Nucleation Behavior of a Single Al-20Si Particle Rapidly Solidified in a Fast Scanning Calorimeter

Understanding the rapid solidification behavior characteristics, nucleation undercooling, and nucleation mechanism is important for modifying the microstructures and properties of metal alloys. In order to investigate the rapid solidification behavior in-situ, accurate measurements of nucleation undercooling and cooling rate are required in most rapid solidification processes, e.g., in additive manufacturing (AM). In this study, differential fast scanning calorimetry (DFSC) was applied to investigate the nucleation kinetics in a single micro-sized Al-20Si (mass%) particle under a controlled cooling rate of 5000 K/s. The nucleation rates of primary Si and secondary α-Al phases were calculated by a statistical analysis of 300 identical melting/solidification experiments. Applying a model based on the classical nucleation theory (CNT) together with available thermodynamic data, two different heterogeneous nucleation mechanisms of primary Si and secondary α-Al were proposed, i.e., surface heterogeneous nucleation for primary Si and interface heterogenous nucleation for secondary α-Al. The present study introduces a practical method for a detailed investigation of rapid solidification behavior of metal particles to distinguish surface and interface nucleation.     

Microstructure and Thermal Deformation Behavior of Hot-Pressing Sintered Zr-6Al-0.1B Alloy

Zr-6Al-0.1B alloy rich in Zr₃Al phase is prepared by hot-pressing sintering. The thermal deformation behavior of sintered Zr-6Al-0.1B is analyzed by isothermal compression tests at deformation temperatures of 950, 1050, and 1150 °C with strain rates of 0.01, 0.1, and 1 s⁻¹. The results indicate that at the early stage of thermal deformation, the stress increases rapidly with the increase of strain and then reaches the peak value. Subsequently, the stress decreases with the increase of strain under the softening effect. On the whole, the true stress-strain curve shifts to the high stress area with the increase of strain rate or the decrease of deformation temperature, so the sintered Zr-6Al-0.1B alloy belongs to the temperature and strain rate sensitive material. For the microstructure evolution of sintered Zr-6Al-0.1B during the isothermal compression, the high strain rate can improve the grain refinement. However, because sintered Zr-6Al-0.1B is a low plastic material, too high strain rate will exceed the deformation capacity of the material, resulting in an increase in defects. The increase of deformation temperature also contributes to grain refinement, but when the temperature is too high, due to the decomposition of Zr₃Al phase, the deformation coordination of the material decreases, leading to the increase of the probability of the occurrence of defects. This study verified the feasibility of hot-pressing sintering to prepare Zr-6Al-0.1B alloy rich in Zr₃Al phase and laid the foundation of “hot-pressing sintering + canning hot-extrusion” process of Zr-6Al-0.1B alloy components.     

Microstructure and Corrosion Resistance of AA4047/AA7075 Transition Zone Formed Using Electron Beam Wire-Feed Additive Manufacturing

A gradient transition zone was obtained using electron beam deposition from AA4047 wire on AA7075 substrate and characterized for microstructures, tensile strength and corrosion resistance. The microstructure of the transition zone was composed of aluminum alloy grains, Al/Si eutectics and Fe-rich and Si-rich particles. Such a microstructure provided strength comparable to that of AA7075-T42 substrate but more intense corrosion due to the higher amount of anodic Mg₂Si particles. The as-deposited AA4047 zone formed above the transition zone was composed of aluminum alloy dendrites and interdendritic Al/Si eutectics with low mechanical strength and high corrosion potential.     

Influence of Thermal Sensitivity of Functionally Graded Materials on Temperature during Braking

The model of the frictional heating process during single braking to determine the temperature of the functionally graded friction elements with an account of the thermal sensitivity of materials was proposed. The basis of this model is the exact solution of the one-dimensional thermal problem of friction during braking with constant deceleration. The formulas approximating the experimental data of the temperature dependencies of properties of the functionally graded materials (FGMs) were involved in the model to improve the accuracy of the achieved results. A comparative analysis was performed for data obtained for temperature-dependent FGMs and the corresponding data, calculated without consideration of thermal sensitivity. The results revealed that the assumption of thermal stability of FGMs during braking may cause a significant overestimation of temperature of the friction pair elements.     

Investigation of Dry Sliding Friction,Wear and Mechanical Behavior of the Ti-6Al-7Nb Alloy after Thermal Oxidation

The mechanical and tribological characteristics of the Ti-6Al-7Nb alloy were investigated within a wide range of temperature and time parameters of thermal oxidation. The hardness, H_IT, and indentation modulus, E_IT, of the alloy in question, with and without an anti-wear oxide layer, were determined. The tribological properties of sliding couples were studied under technically dry friction conditions, using a ball-on-disc tribometer. The test pieces were non-oxidized and oxidized Ti-6Al-7Nb alloy discs, and Al₂O₃, ZrO_2, and 100Cr6 balls were used as counter specimens. After thermal oxidation, the surface of the titanium alloy was characterized by a significantly higher hardness, H_IT (8–10 GPa), compared to the surface not covered with oxide layers (3.6 GPa). The study showed that the curvature of the loading segments increased with an increasing oxidation temperature, indicating a strong positive dependence of hardness on the thermal oxidation temperature. The value of the indentation modulus, E_IT, was also found to increase with the increasing oxidation temperature. The intensity of the tribological processes was strictly dependent on the oxidation parameters and the couple’s material (Al₂O₃, ZrO₂, 100Cr6). It has been shown that the thermal oxidation process makes it possible to control, within a wide range, the friction-wear characteristics of the Ti-6Al-7Nb alloy.     

Thermal Expansion of a Multiphase Intermetallic Ti-Al-Nb-Mo Alloy Studied by High-Energy X-ray Diffraction

Intermetallic γ-TiAl-based alloys are lightweight materials for high-temperature applications, e.g., in the aerospace and automotive industries. They can replace much heavier Ni-based alloys at operating temperatures up to 750 °C. Advanced variants of this alloy class enable processing routes that include hot forming. These alloys consist of three relevant crystallographic phases (γ-TiAl, α₂-Ti₃Al, β_o-TiAl) that transform into each other at different temperatures. For thermo-mechanical treatments as well as for adjusting alloy properties required under service conditions, the knowledge of the thermal expansion behavior of these phases is important. Therefore, thermal expansion coefficients were determined for the relevant phases in a Ti-Al-Nb-Mo alloy for temperatures up to 1100 °C using high-energy X-ray diffraction.     

Influence of Modification on Flow Stress Behavior and Corrosive Properties of a Hypoeutectic Al-Si Alloy

The flow stress behavior and corrosive properties of Al-7Si alloy were studied by thermal compression test, electrochemical test, and electron probe microanalysis. The influences of temperatures, strain rates, strains, and morphology of Si particles on stress-strain curves of Al-7Si alloy were analyzed. The peak stress of unmodified-Al-7Si alloy is higher than that of Sr-modified-Al-7Si alloy at the same deformation conditions, and the phenomenon is obviously relevant to the distribution and morphology of Si particles. The morphology of Si particles of unmodified-undeformed-Al-7Si alloy is a typical thick layer, and that of unmodified-deformed-Al-7Si alloy is broken into relatively small particles and the distribution is relatively even in homogeneous deformation zone II. The distribution of Si particles in Sr-modified-deformed-Al-7Si alloy is obviously more even than undeformed alloy. The effect of a small deformation of 20% on the distribution and morphology of Si particles is obviously smaller than that of a large deformation of 50%. The electrochemical self-corrosion potential of Sr-modified-Al-7Si alloy is higher than that of unmodified-Al-7Si alloy, and it proves that the distribution and morphology of Si particles have a certain influence on the corrosive properties of Al-7Si alloy. That is, the even fine Si particles are more conducive to improving the corrosive properties of Al-7Si alloy.     

The Effect of Tin on Microstructure and Properties of the Al-10 wt.% Si Alloy

In this paper, the results from studies regarding near-eutectic Al-Si alloys with Sn as an alloying addition are presented. In most Al-Si alloys, tin is regarded as a contaminant; thus, its amount is limited to up to 0.3 wt.%. The few studies that can be found in the literature regarding the behaviour of tin in aluminium alloys suggest the beneficial effect of this element on selected properties. However, these results were obtained for hypereutectic Al-Si alloys or wrought aluminium alloys. In our studies, the influence of tin contents of up to 1.7 wt.% was determined on the AlSi10 alloy. Thermal analysis, measurements of the mechanical properties of the cast and heat-treated alloy, metallographic observations (light microscopy, scanning electron microscopy), and EDS (X-ray energy dispersive spectrometry) measurement allowed us to fully describe the effect of tin on the aluminium alloy. The results of the thermal analysis showed changes in the range of the α-Al solution crystallisation and the α+β eutectic through a decrease in the alloy’s solidification start point and eutectic solidification point. As a result, the elongation of the alloy was more than double in the AlSi10Sn1.7 alloy, with an A5 value of 8.1% and a tensile strength that was above 200 MPa.     

Effect of Initial Temperature on the Microstructure and Properties of Stellite-6/Inconel 718 Functional Gradient Materials Formed by Laser Metal Deposition

Stelite-6/Inconel 718 functionally gradient materials (FGM) is a heat-resisting functional gradient material with excellent strength performance under ultra-high temperatures (650–1100 °C) and, thus, has potential application in aeronautic and aerospace engineering such as engine turbine blade. To investigate the effect of initial temperature on the microstructure and properties of laser metal deposition (LMD) functional gradient material (FGM), this paper uses the LMD technique to form Stelite-6/Inconel 718 FGM at two different initial temperatures: room temperature and preheating (300 °C). Analysis of the internal residual stress distribution, elemental distribution, microstructure, tensile properties, and microhardness of 100% Stelite-6 to 100% Inconel 718 FGM formed at different initial temperatures in a 10% gradient. The experimental results prove that the high initial temperature effectively improves the uneven distribution of internal residual stresses. Preheating slows down the solidification time of the melt pool and facilitates the escape of gases and the homogeneous diffusion of elements in the melt pool. In addition, preheating reduces the bonding area between the gradient layers, enhancing the metallurgical bonding properties between the layers and improving the tensile properties. Compared with Stellite-6/Inconel 718 FGM formed at room temperature, the mean yield strength, mean tensile strength, and mean elongation of Stellite-6/Inconel 718 FGM formed at 300 °C are increased by 65.1 Mpa, 97 MPa, and 5.2%. However, the high initial temperature will affect the hardness of the material. The average hardness of Stellite-6/Inconel 718 FGM formed at 300 °C is 26.9 HV (Vickers hardness) lower than that of Stellite-6/Inconel 718 FGM formed at 20 °C.     

Thermal Expansion and Rattling Behavior of Gd-Filled Co4Sb12 Skutterudite Determined by High-Resolution Synchrotron X-ray Diffraction

In this work, Gd-filled skutterudite Gd_xCo₄Sb₁₂ was prepared using one step method under high pressure in a piston-cylinder-based press at 3.5 GPa and moderate temperature of 800 °C. A detailed structural characterization was performed using synchrotron X-ray diffraction (SXRD), revealing a filling fraction of x = 0.033(2) and an average <Gd–Sb> bond length of 3.3499(3) Å. The lattice thermal expansion accessed via temperature-dependent SXRD led to a precise determination of a Debye temperature of 322(3) K, from the fitting of the unit-cell volume expansion using the second order Grüneisen approximation. This parameter, when evaluated through the mean square displacements of Co and Sb, displayed a value of 265(2) K, meaning that the application of the harmonic Debye theory underestimates the Debye temperature in skutterudites. Regarding the Gd atom, its intrinsic disorder value was ~5× and ~25× higher than those of the Co and Sb, respectively, denoting that Gd has a strong rattling behavior with an Einstein temperature of θE = 67(2) K. As a result, an ultra-low thermal conductivity of 0.89 W/m·K at 773 K was obtained, leading to a thermoelectric efficiency zT of 0.5 at 673 K.     

Microstructure,Tensile Properties,and Fatigue Behavior of Linear Friction-Welded Ti-6Al-2Sn-4Zr-2Mo-0.1Si

This paper presents the microstructural characteristics and mechanical properties of linear friction-welded (LFWed) Ti-6Al-2Sn-4Zr-2Mo-0.1Si (Ti-6242) in as-welded (AWed) and stress relief-annealed (SRAed) conditions. The weld center (WC) of the AWed Ti-6242 consisted of recrystallized prior-β grains with α’ martensite that were tempered during SRA at 800 °C for 2 h and transformed into an acicular α + β microstructure. The peak hardness values, obtained in the AWed joints at the WC, sharply decreased through the thermomechanically affected zones (TMAZs) to the heat-affected zone (HAZ) of the Ti-6242 parent metal (PM). The SRA lowered the peak hardness values at the WC slightly and fully recovered the observed softening in the HAZ. The tensile mechanical properties of the welds in the AWed and SRAed conditions surpassed the minimum requirements in the AMS specifications for the Ti-6242 alloy. Fatigue tests, performed on the SRAed welds, indicated a fatigue limit of 468 MPa at 10⁷ cycles, just slightly higher than that of the Ti-6242 PM (434 MPa). During tensile and fatigue testing, the welds failed in the PM region, which confirms the high mechanical integrity of the joints. Both the tensile and fatigue fracture surfaces exhibited characteristic features of ductile Ti-6242 PM.     

Fabrication of Functionally Graded Diamond/Al Composites by Liquid–Solid Separation Technology

The electronic packaging shell, the necessary material for hermetic packaging of large microelectronic device chips, is made by mechanical processing of a uniform block. However, the property variety requirements at different positions of the shell due to the performance have not been solved. An independently developed liquid–solid separation technology is applied to fabricate the diamond/Al composites with a graded distribution of diamond particles. The diamond content decreases along a gradient from the bottom of the shell, which houses the chips, to the top of the shell wall, which is welded with the cover plate. The bottom of the shell has a thermal conductivity (TC) of 169 W/mK, coefficient of thermal expansion (CTE) of 11.0 × 10⁻⁶/K, bending strength of 88 MPa, and diamond content of 48 vol.%. The top of the shell has a TC of 108 W/mK, CTE of 19.3 × 10⁻⁶/K, bending strength of 175 MPa, and diamond content of 15 vol.%, which solves the special requirements of different parts of the shell and helps to improve the thermal stability of packaging components. Moreover, the interfacial characteristics are also investigated. This work provides a promising approach for the preparation of packaging shells by near-net shape forming.     

Sintering Behavior,Thermal Expansion,and Environmental Impacts Accompanying Materials of the Al2O3/ZrO2 System Fabricated via Slip Casting

This work focuses on research on obtaining and characterizing Al₂O₃/ZrO₂ materials formed via slip casting method. The main emphasis in the research was placed on environmental aspects and those related to the practical use of ceramic materials. The goal was to analyze the environmental loads associated with the manufacturing of Al₂O₃/ZrO₂ composites, as well as to determine the coefficient of thermal expansion of the obtained materials, classified as technical ceramics. This parameter is crucial in terms of their practical applications in high-temperature working conditions, e.g., as parts of industrial machines. The study reports on the four series of Al₂O₃/ZrO₂ materials differing in the volume content of ZrO₂. The sintering process was preceded by thermogravimetric measurements. The fabricated and sintered materials were characterized by dilatometric study, scanning electron microscopy, X-ray diffraction, and stereological analysis. Further, life cycle assessment was supplied. Based on dilatometric tests, it was observed that Al₂O₃/ZrO₂ composites show a higher coefficient of thermal expansion than that resulting from the content of individual phases. The results of the life cycle analysis showed that the environmental loads (carbon footprint) resulting from the acquisition and processing of raw materials necessary for the production of sinters from Al₂O₃ and ZrO₂ are comparable to those associated with the production of plastic products such as polypropylene or polyvinyl chloride.