involving liquid magnesium take place before following its ignition characteristics. Furthermore, the behavior of dissolved carbon concerning the remaining magnesium and magnesium-containing reaction products in molten iron is also empirically identified. Specifically, large graphite flakes and an indication of solidification behavior shifting are circumstantially detected in the magnesium-rich regions, which, to a certain extent, can provide additional insight into the role of magnesium during graphite nucleation.

Influence of Process Parameters on Flatness During Single-Track Laser Cladding.

During the laser cladding process, poor flatness of the cladding track can cause the surface structure to be uneven or corrugated, affecting the geometrical accuracy of the workpiece. Adjusting process parameters is an effective way to achieve high cladding track flatness. This study established a mesoscale model of the laser cladding process for CoCrMoSi powder to simulate the formation of a single cladding track. Subsequently, the formation mechanism of cladding track flatness was revealed by analyzing the flow within the molten pool and the solidification behavior of the molten pool edge. The influences of laser power, scanning speed, and powder feeding rate on flatness were determined through simulations and physical experiments. Finally, a parameter window of flatness was established using simulation and experimental results. The window indicates that high flatness is achieved with a high scanning speed (v > 260 mm/min), high laser power (P > 2300 W), and low powder feed rate (Pf < 5.5 g/min). The accuracy of the numerical model was verified by comparing the simulated results with the experimental measurements.

Growth kinetics and microstructure transition of undercooled Fe7(CoNi)75B18 eutectic muti-principal element alloy

The mechanism of rapid solidification behavior of eutectic muti-principal element alloys (EMPEAs) is an eye-catching field. In this study, the novel Fe7(CoNi)75B18 EMPEA was undercooled via rapid solidification and B2O3 glass purification method and the maximum undercooling up to 190 K was achieved. A clear microstructure evolution path was identified with the undercooling: fully regular eutectic → primary dendrite and regular eutectic → primary dendrite and divorced eutectic. The orientation relationship (OR) between the primary (Fe, Co, Ni) phase and secondary B-rich phase was revealed both at low and medium undercoolings by electron backscatter diffraction (EBSD) analysis. The results show that the OR disappears at high undercooling (190 K) owing to the microstructure fragment and rotation during the post-recalescence. Furthermore, the growth velocity exponentially raised with the increase of undercooling. The maximum growth velocity of the primary phase was 1.152×10−1 m/s, which is significantly lower than binary alloys due to the sluggish kinetics effect of EMPEAs. This study helps to understand the solidification kinetics and microstructure transition of the novel EMPEA and has important implications for controlling the solidification process of more complex alloys.

Evolutionary Mechanism of Solidification Behavior in the Melt Pool during Disk Laser Cladding with 316L Alloy

Laser cladding is an emerging environmentally friendly surface-strengthening technology. During the cladding process, the changes in molten pool temperature and velocity directly affect the solidification process and element distribution. The quantitative revelation of the directional solidification mechanism in the molten pool during the cladding process is crucial for enhancing the quality of the cladding layer. In this study, a multi-field coupling numerical model was developed to simulate the coating process of 316L powder on 45 steel matrices using a disk laser. The instantaneous evolution law of the temperature and flow fields was derived, providing input conditions for simulating microstructure evolution in the molten pool’s paste zone. The behavior characteristics of the molten pool were predicted through numerical simulation, and the microstructure evolution was simulated using the phase field method. The phase field model reveals that dendrite formation in the molten pool follows a sequence of plane crystal growth, cell crystal growth, and columnar crystal growth. The dendrites can undergo splitting to form algal structures under conditions of higher cooling rates and lower temperature gradients. The scanning speed of laser cladding (6 mm/s) has minimal impact on dendrite growth; instead, convection within the molten pool primarily influences dendrite growth and tilt and solute distribution.

Solidification behavior of WC particles reinforced nickel alloy cladding layers by plasma surfacing: Simulation and experiment

In this work, a numerical simulation model was developed to investigate the complex heat and mass transfer process inside the molten pool during plasma surfacing. The temperature distribution and fluid flow were employed to depict the evolution of the molten pool. The findings revealed that the maximum temperature is located on the surface of the cladding layer corresponding to the position of heat source, and the temperature distribution follows a Gaussian distribution along the scanning direction. Thermal accumulation is obvious due to the continuous energy input in the initial stage, as a result, the maximum temperature and fluid flow velocity gradually increase with the deposition process. The maximum temperature and fluid flow velocity at 4.0 s are 1893 K and 0.281 m/s in case 110 A, respectively. The predicted shapes and dimensions are consistent with the results of the deposition experiments, with a maximum error of no more than 15 %. In order to investigate the impact of WC particles on the solidification microstructure of nickel composite layers, corresponding plasma surfacing experiment was implemented. The solidification characteristics of the microstructure follow planar-cellular-columnar-equiaxed crystals in the bonding layer and WC particles-columnar-equiaxed dendritic crystals in hard layer, respectively. Furthermore, the Ni dendritic near the retained WC particles transformed into columnar crystals due to temperature gradient in the local area.

Multiscale Simulation of Droplets In-flight Solidification Behavior During Spray Forming

Multiscale Simulation of Droplets In-flight Solidification Behavior During Spray Forming

Continuous Casting Slab Mold: Key Role of Nozzle Immersion Depth.

Based on a physical water model with a scaling factor of 0.5 and a coupled flow-heat transfer-solidification numerical model, this study investigates the influence of the submerged entry nozzle (SEN) depth on the mold surface behavior, slag entrapment, internal flow field, temperature distribution, and initial solidification behavior in slab casting. The results indicate that when the SEN depth is too shallow (80 mm), the slag layer on the narrow face is thin, leading to slag entrapment. Within a certain range of SEN depths (less than 170 mm), increasing the SEN depth reduces the impact on the mold walls, shortening the "plateau period" of stagnated growth on the narrow face shell. This allows the upper recirculation flow to develop more fully, resulting in an increase in the surface flow velocity and an expansion in the high-temperature region near the meniscus, which promotes uniform slag melting but also heightens the risk of slag entrainment due to shear stress at the liquid surface (with 110 mm being the most stable condition). As the SEN depth continues to increase, the surface flow velocity gradually decreases, and the maximum fluctuation in the liquid surface diminishes, while the full development of the upper recirculation zone leads to a higher and more uniform meniscus temperature. This suggests that in practical production, it is advisable to avoid this critical SEN depth. Instead, the immersion depth should be controlled at a slightly shallower position (around 110 mm) or a deeper position (around 190 mm).

Study on solidification and heat transfer of billet shell in a new-structure high-speed continuous casting mold

In this work, a three-dimensional finite element model of a newly structured high-speed continuous casting mold was established to study the heat transfer and solidification process of the billet shell. A complete billet shell, from the meniscus to the secondary cooling zone, was obtained through flame cutting. Using both simulations and test verification, detailed analyses were conducted on the temperature field distribution, thickness variation law, and cooling rate law of the billet shell within the mold, revealing its solidification behavior. Additionally, the effects of casting speed, molten steel superheat, and mold taper on the solidification behavior of the billet shell were discussed. Results showed that the simulation data were basically consistent with the test verification results. Within 200 mm from the meniscus, the heat dissipation accounted for three-quarters of the mold's total heat dissipation. The cooling rate at the corners of the billet shell was slightly higher than that at the sides. Between 200 mm and 400 mm from the meniscus, air gaps caused the temperature at the corners of the billet shell to rise. Afterwards, the whole billet shell eventually reached a similar the heat dissipation rates. The thickness of the billet shell increased exponentially within 110 mm from the curved meniscus, and from 110 mm to the exit of the mold, the thickness increased linearly but slowly. The effect of molten steel superheat within a range of 10 °C on billet shell solidification was relatively minor. Increasing the casting speed reduced the billet shell thickness and raised the billet shell surface temperature. However, increasing the taper of the mold had the opposite effect. Both adjustments shifted the gap formation position backward.

Microstructure-Linked Mechanical Properties of P91-Incoloy 800HT Dissimilar Metal Welds

Dissimilar metal welds (DMWs) between P91 steel and Incoloy 800HT® using shielded metal arc welding (SMAW) with ENiCrCoMo-1 filler electrode were characterized in detail. The impact of multiple weld passes on microstructure in the heat-affected zone (HAZ) and weld fusion zone (WFZ) was thoroughly investigated. Postweld heat treatment (PWHT) impacts on mechanical characteristics and microstructure were also observed. The DMW was observed with heavy C, Cr, and Mo microsegregation in the WFZ, which deteriorated mechanical strength. The microstructural changes directly affected the mechanical behavior of the DMW. The ultimate tensile strength of the weld fusion zone was low at 576 MPa compared to the base metals’ strength. The tensile specimens failed in the IN 800HT base metal and WFZ. The WFZ had significant microsegregation near the solidified grain boundaries (SGBs). The metallurgical heterogeneity in the WFZ caused the formation of localized stress zones, which directly affected the mechanical behavior of the WFZ. The carbide particles influenced the microhardness in the WFZ and P91 HAZ regions. The PWHT successfully homogenized the microhardness in the WFZ and P91 HAZ regions. The impact toughness decreased to 64 J from 82 J after PWHT due to precipitation at SGBs and its coarsening. The SMAW process involves multiple thermal cycles during welding. The deposition of filler metal in multiple welding passes created uncontrolled variations in the solidification behavior of the WFZ. Microsegregation had a detrimental impact on the microstructure and mechanical properties of the P91 and IN 800HT dissimilar metal welds.

Study on the phase transition characteristics of nano-hydrated salts based on molecular dynamics simulations

Hydrated salts possess great competitiveness in terms of enhancing utilization efficiency of heat due to large densities of heat storage and low costs. However, the existence of supercooling degree is the common phenomenon for hydrated salts, which might restrict the application prospects in partial fields. This work focuses on hydrated salts with relatively larger latent heats, namely Na2CO3·10H2O and Na2HPO4·14H2O in the absence and presence of SiO2 as well as eutectic hydrated salt prepared with 40 wt% Na2CO3·10H2O and 60 wt% Na2HPO4·12H2O. Their melting/solidification temperatures were determined and the supercooling behavior was analyzed based on molecular dynamics simulations. The simulation results of melting/solidification temperatures present small deviations of 0.17–3.24 ℃ in comparison with experimental data. Additionally, the aggregation phenomenon among salt ions and dispersion phenomena among water molecules and between water molecules and salt ions for supercooled liquid hydrated salts are revealed, which are attributed to stronger electrostatic interactions and weaker van der Waals interactions as well as lower binding energies. Moreover, SiO2 not only lowers melting temperatures due to its higher thermal conductivity than hydrated salts and the existence of micro-convection, but affects solidification behavior of hydrated salts. The different influences of SiO2 on solidification temperatures of Na2HPO4·14H2O and Na2CO3·10H2O were associated with dispersion degree between water molecules and salt ions around SiO2, which would be attributed to different strengths of interaction forces between SiO2 and salt ions. On these bases, this work provides new perspectives for clarifying phase change characteristics of nano-hydrated salts.

Effect of isothermal cooling on solidification behaviour of peritectic steel under in situ observation

In order to improve the volume shrinkage of peritectic steel during solidification, the solidification path of peritectic steel was changed by adjusting the cooling mode in this article. The solidification behaviour of peritectic steel under isothermal cooling conditions was studied by in situ observation experiment. The transformation shrinkage degree was reflected by sample surface roughness. The results show that the solidification path under the isothermal cooling is L→L+δ-Fe→δ-Fe→δ-Fe+γ-Fe without peritectic reaction. Moreover, the sample surface morphology was flat under isothermal cooling, and no granular morphology was observed. The surface roughness was 2.55 μm under isothermal cooling, which is much lower than that under different continuous cooling conditions. The surface roughness decrease indicates the solidification volume shrinkage is reduced. Therefore, the risk of cracking can be decreased by adjusting the cooling mode to control the solidification pattern of peritectic steel.

Laser Metal Deposition of Rene 80—Microstructure and Solidification Behavior Modelling

New developments in nickel-based superalloys and production methods, such as the use of additive manufacturing (AM), can result in innovative designs for turbines. It is crucial to understand how the material behaves during the AM process to advance the industrial use of these techniques. An analytical model based on reaction–diffusion formalism is developed to better explain the solidification behavior of the material during laser metal deposition (LMD). The well-known Scheil–Gulliver theory has some drawbacks, such as the assumption of equilibrium at the solid–liquid interface, which is addressed by this method. The solidified fractions under the Scheil model and the pure equilibrium model are calculated using CALPHAD simulations. A differential scanning calorimeter is used to measure the heat flow during the solid–liquid phase transformation, the result of which is further converted to solidified fractions. The analytical model is compared with all the other models for validation.

Ablation and molten layer flow simulation for plate model of SiO2f/SiO2 composite material using particle method

In this paper, the moving particle semi-implicit method (MPS) is extended from calculating free mobility to simulating the extremely viscous and temperature-dependent molten layer flow of SiO2f/SiO2 composite material under aerodynamic heating conditions, which includes strong heating and shear of incoming flow. A method for applying heat flux and airflow shear, based on the conceptual particle approach, has been established. Heat transfer, melting, solidification, and evaporation behaviors are considered, with temperature-dependent viscosity variations also accounted for. The ablative regression of the plate model is verified using experimental results of the SiO2f/SiO2 composite material, and results from convergence analysis demonstrate the accuracy of the space step size selection. Surface morphology analysis through three-dimensional computation indicates that the extended particle method also accurately describes the surface morphology of SiO2f/SiO2 composite material under aerodynamic heating conditions. Thus, the extended particle method accurately simulates both the ablation process and the surface morphology of the SiO2f/SiO2 composite material. The influences of acceleration and surface tension are discussed. Ablative recession, when subject to acceleration, is smaller than that observed in its absence. When exposed to surface tension, the liquid layer tends to form a spherical shape, and the particles behave as a cohesive unit, resulting in smaller ablative recession than in the absence of surface tension.

Laser-induced in-situ electrohydrodynamic jet printing of micro/nanoscale hierarchical structure

With the rapid advancement of micro/nanoscale devices, there is a growing demand for hierarchical micro/nano porous-structure, particularly in fields of high-performance sensors, electrochemical energy storage, and photocatalysis. The fabrication methods for hierarchical micro/nano-porous structures have been limited by complex processes and high costs, making further development and application difficult. In this paper, a novel strategy of laser-induced in-situ electrohydrodynamic jet (E-Jet) printing of hierarchical micro/nano-porous structures was proposed. Based on the mechanism of high-energy laser beam induction on the jet, it successfully fabricated hierarchical porous ZnO structures from nanoscale to dozens of microns. The jet size focusing and solidification behavior were analyzed by combining experimental and simulative exploration. The resultant effects of the thermal field, flow field, and laser field on the spatial temperature distribution and the jetting morphology were examined. Furthermore, the laser-induced influence on the morphology of the printed micro/nano-porous ZnO structures was explored. Meanwhile, the performance of micro/nano-porous ZnO photoelectric sensors printed by E-Jet under different laser powers was investigated. The laser-induced in-situ E-Jet printing method provided an innovative pattern for the high-resolution additive manufacturing of hierarchical porous structures, demonstrating its potential for applications in advanced material and high-performance devices.