Casting Alloy Design and Characterization—2nd Edition

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: 25 June 2025 | Viewed by 6151

Special Issue Editors


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Guest Editor
School of Technology, Pontifícia Universidade Católica do Rio Grande do Sul, Porto Alegre 90619-900, Brazil
Interests: materials science and engineering; solidification; material testing; wear; manufacturing processes
Special Issues, Collections and Topics in MDPI journals

E-Mail Website
Guest Editor
School of Technology, Pontifícia Universidade Católica do Rio Grande do Sul, Porto Alegre 90619-900, Brazil
Interests: materials science and engineering; solidification; material testing; corrosion sciences; microscopy
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

Metal casting processes normally used in the foundry industry (e.g., gravity or pressure casting) are subjected to a wide range of operational parameters. Consequently, a variety of solidification microstructures are formed, directly affecting mechanical, physical and chemical properties, strength–ductility response, corrosion and wear resistance, electrical conductivity, and others. In general, aspects such as the phase and microconstituents present, grain size, macrostructure morphology, porosity, and alloying segregation are responsible for defining the main properties of the final casting. Since there is a close correlation between solidification conditions, microstructure and properties, the effects of solidification conditions and alloying elements on microstructure design and the resulting properties in cast alloys have stimulated new research interest. In addition, it is fundamental to understand the influence of these characteristics on subsequent manufacturing processes such as heat treatment, forming, welding and machining.

The possibility of replacing wrought alloys with cast alloys, with associated cost reduction and improved mechanical properties, has motivated the modern industry to design new alloys by adding new elements or by using additive manufacturing techniques. Thus, this Special Issue aims to collect research articles focused on the design and characterization of cast alloys, especially on the interrelationship between solidification, microstructure and properties; both experimental and theoretical research is welcome.

The scope of the Special Issue includes, but is not limited to, the following technical topics:

  • Casting processes and novel techniques;
  • Solidification: experimental and theoretical studies;
  • Microstructure and property characterization;
  • Numerical and analytical simulations;
  • Heat and mass transfer;
  • Processing-structure-property relations;
  • Industrial applications.

Dr. Carlos Alexandre Dos Santos
Dr. Eleani Maria Da Costa
Guest Editors

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • casting
  • solidification
  • microstructures
  • properties
  • characterization
  • casting design

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Related Special Issue

Published Papers (4 papers)

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Research

17 pages, 13990 KiB  
Article
Physical Model of Liquid Steel Jets Impacting on Solid-Rigid Surfaces
by Octavio Flores Jazmín, Jafeth Rodriguez, Jesus Fernando Martinez Villafañe, Rodolfo Morales Davila, Javier Guarneros and Alfonso Nájera-Bastida
Metals 2025, 15(4), 339; https://doi.org/10.3390/met15040339 - 21 Mar 2025
Viewed by 249
Abstract
The study analyzes the splash dynamics of liquid steel jets impacting solid surfaces, using a physical model with scaled-down water experiments. Two turbulence inhibitor designs are compared, focusing on droplet formation and distribution. The interaction of the jet with the inhibitors influences droplet [...] Read more.
The study analyzes the splash dynamics of liquid steel jets impacting solid surfaces, using a physical model with scaled-down water experiments. Two turbulence inhibitor designs are compared, focusing on droplet formation and distribution. The interaction of the jet with the inhibitors influences droplet generation and dispersion, impacting the safety and quality of the continuous casting process. Key parameters such as the Weber number and surface tension are identified as factors affecting the stability of liquid films. Finally, similarities between splash dynamics in water and steel are highlighted. Full article
(This article belongs to the Special Issue Casting Alloy Design and Characterization—2nd Edition)
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10 pages, 2335 KiB  
Article
Microstructure Formation and Dry Reciprocating Sliding Wear Response of High-Entropy Hypereutectic White Cast Irons
by Willian Martins Pasini, Wojciech Polkowski, Tomasz Dudziak, Carlos Alexandre dos Santos and Vinicius Karlinski de Barcellos
Metals 2025, 15(1), 4; https://doi.org/10.3390/met15010004 - 26 Dec 2024
Viewed by 620
Abstract
White cast irons (WCI) are widely used in industries requiring high wear resistance due to their microstructure consisting of hard carbides dispersed within a metallic matrix. This study focuses on developing wear-resistant multi-component hypereutectic high chromium cast irons, merging concepts of high entropy [...] Read more.
White cast irons (WCI) are widely used in industries requiring high wear resistance due to their microstructure consisting of hard carbides dispersed within a metallic matrix. This study focuses on developing wear-resistant multi-component hypereutectic high chromium cast irons, merging concepts of high entropy alloys with the conventional metallurgy of white cast irons, specifically exploring the influence of carbide-forming elements such as V, Mo, and Ni on solidification behavior, microstructure, and wear performance. The research investigates the solidification process of the alloys using Computer-Aided Cooling Curve Analysis (CA-CCA) and characterizes the microstructures through X-ray diffraction (XRD) and scanning electron microscopy (SEM). The wear behavior of the developed alloys is evaluated through reciprocating sliding wear tests, revealing the impact of varying chemical compositions on wear resistance. The results demonstrate that high-entropy white cast iron (HEWCI), particularly those enriched with carbide-forming elements, exhibit superior abrasion resistance compared to conventional high-chromium cast irons. The alloy with 2 Mo and 4 V content showed the best performance, presenting the lowest wear rate (61.5% lower than HCCI alloy) and CoF (values ranging from 0.20 to 0.22) due to the highest concentration of V carbides. Full article
(This article belongs to the Special Issue Casting Alloy Design and Characterization—2nd Edition)
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13 pages, 3533 KiB  
Article
Nodular Graphite Dissolution and Nucleus Observation: High-Temperature Dynamics of Ductile Iron Recycling
by I. Adhiwiguna, N. Nobakht and R. Deike
Metals 2024, 14(8), 915; https://doi.org/10.3390/met14080915 - 13 Aug 2024
Cited by 3 | Viewed by 2864
Abstract
This investigation examines the dynamic behavior of the nodular graphite structure in ductile cast iron at elevated temperatures during the recycling process. It comprises a systematic analysis of the impact of high temperature on the change in chemical composition, followed by a set [...] Read more.
This investigation examines the dynamic behavior of the nodular graphite structure in ductile cast iron at elevated temperatures during the recycling process. It comprises a systematic analysis of the impact of high temperature on the change in chemical composition, followed by a set of examinations of the nodular graphite structure dissolution mechanism at the early phase of the remelting process. The results indicate that prolonged holding at higher temperatures affects the carbon or silicon concentration due to oxidation, which correlates with the operating temperature and the dynamic concentration proportion of those two main alloying elements. It is also substantiated that the dissolution of nodular graphite, the only carbon source during the ductile cast iron remelting process, does not occur primarily in the liquid state but has already started during the solid phase because of austenitization. This dissolution is governed mainly by a surface reaction, as indicated by the residual graphite structure with preserved nonmetallic nuclei. Hence, this approach also provides an alternative method for observing the nodular graphite core by intentionally partially dissolving the graphite structure. Full article
(This article belongs to the Special Issue Casting Alloy Design and Characterization—2nd Edition)
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15 pages, 3642 KiB  
Article
Effect of Annealing after Casting and Cold Rolling on Microstructure and Electrochemical Behavior of High-Entropy Alloy, Cantor
by Jinsurang Lim, Byung-Hyun Shin, Doo-In Kim, Jong-Seong Bae, Jung-Woo Ok, Seongjun Kim, Jinyong Park, Je In Lee and Jang-Hee Yoon
Metals 2024, 14(8), 846; https://doi.org/10.3390/met14080846 - 24 Jul 2024
Cited by 3 | Viewed by 1703
Abstract
High-entropy alloys (HEAs), a relatively new class of materials, have attracted significant attention in materials science owing to their unique properties and potential applications. High entropy stabilizes the phase of a solid solution over a wide range of chemical compositions, yielding unique properties [...] Read more.
High-entropy alloys (HEAs), a relatively new class of materials, have attracted significant attention in materials science owing to their unique properties and potential applications. High entropy stabilizes the phase of a solid solution over a wide range of chemical compositions, yielding unique properties superior to those of conventional alloys. Therefore, this study analyzed the microstructure and electrochemical behavior of HEAs (Cantor) to evaluate their corrosion resistance, according to their manufacturing process (casting, cold rolling, and annealing). The microstructural morphologies and sizes were analyzed using electron backscatter diffraction. The electrochemical behavior was examined using open circuit potential measurements, electrochemical impedance spectroscopy, potentiodynamic polarization tests, and critical pitting temperature measurements using a potentiostat. The casting process formed a nonuniform microstructure (average grain size = 19 μm). The cold rolling process caused the formation of fine grains (size = 4 μm). A uniform microstructure (grain size > 151 μm) was formed after heat treatment. The corrosion resistance of the HEAs was determined from the passivation layer formed by Cr oxidation. These microstructural differences resulted in variations in the electrochemical behavior. Microstructural and electrochemical analyses are crucial because HEAs have diverse potential applications. Therefore, this study contributes to future improvements in HEA manufacturing processes. Full article
(This article belongs to the Special Issue Casting Alloy Design and Characterization—2nd Edition)
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