Microstructure,Properties, and Numerical Simulation of Semi-Solid Aluminum Alloy under Planetary Stirring Process

In order to solve the problem of insufficient convective heat transfer of uniaxial stirred melt, the temperature field and shear rate of melt under planetary stirring were studied based on CFD simulation. The microstructure and properties of this technology were also experimentally studied. The results show that compared with the uniaxial stirring semi-solid technology, the convective heat transfer ability of aluminum alloy, semi-solid slurry in planetary stirring mode is stronger. In addition, its temperature field can be reduced to the semi-solid range faster and more evenly, which is conducive to a large number of nucleation and improves the nucleation rate. The temperature difference of the whole melt is small, so the preferred direction growth and uniform growth of dendrites are avoided, and the morphology is improved. Properly increasing the revolution and rotation speed of the stirring shaft can refine the grains of semi-solid aluminum alloy parts, improve the grain morphology, and improve the tensile strength. The planetary stirring semi-solid process is very suitable for rheological high-pressure casting.     

Numerical and Experimental Study on the Direct Chill Casting of Large-Scale AA2219 Billets via Annular Coupled Electromagnetic Field

The internal coupled electromagnetic melt treatment (ICEMT) method is firstly proposed to produce high-quality and large-sized aluminum alloy billets. A three-dimensional model was established to describe the ICEMT process of direct chill casting (DC casting). The effect of ICEMT on the fluid flow patterns and temperature field in the DC casting of ϕ880 mm AA2219 billets is numerically analyzed. Moreover, the mechanisms of the ICEMT process on grain refinement and macrosegregation were discussed. The calculated results indicate that the electromagnetic field appears to be coupled circinate at the cross section of the melt, the fluid flow becomes unstable accompanied by the bias flow, and the temperature profiles are significantly more uniform. An experimental verification was conducted and the results prove that compared with traditional direct chill casting, the microstructures of the AA2219 large-scale billet under the ICEMT process are uniform and fine.     

Microstructures and Macrosegregation of Al–Zn–Mg–Cu Alloy Billet Prepared by Uniform Direct Chill Casting

In this study, large-sized Al–Zn–Mg–Cu alloy billets were prepared by direct chill casting imposed with annular electromagnetic stirring and intercooling; a process named uniform direct chill casting. The effects of uniform direct chill casting on grain size and the alloying element distribution of the billets were investigated and compared with those of the normal direct chill casting method. The results show that the microstructures were refined and the homogeneity of the alloying elements distribution was greatly improved by imposing the annular electromagnetic stirring and intercooling. In uniform direct chill casting, explosive nucleation can be triggered, originating from the mold wall and dendrite fragments for grain refinement. The effects of electromagnetic stirring on macrosegregation are discussed with consideration of the centrifugal force that drives the movement of melt from the central part towards the upper-periphery part, which could suppress the macrosegregation of alloying elements. The refined grain can reduce the permeability of the melt in the mushy zone that can restrain macrosegregation.     

Parameter optimization of CO2 casting process by using Taguchi method

This study demonstrates optimization of CO₂ casting process parameters by using Taguchi’s design of experiments method. The CO₂ casting process involves a large number of parameters affecting the various quality features of the final product. The process parameters considered in this research work are weight of CO₂ gas, mould hardness number, sand particle size, percentage of sodium silicate, sand mixing time, pouring time, pouring height, pouring temperature, and cooling time of poured metal. The effect of the selected process parameters on casting defects and subsequent setting of the parameters have been accomplished by using Taguchi’s parameter design approach. The result indicates that the selected process parameters significantly affect the defects of CO₂ casting. The results are further conformed by conducting confirmation experiments.     

A Method for Characterising the Influence of Casting Parameters on the Metallurgical Bonding of Copper and Steel Bimetals

Traditional casting technology offers two mayor drawbacks towards research activities. On the one hand, time and resources needed for every casting are rather high. The mould has to be able to withstand the high temperatures introduced by the melt and provide cooling for the cast part. Preparation and installation of measuring equipment therefore takes time. Additionally, due to the high mass of the mould when compared to the cast part, parameter variations are rather limited in their resulting effect on the temperature-time profile being one of the most prominent factors regarding cast quality. Especially when pouring by hand, variations in casting times and rates superimpose effects created intentionally. Therefore, a different process was advanced and evaluated, allowing to minimise some of the drawbacks mentioned before. The key idea is to drastically reduce casting size to the dimensions of one specimen and to apply a highly automated production route. As such, a mirror furnace was modified as to allow the processing of melt. Due to the specimens size, an adaption of mechanical testing equipment was performed and evaluated. As an example, copper-iron bimetal specimens were examined by light microscopy, micro hardness testing, nanoindentation as well as tensile and torsion testing. As the results were consistent, the newly introduced method can be applied successfully in casting research. This allows for highly reproducible results, reducing the uncertainty of temperature measurements of a specimen due to the distance between them. The possibility of separating influencing variables like maximum temperature and cooling rate allows an analysis of the casting process, which would require different moulds to do so in traditional casting methods. The next steps will be directed at a broader variety of metals processed and at a direct comparison between the new process route and traditional casting technology.     

Motion and Distribution of Floating Grain in Direct-Chill Casting of Aluminum Alloys: Experiments and Numerical Modeling

Sedimentation of free-floating grains is the main origin of the negative centerline segregation in direct-chill casting of aluminum alloys. This study examines the motion and distribution of the floating grains during casting using experimental measurements and numerical modeling. The typical floating grains consisting of interior solute-lean coarse dendrites and periphery fine dendrites were experimentally observed only in the central region of the billet along with the negative segregation. The billet exhibits the strongest segregation at the center where the most floating grains are found. In simulations, under the action of the convection and the underlying forces, the grains floating in the transition region exhibit different motion behaviors, i.e., settling to the mushy zone, floating in the slurry zone, and moving upward to the liquid zone. However, most grains were transported to the central region of the billet and then were captured by the mushy zone and settled. Therefore, the floating grains comprise the largest share of the grain structure at the center of the billet, in agreement with the experimental results. Moreover, the simulation results indicate that the increased size of the grains promotes the sedimentation of the floating grains. These results are important for the future alleviation of negative centerline segregation in direct-chill casting of aluminum alloys.     

Effects of Graphene Nanoplates on the Mechanical Behavior and Strengthening Mechanism of 7075Al Alloy

7075Al alloy is the preferred material for lightweight automotive applications, but the existing problem is that it is difficult to combine high strength and high toughness. This paper presents our research aimed at obtaining high strength and high toughness materials by adding a nano-phase to realize microstructure refinement. Graphene nanoplates (GNP)/7075Al composites and 7075Al alloy were prepared by a stirring casting method in the present study. In comparison to 7075Al, the tensile strength of GNP/7075Al composites was increased from 572 MPa to 632 MPa while maintaining good uniform elongation of 8% to 10%. The increased strength behavior of GNP/7075Al composites while maintaining the plasticity is discussed in terms of grain refinement and dislocation evolution by analyzing the composite microstructure and quantitatively analyzing the contributions of grain boundary strengthening, solid solution strengthening, precipitation strengthening and dislocation strengthening. GNP’s strengthening of GNP/7075Al composites is mainly attributed to the refinement of grain size and the increase of dislocation density.     

Direct Chill Casting and Extrusion of AA6111 Aluminum Alloy Formulated from Taint Tabor Scrap

AA6111 aluminum automotive body-sheet alloy has been formulated from 100% Taint Tabor scrap aluminum. Direct chill casting with and without high shear melt conditioning (HSMC) was used to produce the AA6111 alloy billets. Both homogenized and non-homogenized billets were extruded into sheets. The optical micrographs of the melt conditioned direct chill (MC-DC) samples showed refined equiaxed grains in comparison to direct chill (DC) cast and direct chill grain refined (DC-GR) samples. Optical metallography showed extensive peripheral coarse grain (PCG) for the DC, DC-GR and MC-DC planks extruded from the homogenized standard AA6111 billets while planks extruded from modified AA6111 billets (with recrystallization inhibitors) showed thin PCG band. The co-addition of recrystallization inhibitors Mn, Zr, and Cr with elimination of the billet homogenization step had a favorable impact on the microstructure of the AA6111 alloy following the extrusion process where a fibrous grain structure was retained across the whole section of the planks. The mechanical properties of as-cast planks extruded from non-homogenized billets were similar to those extruded from homogenized billets. Eliminating the homogenization heat treatment step prior to extrusion has important ramifications in terms of processing cost reduction.     

Simulation of Subrapid Solidification and Secondary Cooling for the Strip Casting of IF Steel

A combination of droplet solidification tester and confocal laser scanning microscope was used to simulate subrapid solidification and secondary cooling process pertinent to the strip casting. The IF steel droplet had a delamination structure and the bottom part went through sub-rapid solidification. During secondary cooling, γ/α transformation mechanism belonged to interface-controlled massive transformation and the ferrite grains grew quickly. With the increase of cooling rate, the γ/α transformation temperature decreased and the incubation period and phase transformation duration reduced. The hardness showed a slight increase due to fine-grain strengthening. With coiling temperature increasing from 600 °C to 800 °C, the grain size became larger, precipitates became coarse, and defects in grain were recovered. Consequently, the hardness decreased.     

Numerical Simulation and Experimental Validation of Squeeze Casting of AlSi9Mg Aluminum Alloy Component with a Large Size

The squeeze casting process for an AlSi9Mg aluminum alloy flywheel housing component was numerically simulated using the ProCAST software, and orthogonal simulation tests were designed according to the L16 (4) ⁵ orthogonal test table to investigate the alloy melt flow rule under four factors and four levels each of the pouring temperature, mold temperature, pressure holding time and specific pressure, as well as the distributions of the temperature fields, stress fields and defects. The results showed that the flywheel housing castings in all 16 test groups were fully filled, and the thinner regions solidified more quickly than the thicker regions. Hot spots were predicted at the mounting ports and the convex platform, which could be relieved by adding a local loading device. Due to the different constraints on the cylinder surface and the lower end surface, the solidification was inconsistent, the equivalent stress at the corner junction was larger, and the castings with longer pressure holding time and lower mold temperature had larger average equivalent stress. Shrinkage cavities were mainly predicted at mounting ports, the cylindrical convex platform, the peripheral overflow groove and the corner junctions, and there was also a small defect region at the edge of the upper end face in some test groups.     

Effect of High Rotational-Speed Friction-Stir Welding on Microstructure and Properties of Welded Joints of 6061-T6 Al Alloy Ultrathin Plate

The butt joint of an Al alloy ultrathin plate with a thickness of 0.5 mm is realized by a high rotational-speed friction-stir welding process. It overcomes the welding difficulty that the ultrathin plate is often torn, and it cannot be formed by conventional friction-stir welding. The results show that the weld surface is well-formed at a high-rotational speed (more than 8000 rpm), and there are no obvious defects in each area of the joint section. The nugget zone (NZ) is a recovery recrystallization structure dominated by large-angle grain boundaries, with a grain size of about 4.9 μm. During grain growth, the texture is randomly and uniformly distributed, and the strength is balanced. The microhardness of the NZ increases significantly with the increase in rotational speed, and the fluctuation range of hardness value is small. The NZ β–Mg₂Si is finer and significantly less than the base metal (BM). The heat dissipation of the thin plate is fast, so a Cu plate is used as the backing plate to slow down the steep temperature-drop process in the weld area. Compared with a low rotational speed, the precipitation amount of brittle phase Al–Cu–Mg–Cr and Al–Fe–Si–Mn is significantly reduced, which is conducive to improving the mechanical properties of the joint. At a high rotational speed, 12,000 rpm, the best tensile strength of the joint is 220 MPa, which is about 76% of the BM (290 MPa), and the highest elongation is 9.3%, which is about 77.5% of the BM (12%). The fracture mode of the joint is a typical plastic fracture.     

A Novel Preparation of Special-Shaped Phosphors-in-Glass by Gel Casting with Isobam for High-Power WLEDs Lighting

Phosphors-in-glass (PiGs) regarded as a promising phosphor-converter for white light emitting diodes (WLEDs) is being researched widely. However, there are few reports on the effect of changing the shape of PiGs on the color rendering index (CRI) and heat dissipation of WLEDs. In this paper, gel casting with Isobam was first attempted in preparing special-shaped PiGs successfully. It exhibited that 76 wt.% was the optimum solid content based on the rheological properties of slurry and the shrinkage of green bodies. The sintering rate should be kept at a low speed and glass transition temperature (Tg) of glass powders must be higher than sublimation temperatures (Ts) of APS and Isobam. The CRI of PiGs was increased by about 27% after changing the shape of PiGs from cylinder to dome. Most importantly, operating temperature also reduced effectively the increase of the surface area of PiGs. Therefore, changing the shape of PiGs by gel casting with Isobam is a creative way for high-power WLEDs lighting.     

Influence of M-EMS on Fluid Flow and Initial Solidification in Slab Continuous Casting

A mathematical model coupled with electromagnetic field has been developed to simulate the transient turbulence flow and initial solidification in a slab continuous casting mold under different electromagnetic stirring (EMS) currents and casting speeds. Through comparing the magnetic flux density, flow field with measured results, the reliability of the mathematical model is proved. The uniform index of solidified shell thickness has been introduced to judge the uniformity of the solidified shell. The results show that a horizonal recirculation flow has been generated when EMS is applied, and either accelerated or decelerated regions of flow field are formed in the liquid pool. Large EMS current and low casting speed may cause the plug flow near the mold narrow face and a suitable EMS current can benefit to the uniform growth of solidified shell. Meanwhile, an industrial test exhibits that EMS can weaken the level fluctuation and number density of inclusion. Overall, a rational EMS current range is gained, when the casting speed is 1.2 m/min, the rational EMS current is 500–600 A.     

Grain Refinement of Inconel 718 Superalloy—The Effect of Rotating Magnetic Field

The effect of the application of a rotating magnetic field on the average grain size of IN718 castings was experimentally studied. For the purpose, four parts were produced by investment casting and characterized. The first casting was produced without application of RMF for comparison. The remaining ones were submitted to different RMF frequencies for 15 min and subsequently to the pouring of the nickel-based superalloy. In these three castings, the RMF frequencies applied were, respectively, 15 Hz, 75 Hz and 150 Hz. All the other process parameters were kept constant during the execution of the experimental procedure. The average grain size of the samples was determined according to the ASTM E112-13 standard, using intercept methods. Macro hardness measurements, tensile testing and SEM-EDS analysis were conducted in order to evaluate the casting’s mechanical properties and microstructures. The results demonstrate a noticeable grain size reduction in the samples submitted to rotating magnetic field. An average grain area reduction, greater than 96%, was achieved in the castings where RMF frequencies of 75 Hz and 150 Hz were applied. The application of RMF also caused a morphological change in the casting’s dendrites from cellular to almost equiaxed. Additionally, it originated the decrease of the size and amount of needle-like δ phase. Regarding mechanical properties of the cast parts, no major differences were verified.     

Bending and Straightening of a Medium Carbon Steel Continuous Casting Slab with Low Temperature End Plastic Groove

The high temperature brittleness range of medium carbon microalloyed steel under an actual continuous casting process was determined by the high temperature tensile test. The test results revealed that only a third of the brittle temperature range from 650–825 °C was due to intergranular ferrite in the experimental steel. In addition, it was found that the plastic recovery was fast and stable when the temperature was lower than 725 °C (the lowest plastic temperature). Bending/straightening operation in this temperature range was conducive to controlling the generation of corner cracks. In order to keep the corner temperature at the low temperature end of the plastic curve when the slab was bent/straightened, the cooling water scheme of the secondary cooling zone of the continuous caster was formulated by numerical calculation. By appropriately increasing the cooling water flow in the foot roll and the secondary cooling zones 1–5, the corner temperature of slab during bending operation was 600–700 °C, avoiding the brittle temperature range. The industrial test was then carried out. The results showed that after using the optimized water volume, the corner grains of the slab were uniform and the microstructure was mainly pearlite + ferrite. In addition, the abnormally large grain size was reduced, and a large amount of ferrite was generated inside the grain, which avoided stress concentration at the corner of the slab during bending/straightening operation, and basically eliminated the corner crack of the slab.     

Analysis and Design of Lattice Structures for Rapid-Investment Casting

This paper aims to design lattice structures for rapid-investment casting (RIC), and the goal of the design methodology is to minimize casting defects that are related to the lattice topology. RIC can take full advantage of the unprecedented design freedom provided by AM. Since design for RIC has multiple objectives, we limit our study to lattice structures that already have good printability, i.e., self-supported and open-celled, and improve their castability. To find the relationship between topological features and casting performance, various lattice topologies underwent mold flow simulation, finite element analysis, casting experiments, and grain structure analysis. From the results, the features established to affect casting performance in descending order of importance are relative strut size, joint number, joint valence, and strut angle distribution. The features deemed to have the most significant effect on tensile and shear mechanical performance are strut angle distribution, joint number, and joint valence. The practical application of these findings is the ability to optimize the lattice topology with the end goal of manufacturing complex lattice structures using RIC. These lattice structures can be used to create lightweight components with optimized functionality for various applications such as aerospace and medical.     

Base Plate Preheating Effect on Microstructure of 316L Stainless Steel Single Track Deposition by Directed Energy Deposition

The microstructural morphology in additive manufacturing (AM) has a significant influence on the building structure. High-energy concentric heat source scanning leads to rapid heating and cooling during material deposition. This results in a unique microstructure. The size and morphology of the microstructure have a strong directionality, which depends on laser power, scanning rate, melt pool fluid dynamics, and material thermal properties, etc. The grain structure significantly affects its resistance to solidification cracking and mechanical properties. Microstructure control is challenging for AM considering multiple process parameters. A preheating base plate has a significant influence on residual stress, defect-free AM structure, and it also minimizes thermal mismatch during the deposition. In the present work, a simple single track deposition experiment was designed to analyze base plate preheating on microstructure. The microstructural evolution at different preheating temperatures was studied in detail, keeping process parameters constant. The base plate was heated uniformly from an external heating source and set the stable desired temperature on the surface of the base plate before deposition. A single track was deposited on the base plate at room temperature and preheating temperatures of 200 °C, 300 °C, 400 °C, and 500 °C. Subsequently, the resulting microstructural morphologies were analyzed and compared. The microstructure was evaluated using electron backscattered diffraction (EBSD) imaging in the transverse and longitudinal sections. An increase in grain size area fraction was observed as the preheating temperature increased. Base plate preheating did not show influence on grain boundary misorientation. An increase in the deposition depth was noticed for higher base plate preheating temperatures. The results were convincing that grain morphology and columnar grain orientation can be tailored by base plate preheating.     

Optimization of Friction Stir Welding Tool Advance Speed via Monte-Carlo Simulation of the Friction Stir Welding Process

Recognition of the friction stir welding process is growing in the aeronautical and aero-space industries. To make the process more available to the structural fabrication industry (buildings and bridges), being able to model the process to determine the highest speed of advance possible that will not cause unwanted welding defects is desirable. A numerical solution to the transient two-dimensional heat diffusion equation for the friction stir welding process is presented. A non-linear heat generation term based on an arbitrary piecewise linear model of friction as a function of temperature is used. The solution is used to solve for the temperature distribution in the Al 6061-T6 work pieces. The finite difference solution of the non-linear problem is used to perform a Monte-Carlo simulation (MCS). A polynomial response surface (maximum welding temperature as a function of advancing and rotational speed) is constructed from the MCS results. The response surface is used to determine the optimum tool speed of advance and rotational speed. The exterior penalty method is used to find the highest speed of advance and the associated rotational speed of the tool for the FSW process considered. We show that good agreement with experimental optimization work is possible with this simplified model. Using our approach an optimal weld pitch of 0.52 mm/rev is obtained for 3.18 mm thick AA6061-T6 plate. Our method provides an estimate of the optimal welding parameters in less than 30 min of calculation time.     

Laser Powder Bed Fusion of Pure Tungsten: Effects of Process Parameters on Morphology,Densification, Microstructure

Tungsten has been widely used in many industrial fields due to its excellent properties. However, owing to its characteristics of inherent brittleness at room temperature and high melting point, it is difficult to prepare tungsten parts with high complexity via traditional methods. In the present work, tungsten samples were prepared by laser powder bed fusion. The influence of each process parameter including laser power, scanning speed, and hatch spacing on the surface morphology, densification, and microstructure of tungsten samples was systematically investigated. The results showed that the use of the appropriate parameters, especially high laser power, can effectively improve the surface quality and obtain a dense surface. The tungsten samples with a relative density of 98.31% were obtained with optimized parameter combinations: a laser power of 300 W, scanning speed of 400 mm/s, and hatch spacing of 0.08 mm. Compared with scanning speed and hatch spacing, the laser power had a more obvious influence on the relative density. Additionally, for the grain morphology by microstructure inspection, elongated curved grains gradually transformed into fine straight columnar grains as the scanning speed increased. The hatch spacing would change the grain morphology slightly but had no significant effect on the grain size.     

Influence of Gating System Parameters of Die-Cast Molds on Properties of Al-Si Castings

The resulting quality of castings indicates the correlation of the design of the mold inlet system and the setting of technological parameters of casting. In this study, the influence of design solutions of the inlet system in a pressure mold on the properties of Al-Si castings was analyzed by computer modelling and subsequently verified experimentally. In the process of computer simulation, the design solutions of the inlet system, the mode of filling the mold depending on the formation of the casting and the homogeneity of the casting represented by the formation of shrinkages were assessed. In the experimental part, homogeneity was monitored by X-ray analysis by evaluating the integrity of the casting and the presence of pores. Mechanical properties such as permanent deformation and surface hardness of castings were determined experimentally, depending on the height of the inlet notch. The height of the inlet notch has been shown to be a key factor, significantly influencing the properties of the die-cast parts and influencing the speed and filling mode of the mold cavity. At the same time, a significant correlation between porosity and mechanical properties of castings is demonstrated. With the increasing share of porosity, the values of permanent deformation of castings increased. It is shown that the surface hardness of castings does not depend on the integrity of the castings but on the degree of subcooling of the melt in contact with the mold and the formation of a fine-grained structure in the peripheral zones of the casting.