Search Results (155)

Foundry produces casting products with desired properties suitable for engineering applications. The grain refiners came in handy to improve the melt casting process to achieve these desired properties. Aluminum alloy casting mostly uses Al-Ti-B grain refiners that are commercially available. The study examined the efficiency of Al-Ti-B grain refiners that were sourced from six different commercial suppliers across the globe. This work serves as quality control of sourced commercial grain refiners. It was found that type GR-4 (3:1) refined cast structures more efficiently than all other five tested Al-Ti-B grain refiners on commercial pure aluminum (CPAl). A holding time of 2 to 10 min proved to be the optimum melt holding time. Full article

Aluminum–vanadium (Al–V) master alloy is a key raw material for manufacturing high-end alloys, but the internal temperature transient field during its self-propagating high-temperature synthesis (SHS) is nearly impossible to measure in situ. This work develops a numerical simulation framework for Al–V master alloy SHS, featuring a novel temperature–time dual-criteria adaptive moving heat source and a gas–liquid–solid three-phase heat transfer model coupled with temperature-dependent thermophysical properties. The model, implemented in ANSYS Fluent via a customized user-defined function (UDF), is experimentally validated with a maximum temperature error below 7%. Results reveal that higher compact relative density accelerates combustion wave propagation, while increased slagging agent content exerts an inhibitory effect. This study provides a theoretical and quantitative tool for mechanism analysis and industrial process optimization of Al–V master alloy SHS production. Full article

Magnesium alloys’ poor corrosion resistance limits their applications as biodegradable bone repair materials. Alloying tailors Mg alloys’ microstructure and properties. The present study investigates the effect of 2 wt.% Ag addition on the microstructure and initial corrosion behavior of hot-rolled Mg-1Ca alloy. Mg-1Ca and Mg-1Ca-2Ag alloys were prepared by melting using Mg-2Ca and Mg-4Ag master alloys, followed by homogenization at 400 °C for 2 h, hot rolling, and stress-relief annealing at 400 °C for 6 h. The alloys were systematically characterized using field-emission scanning electron microscopy (FESEM), transmission electron microscopy (TEM), electron backscatter diffraction (EBSD), and X-ray diffraction (XRD). Initial corrosion behavior was evaluated via 3 h immersion tests in simulated body fluid (SBF). Results reveal Ag’s high thermal diffusivity promotes segregation at tensile twin boundaries, forming Ag₃Mg nanoparticles. These nanoparticles hinder grain boundary migration and, with increased deformation, facilitate grain rotation and high-angle grain boundary formation, weakening texture. Internal stress accumulation near twin boundaries—driven by grain orientation variation and nanoparticles—induces ~86° rotation of {10–12} tensile twins around the c-axis, forming double twins. During corrosion, nanoparticles and double twins synergistically promote dense protective film formation, significantly reducing corrosion rates. Full article

Vanadium (V), molybdenum (Mo), iron (Fe), and aluminum (Al) are crucial alloying elements in certain high-performance titanium alloys. Traditionally, these elements are added to titanium alloys in the form of binary master alloys such as V-Al, Mo-Al, and Ti-Fe. The preparation and use of multiple master alloys complicates titanium alloy production and increases cost. It is therefore desirable to introduce a single multi-component master alloy containing several alloying elements into the titanium alloy smelting process. This study proposes an aluminothermic co-reduction process for V₂O₅ and MoO₃ to form a V-Al-Mo-Fe alloy with Al and Fe. Thermodynamic analysis indicates that the reduction of MoO₃ by aluminum takes precedence over that of Fe₂O₃ and V₂O₅. Utilizing metallic iron as the iron source can effectively control the heat release of the system and reduce aluminum consumption. The formation of an Al-Fe alloy prior to the aluminothermic reactions decreases the reducibility of Al. Experiments confirmed that a specific Al/O ratio in the starting materials is necessary to complete the aluminothermic reduction of V₂O₅ and MoO₃. The results show that the recovery rates of V, Mo, and Fe are strongly influenced by the Al/O ratio. When the Al/O ratio exceeds 1.6, recovery rates over 99% can be achieved for all alloying elements, with complete reduction of vanadium oxide and clear slag–alloy separation. This research provides a fundamental basis for preparing V-Al-Mo-Fe multi-component master alloys, demonstrating significant potential for applying the aluminothermic process to the preparation of other alloys. Full article

Hypoeutectic aluminum–silicon casting alloys in their unmodified state have a coarse-grained eutectic (α + β), which results in poor mechanical properties and brittleness. Microstructure refinement and improved mechanical properties are possible, among other things, by introducing various elements and chemical compounds. The literature presents numerous studies on the modification of hypoeutectic silumins, but there are no results confirming the effectiveness of the interaction of a master alloy containing titanium and boron with its main component, which may be aluminum, aluminum with silicon, or aluminum with silicon and magnesium. This paper presents the results of microstructure refinement using titanium or boron introduced into the Al, AlSi7, and AlSi7Mg master alloys. The introduction of titanium and boron into the aluminum-based master alloy resulted in microstructure refinement and improved mechanical properties. The results indicate that the most favorable results were obtained when titanium and boron were introduced into the AlSi7 master alloy. The addition of magnesium to the master alloy AlSi7 resulted in less effective microstructure refinement of the AlSi9 silumin, which resulted in lower mechanical properties than those obtained for the master alloy without Mg. Full article

Cu and Cr are the essential alloying elements for low-Ni stainless steels. An effective and economical method has been developed for the direct production of Cu-Cr-Fe master alloys through the synergistic reduction of chromite and copper smelting slag. The smelting conditions for synergy reduction were systematically investigated by combining thermodynamic calculations and high-temperature experiments. The results indicate that synergistic reduction drives the reactions of Cr₂O₃, FeO, and Cu₂O with carbon in a positive direction, which can increase their recovery and decrease the flux and fuel costs. The optimum slag composition was identified to control the (CaO + MgO)/(SiO₂ + Al₂O₃) ratio between 0.62 and 0.72, where the slag is fully liquid, resulting in an efficient separation of the alloy from the slag. At 1550 °C, with 50 wt% chromite and 50 wt% copper smelting slag as raw materials, a Cu-Cr-Fe alloy containing 5.2 wt% Cu, 28.6 wt% Cr and 57.9 wt% Fe was produced, while the contents of FeO, Cu₂O, and Cr₂O₃ in the final slag were 0.057 wt%, 0.059 wt%, and 0.23 wt%, respectively. Full article

The room-temperature and high-temperature microstructural characteristics and tensile properties of an Al-12Si-4Cu-2Ni-0.5Mg piston alloy modified with calcium (Ca; denoted as AC sample) or phosphorus (P; denoted as AP sample) under different heat treatment conditions were systematically analyzed. Under Ca modification, the second-phase network structure of the alloy was adjusted and strengthened by an Al-TCB master alloy. Eutectic silicon (Si) particles in the AC sample possessed a fibrous structure, whereas the AP sample contained elongated eutectic Si particles, and Ca modification was found to be a potential method for simultaneously enhancing the strength and plasticity of the alloy to a matching degree at high temperatures. The T6 treatment noticeably increased the density of nanoscale precipitates; however, it also disrupted the growth of the second-phase network structure. Micron and submicron C-TiB₂ and Al₄C₃ particles formed by the in-situ reaction of TCB particles acted as bridging phases within the second-phase network structure and enhanced the strength of the piston alloy. The ultimate tensile strength of the alloy at 350 °C increased from 74 to 101 MPa, representing a 36.5% enhancement. A comprehensive analysis revealed that Orowan strengthening was the main strengthening mechanism of the alloy at room temperature, whereas load transfer and network structure strengthening were the dominant strengthening mechanisms at high temperatures. Full article

Titanium (Ti) alloy sheets are important mechanical and structural components. However, thickness deviations may occur during the production of Ti-alloy sheets, significantly compromising product quality and structural safety. Eddy current testing (ECT) is a common method for measuring the thickness deviation of metal sheets. Nevertheless, conventional ECT methods often rely on complex calibration procedures or iterative inversion algorithms, thereby limiting their applicability. It was found that when low-frequency ECT excitation is used, such that the eddy current penetration depth exceeds three times the maximum target thickness of the Ti-alloy sheet, the tangent of the ECT coil impedance phase exhibits a linear relationship with the thickness. Based on this observation, by analyzing the low-frequency ECT response of Ti-alloys and separating the real and imaginary parts of the impedance under approximate conditions, a phase feature model was developed. The model effectively describes the linear dependence of the phase tangent on the thickness of the Ti-alloy sheet, offering a succinct characterization. The measurement method based on this model thereby allows for direct thickness calculation from the measured coil impedance without requiring master-curve calibration or iterative computation. Experiments were conducted using a custom-designed ECT coil and impedance analyzer to measure different Ti-alloy specimens. The results indicate that the measurement error was less than 3.5%. This research provides a theoretical foundation as well as a straightforward engineering solution for online, high-speed thickness measurement of Ti-alloy sheets. Full article

This study reported the development of a novel Al-Si-Mg-based composite reinforced by micron-sized Cu-Mn binary solid solution phases and submicron-sized α-Al(Mn,Fe)Si dispersoids. The Cu-Mn binary solid solution phases were added to the melt in the form of an Al-3%CuMn master alloy, whereas α-Al(Mn,Fe)Si dispersoids were obtained via heat treatment. The microstructure analysis confirmed the presence of micron-sized Cu-Mn binary, eutectic Mg₂Si, and Al₁₅(FeMn)₃Si₂ intermetallic phases, submicron-sized α-Al(Mn,Fe)Si dispersoids, and nano-sized precipitates in the Al-based composite. At room temperature, tensile results represented a yield strength of 287 MPa and a tensile strength of 306 MPa, with an elongation of 17%. Moreover, the Al-based composite maintained a yield strength of 277 MPa up to 250 °C, with a slight increase in elongation. The composite also exhibited excellent high-temperature high-cycle fatigue properties and showed a high-cycle fatigue limit of 140 MPa at 130 °C, which is ~2.3 times higher than that of the commercial A319 alloy. A fractography study revealed that the secondary particles hindered the movement of dislocations, thus delaying crack initiation under cyclic loading at high temperatures. Additionally, Cu-Mn binary solid solutions and Al₁₅(FeMn)₃Si₂ phases were found to be effective in reducing the crack propagation rate by hindering the movement of the propagated crack. Full article

The fracture toughness of nuclear reactor pressure vessel (RPV) steel is an important basis for the structural integrity evaluation of equipment. SA508 Gr.4N (Cr–Ni–Mo) low-alloy steel has attracted people’s attention because of its excellent strength and toughness, and it is considered as a candidate material for the next generation of RPV. The fracture toughness of SA508 Gr.4N alloy steel was analyzed from the perspective of macroscopic mechanical properties and microstructure, and compared with that of the SA508 Gr.3 (Mn–Ni–Mo) steel used in commercial PWR nuclear power plants. SA508 Gr.4N steel showed better toughness reserve than SA508 Gr.3 steel in terms of fracture toughness parameters such as the reference nil-ductility transition temperature RT_NDT, brittleness transition characteristic temperature T_41J, upper shelf energy and master curve reference temperature T₀. The reasons for the excellent fracture toughness of SA508 Gr.4N steel were analyzed from the aspects of microstructure, precipitation and grain boundary structure. Full article

Vanadium (V), molybdenum (Mo), and aluminum (Al) are important alloying elements in titanium alloys, typically introduced through master alloys such as V-Al and Mo-Al. Current preparation of these master alloys predominantly relies on the spontaneous reduction of V₂O₅ or MoO₃ by aluminum. However, separate production and addition of master alloys increase the cost of the titanium alloy. Insufficient understanding of the exothermic behavior and slag-forming process during the aluminothermic reaction often leads to low alloy yield and elevated impurity levels due to splashing and poor alloy–slag separation. This study focused on the controllable aluminothermic reaction of V₂O₅ and MoO₃ to produce high-quality and high-yield V/Al/Mo alloy. Thermodynamic calculations indicate that the reduction of MoO₃ to Mo by aluminum is more favorable than the reduction of V₂O₅ to V. Al% in the V-Al-Mo alloy is crucial for controlling reaction temperature. When the Al/O ratio in the raw materials exceeds 1.0, increasing aluminum reduces both the reaction exothermicity and theoretical reaction temperature. A combination of thermodynamic calculations and high-temperature experiments demonstrates that the heat generation and slag composition can be effectively controlled by Al/O ratio in raw materials. When the Al/O ratio in raw materials is 1.6–2.0, the yields of Mo and V exceed 99% and 95%, respectively. This study provides an effective approach to producing V/Al/Mo alloy under controllable conditions, which shows great potential for other aluminothermic reactions. Extensive solid solutions of V/Al/Mo also provide invaluable data for the optimization of the alloy database. Full article

One of the most effective methods of improving the properties of aluminium alloys is grain refining using Al-Ti-B master alloys. In contrast, zirconium is a key alloying element, used mainly in 2xxx and 7xxx series aluminium alloys, where it contributes to dispersion enhancement and reduces the rate of dynamic recrystallisation. However, even trace amounts of zirconium—just a few hundredths of ppm—significantly reduce the performance of Al-Ti-B grain refiners, a phenomenon known as ‘Zr poisoning’. This study investigates the impact of holding time and the level of Al-5Ti-1B addition on the microstructure and properties of an AlMgSi(Cu) alloy containing 0.15 wt.% Zr, cast as 7-inch DC billets. The structure and phase distribution were characterised using optical microscopy (OM), scanning electron microscopy (SEM) with energy-dispersive spectroscopy (EDS), and transmission electron microscopy (TEM). Grain size and morphology were evaluated through macrostructure analysis (etched cross-sections and polarised light microscopy), while chemical and elemental distributions were analysed via SEM-EDS and STEM-EDS mapping. Additionally, Brinell hardness measurements were conducted across the billet diameter to assess the correlation between grain size and mechanical properties. The results show that reducing holding time and increasing the Al-5Ti-1B addition improves grain refinement efficiency despite the presence of Zr. The finest grain structure (150–170 μm) and most homogeneous hardness distribution were achieved when the grain refiner was continuously fed during casting at 80 ppm B. These findings are supported by the literature and contribute to a deeper understanding of the Zr poisoning effect and its mitigation through optimized casting practice. Full article

This study systematically investigates the influence of grain refinement on the microstructural evolution and mechanical properties of recycled Al-7Si-0.3Mg-1Fe alloy through the addition of varying concentrations (0–1.25 wt.%) of Al-5Ti-2B master alloy. The synergistic effects of Al-5Ti-2B on the α-Al phase, eutectic Si, and Fe-rich intermetallics were characterized using metallographic analysis, XRD, SEM-BSE imaging, and EDS. In the unrefined alloy, the microstructure consisted of an α-Al solid solution with coarse plate-like eutectic Si, while Fe primarily formed needle-like β-Al₅FeSi phases that either surrounded or penetrated the eutectic Si. Increasing the Al-5Ti-2B addition refined both the α-Al dendrites and eutectic Si, while the β-Al₅FeSi phase transitioned from coarse to fine needles. The optimal refinement was achieved at a 1% Al-5Ti-2B addition, yielding a tensile strength of 149.4 MPa and elongation of 4.3%. However, excessive addition (1.25%) led to eutectic Si aggregation and β-Al₅FeSi coarsening, resulting in mechanical property deterioration and brittle fracture behavior. These findings provide insights into optimizing grain refinement for enhancing the performance of recycled Al-Si-Mg-Fe alloys. Full article

Secondary Al-Si alloys typically encompass several impurities that substantially influence the materials’ microstructure and mechanical performance. This study employed a composite addition of chlorinated salt fluxing and an aluminum–boron master alloy to reduce the levels of the impurity elements magnesium (Mg), titanium (Ti), and vanadium (V) in secondary Al-Si alloys. The investigation of the performance mechanism revealed that the distribution of alloys’ grain orientation and the ratio of small-angle grain boundaries were modified via synergistic purification, leading to the refined microstructure and mechanical performance of secondary Al-Si alloys. The removal rates of impurity elements under these optimal refining conditions were 89.9% for Mg, 68.9% for Ti, and 61.5% for V. The refined alloy exhibited a 45.5% decrease in grain size and a 28.7% improvement in tensile strength compared to the raw material. These findings demonstrate that fluxing can improve the extraction of Ti and V from secondary Al-Si alloy melts of aluminum–boron master alloys, providing a new cost-effective strategy for the removal of impurities and the optimization of the properties of secondary Al-Si alloys. Full article

Commercially pure aluminum (Al) was refined through the addition of the Al-5Ti-0.25C master alloy, resulting in the formation of Al₃Ti and TiC phases, which serve as refining agents. Open-cell metallic foams were successfully produced using the replication casting technique, with pore sizes ranging from 1.00 to 3.35 mm. For the infiltration process, refined aluminum was used, while unrefined aluminum served as a baseline reference. The resultant foams underwent multiple annealing cycles at 480 °C, with the most refined and homogeneous microstructure observed after 504 h. Comprehensive microstructural characterization was conducted utilizing scanning electron microscopy and optical microscopy. Additionally, uniaxial compression tests were performed to generate stress–strain profiles for the foams, facilitating an assessment of their energy absorption capacity. The findings indicated an enhancement in energy absorption capacity by a factor of 2.4 to 3, which can be attributed to the incorporation of Al-5Ti-0.25C and the subsequent annealing process. Full article