Search Results (9)

This study presents the design and microstructural investigation of a single-crystal (SX) Re-bearing high-entropy superalloy (HESA-X1) featuring a thermally stable γ–γ′–γ hierarchical microstructure. The alloy exhibits FCC γ nanoparticles embedded within L1₂-ordered γ′ precipitates, themselves distributed in a γ matrix, with the suppression of detrimental topologically close-packed (TCP) phases. To elucidate solidification behavior and phase stability, Scheil–Gulliver and TC-PRISMA simulations were conducted alongside SEM and XRD analyses. Near-atomic scale analysis in 3D using Atom Probe Tomography (APT) revealed pronounced elemental partitioning, with Re strongly segregating to the γ matrix, while Al and Ti were preferentially enriched in the γ′ phase. Notably, Re demonstrated a unique partitioning behavior compared to conventional superalloys, facilitating the formation and stabilization of γ nanoparticles during two-step aging (Ag-2). These γ nanoparticles significantly contribute to improved mechanical properties. Long-term aging (up to 200 h) at 750–850 °C confirmed exceptional phase stability, with minimal coarsening of γ′ and retention of γ nanoparticles. The coarsening rate constant K of γ′ at 750 °C was significantly lower than that of Re-free HESA, confirming the diffusion-suppressing effect of Re. These findings highlight critical roles of Re in enhancing microstructural stability by reducing atomic mobility, enabling the development of next-generation HESAs with superior thermal and mechanical properties for high-temperature applications. Full article

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. Full article

In this study, the solidified microstructure and phase transition temperatures of Ag_50.5Cu_33.3Sn_16.2-xIn_x (x = 5.0, 6.6, 8.2, 9.1, 9.9, 10.7, 11.5, 12.3; at.%) alloys were investigated using a scanning electron microscope with energy dispersive spectrometer (SEM-EDS) and differential thermal analysis (DTA). The experimental microstructure of Ag_50.5Cu_33.3Sn_16.2-xIn_x alloys demonstrates that the phase fraction of Fcc(Ag) phase increased gradually as the addition of In increased, while the phase fraction of Fcc(Cu) phase decreased. Moreover, the liquidus temperatures of Ag_50.5Cu_33.3Sn_16.2-xIn_x alloys also decrease with increasing In content. In this work, the Ag-Cu-Sn-In quaternary thermodynamic database was ideally extrapolated from the published literature for Ag-Cu-Sn, Ag-Cu-In, Ag-Sn-In and Cu-Sn-In thermodynamic databases. The calculated vertical section of Ag_50.5Cu_33.3Sn_16.2-Ag_50.5Cu_33.3In_16.2 agreed generally with the phase transition temperatures measured in the present experiment. Finally, the solidification behaviors of Ag_50.5Cu_33.3Sn_16.2-xIn_x as-cast alloys were analyzed by thermodynamic calculation of the Scheil–Gulliver non-equilibrium model. The simulated solidification processes of some Ag_50.5Cu_33.3Sn_16.2-xIn_x alloys are, in general, consistent with the experimental results in the present work, which would provide a theoretical basis for the design of novel Ag-Cu-Sn-In brazing alloys. Full article

In this work, the solidification microstructure and phase transitions of Dy-Tb-Fe alloy samples were studied by using scanning electron microscopy with energy dispersive spectroscopy (SEM-EDS), X-ray diffraction (XRD) and differential thermal analysis (DTA). No stable ternary compound was detected in the present experiments. The phase transformation temperatures of eight Dy-Tb-Fe alloy samples were measured. Based on the experimental results determined in this work and reported in the literature, the phase equilibria of the Dy-Tb-Fe system was calculated using the CALPHAD method. The calculated vertical sections are consistent with the experimental results determined in this work and reported in the literature. Furthermore, in combination with the experimental solidification microstructure, the solidification behavior of Dy-Tb-Fe alloy samples was analyzed through the thermodynamic calculation with the Gulliver–Scheil non-equilibrium model. The simulated results agree well with the experimental results. This indicates that the reasonable thermodynamic parameters of the Dy-Tb-Fe system were finally obtained. Full article

In this paper, an efficient design of a Ti-modified Al-Si-Mg-Sr casting alloy with simultaneously enhanced strength and ductility was achieved by integrating computational thermodynamics, machine learning, and key experiments within the Bayesian optimization framework. Firstly, a self-consistent Al-Si-Mg-Sr-Ti quinary thermodynamic database was established by the calculation of phase diagram method and verified by key experiments. Based on the established thermodynamic database, a high-throughput Scheil-Gulliver solidification simulation of the A356-0.005Sr alloy with different Ti contents was carried out to establish the “composition-microstructure” quantitative relationship of the alloy. Then, by combining the computational thermodynamic, machine learning, and experimental data within the Bayesian optimization framework, the relationship “composition/processing-microstructure-properties” of A356-0.005Sr with different Ti contents was constructed and validated by the key experiments. Furthermore, the optimum alloy composition of the Ti-modified A356-0.005Sr casting alloy was designed based on this integration method with the Bayesian optimization framework and verified by the experiments. It is anticipated that the present integration method may serve as a general one for the efficient design of casting alloys, especially in the high-dimensional composition space. Full article

In this paper, we report two cases studies where solidification processes were successfully investigated with CALPHAD-based methodologies. The first one refers to the use of thermodynamic databases to describe the solidification processes of a precious Au-base alloy containing Ir as a grain refiner. The second one concerns the development and use of a quaternary database for Al-Mg-Si-Er alloys for additive manufacturing, where Er is added as a nucleating agent. While in the former case, the solidification process was investigated by running the Thermo-Calc software with a specific TCNOBL1 commercial database, in the latter, the necessary database was first constructed, using available thermodynamic assessments in the literature and experimental data, and then applied to investigate the solidification behavior of selected alloys. Full article

Inconel 738LC (IN738LC) is a nickel-based superalloy specially used in the hot section components of turbine engines. One of its main drawbacks relies on the cracking susceptibility when it is manufactured by laser powder bed fusion (LPBF). This paper analyzes the influence of minor alloying element concentration on cracking tendency of IN738LC superalloy manufactured by LPBF. For that objective, samples were manufactured using two powders, which presented different minor alloying elements concentration (Si, Zr and B). It was shown that the samples crack tendency was very different depending on the powder used for their manufacturing. In fact, the measured crack density value was 2.73 mm/mm² for the samples manufactured with the powder with higher minor alloying elements concentration, while 0.25 mm/mm² for the others. Additionally, a special emphasis has been put on elemental composition characterization in cracked grain boundaries in order to quantify possible Si or Zr enrichment. It has been also studied the differences of solidification ranges and grain structures between both samples as a consequence of different minor alloying elements concentration in order to analyze their effect on crack susceptibility. In this sense, Scheil-Gulliver simulation results have shown that samples with higher Si and Zr contents presented higher solidification range temperature. This fact, as well as an increase of the presence of high angle grain boundaries (HAGB), leaded to an increment in the crack formation during solidification. Therefore, in this research work, an understanding of the factors affecting crack phenomenon in the LPBF manufactured IN738LC was accomplished. Full article

The current study focusses on the phase composition, solidification path, and microstructure evaluation of gravity cast Al-4Mg-0.5Si-xLa aluminum alloy, where x = 0, 0.1, 0.25, 0.5, 0.75, and 1 wt.% La. A computational CalPhaD approach implemented in Thermo-Calc software and scanning electron microscopy technique equipped with electron microprobe analysis (EMPA) was employed to assess its above-mentioned characteristics. The thermodynamic analysis showed that the equilibrium solidification path of La-containing Al-Mg-Si alloys consists of only binary phases LaSi₂ and Mg₂Si precipitation along with α-Al from the liquid and further solid-state transformation of this mixture into α-Al + Al₁₁La₃ + Mg₂Si + Al₃Mg₂ composition. Scheil–Gulliver simulation showed a similar solidification pathway but was accompanied by an increase in the solidification range (from ~55 °C to 210 °C). Furthermore, microstructural observations were congruent with the calculated fraction of phases at 560 °C and related to α-Al + LaSi₂ + Mg₂Si three-phase region in terms of formation of La-rich phase having both eliminating effect on the eutectic Mg₂Si phase. Quantitative EMPA analysis and elemental mapping revealed that the La-rich phase included Al, La, and Si and may be described as Al₂LaSi₂ phase. This phase shows a visible modifying effect on the eutectic Mg₂Si phase, likely due to absorbing on the liquid/solid interface. Full article

The impact of microsegregation models on thermophysical properties and solidification behaviors of a high strength steel was investigated. The examined microsegregation models include the classical equilibrium Lever rule, the extreme non-equilibrium Scheil-Gulliver, as well as other treatments in the intermediate regime proposed by Brody and Flemings, Clyne and Kurz, Kobayashi and Ohnaka. Based on the comparative analyses performed on three representative regions with varied secondary dendrite arm spacing sizes, the classical equilibrium Lever rule and non-equilibrium Scheil scheme were employed to determine the thermophysical features of the studied steel, using the experimentally verified models from literature. The evaluated thermophysical properties include effective thermal conductivity, specific heat capacity and density. The calculated thermophysical data were used for three-dimensional simulation of the casting and solidification process of a 40 metric ton steel ingot, using FEM code Thercast^®. The simulations captured the full filling, the thermo-mechanical phenomena and macro-scale solute transport in the cast ingot. The results demonstrated that Lever rule turned out to be the most reasonable depiction of the physical behavior of steel in study in large-size cast ingot and appropriate for the relevant macrosegregation simulation study. The determination of the model was validated using the experimentally measured top cavity dimension, the thermal profiles on the mold outside surface by means of thermocouples, and the carbon distribution patterns via mass spectrometer analysis. Full article