Search Results (45)

We investigated the morphological patterns, crystalline structures and their thermal stability in solidified Au–Ge nanoparticles ranging in size from 10 to 500 nm. Liquid Au–Ge alloy nanoparticles with hypoeutectic composition were rapidly cooled from a temperature of 500 °C in a TEM and characterized using advanced TEM techniques. We demonstrated that Au–Ge nanoparticles 10–80 nm in size predominantly solidified into a Janus-like morphology with nearly pure single-crystalline hcp Au and diamond cubic Ge domains. These particles remained stable up to the eutectic temperature, indicating that Ge doping and particle size play key roles in stabilizing the hcp Au phase. In turn, larger nanoparticles exhibited a metastable core–shell morphology with polycrystalline Ge shell and hcp Au-Ge alloy core under solidification. It was shown that the mentioned morphology and crystalline structure evolved into the equilibrium Janus morphology with fcc Au and diamond Ge domains at temperatures above ≈160 °C. Full article

The mechanical properties of a final product are directly influenced by the solidification process, chemical composition heterogeneity, and the thermal variables during solidification. This study aims to analyze the influence of solidification thermal variables on the microstructure, hardness, and phase distribution of the CuMn11Al8Fe3Ni3. The alloy was directionally and upward solidified from a temperature of 1250 °C. Heat extraction occurred through a water-cooled AISI 1020 steel interface. The thermal variables were recorded using a data acquisition system, with temperature monitored at seven different positions, where cooling rates varied from 13.03 °C/s at the closest position to 0.23 °C/s at the farthest. The Brinell hardness decreased from 199 HB at the highest cooling rate position to 184 HB at the slowest cooling rate position. This indicates that higher cooling rates increase the hardness of the alloy, which can be attributed to the stabilization of the metastable β phase with refined and equiaxial grains due to iron addition. Vickers microhardness was observed in regions subjected to slower cooling (244 HV) compared to faster cooling regions (222 HV). Therefore, the correlation between solidification thermal variables and alloy properties provides valuable insights into the relationship between microstructure and the properties of the CuMn11Al8Fe3Ni3 alloy. Full article

In this paper, the solidification microstructure characteristics of metastable immiscible Cu20Fe alloys under natural cooling conditions and subsequent cold rolling were analysed. The findings demonstrate that the Cu20Fe alloy underwent a liquid–solid transformation under natural cooling conditions. The equiaxed Cu matrix and the Fe dendrites exhibited elongation into ribbon-like structures parallel to the cold rolling direction. Following cold rolling, the mean grain size of the Cu20Fe alloy was considerably refined, and the mechanical properties were improved. After cold rolling, the Cu matrix formed both {112}<111> copper and {110}<112> brass textures. Furthermore, the strengthening mechanisms of the cold-rolled Cu20Fe alloy are primarily dependent on the strengthening of grain boundaries and work hardening. This provides an economically friendly method for the preparation of Cu-Fe alloys with high Fe compositions. Full article

The properties of the final product obtained by solidification directly result from the thermal variables during solidification. This study aims to analyze the influence of thermal solidification variables on the hardness, microstructure, and phases of the CuAl₆Si₂ alloy. The material was solidified using unidirectional solidification equipment under non-stationary heat flow conditions, where heat extraction is conducted through a water-cooled graphite base. The thermal solidification variables were extracted using a data acquisition system, and temperature was monitored at six different positions, with cooling rates ranging from 217 to 3 °C/min from the nearest to the farthest position from the heat extraction point. An optical microscope, scanning electron microscope (SEM), and X-ray diffraction (XRD) were used to verify the fusion structure and determine the volumetric fraction of the formed phases. The XRD results showed the presence of β phases, α phases, and possible Fe₃Si₂ and Fe₅Si₃ intermetallics with different morphologies and volumetric fractions. Positions with lower cooling rates showed an increased volume fraction of the α phase and possible intermetallics compared to positions with faster cooling. High cooling rates increased the Brinell hardness of the alloy due to the refined and equiaxed β metastable phase, varying from 143 HB to 126 HB for the highest and lowest rates, respectively. Full article

This study delves into the formation, transformation, and impact on coating performance of MgZn₂ and Mg₂Zn₁₁ phases in low-aluminum Zn-Al-Mg alloy coatings, combining thermodynamic simulation calculations with experimental verification methods. A thermodynamic database for the Zn-Al-Mg ternary system was established using the CALPHAD method, and this alloy’s non-equilibrium solidification process was simulated using the Scheil model to predict phase compositions under varying cooling rates and coating thicknesses. The simulation results suggest that the Mg₂Zn₁₁ phase might predominate in coatings under simulated production-line conditions. However, experimental results characterized using XRD phase analysis show that the MgZn₂ phase is the main phase existing in actual coatings, highlighting the complexity of the non-equilibrium solidification process and the decisive effect of experimental conditions on the final phase composition. Further experiments confirmed that cooling rate and coating thickness significantly influence phase composition, with faster cooling and thinner coatings favoring the formation of the metastable phase MgZn₂. Full article

Conventional book casting of Sm₂TM₁₇-type alloys (where TM = Co, Fe, Cu, Zr) leads to a coarse, highly segregated microstructure, predominantly due to the slow, variable cooling rate from the mould surface towards the centre of the ingot. These cast alloys require a long homogenisation treatment to remove this segregation and develop a super-saturated, metastable SmTM₇-type hexagonal phase. This SmTM₇ phase is a vital precursor phase required during magnet production to develop the complex cellular structure responsible for high magnetic properties. In this work, strip casting was employed to facilitate rapid solidification to develop thin flakes (<0.5 mm thick) with a columnar grain structure. Rapid cooling has the potential to produce a homogenous microstructure consisting predominantly of the metastable SmTM₇ phase. This could remove or significantly reduce the need for the energy-intensive homogenisation treatment usually required in conventional magnet manufacture. This paper investigates the effect of wheel speed (and hence cooling rate) on flake thickness, microstructure, and phase balance of the cast alloys. It was shown that for wheel speeds between 1.1 and 3.0 m/s, the microstructure showed large variation; however, in all cases, evidence of the columnar SmTM₇ phase was presented. The adhesion between the melt and the wheel was deemed to be critical for the nucleation and subsequent columnar growth of SmTM₇ grains, where the wheel speed controlled both the flow of the alloy onto the wheel and the thickness of the resultant flake. It was determined that in order to achieve a homogenous columnar SmTM₇ structure, the maximum flake thickness should be limited to 270 μm to avoid the formation of equiaxed Sm₂TM₁₇ grains through insufficient cooling. Full article

Melting, solidification, and viscosity properties of multicomponent Fe-Cu-Nb-Mo-Si-B alloys with low aluminum addition (up to 0.42 at.% Al) were studied using an oscillating cup viscometer. It is shown that melting and solidification are divided into two stages with a knee point at 1461 K. The temperature dependences of the liquid fraction between the liquidus and solidus temperatures during melting and solidification are calculated. It has been proven that aluminum accelerates the processes of melting and solidification and leads to an increase in liquidus and solidus temperatures. In the liquid state at temperatures above 1700 K in an alloy with a low aluminum content, the activation energy of viscous flow increases. This growth was associated with the liquid–liquid structure transition, caused by the formation of large clusters based on the metastable Fe₂₃B₆ phase. Aluminum atoms attract iron and boron atoms and contribute to the formation of clusters based on the Fe₂AlB₂ phase and metastable phases of a higher order. Full article

Rapid solidification techniques, such as gas atomisation, have been widely implemented in metallic alloys/composites to increase solid solubility, avoid or mitigate segregation phenomena, and favour metastable phase formation to enhance performance. Particularly, gas atomisation can enhance the solid solubility of low diffusion coefficient elements like Fe, Ni, Mn, Zr, and Cr in the α-Al matrix, yielding metastable phases. As a result, Al alloys exhibit excellent strength at high temperatures. In this study, the AISI 304L alloy was employed to introduce Fe, Ni, and Cr elements into the AlSi10Mg alloy through gas atomisation, resulting in the formation of two distinct hypereutectic AlFe-based alloys: AlFe9Si8Cr2Ni and AlFe18Si8Cr5Ni2. Gas-atomised alloy powders were separated into different size fractions by sieving and characterised using X-ray diffraction, differential scanning calorimetry, optical microscopy, and scanning electron microscopy. Microstructural analyses revealed dendritic patterns with distinct phases, highlighting the influence of the alloying element content on the solidification processes. Furthermore, a synergic evaluation of the XRD and EDS analysis results allowed the identification of intermetallic phases and their distribution in the two systems. Full article

To promote the use of γ-TiAl alloys in various domains, such as the aerospace industry, it is pivotal to investigate the unusual phase transformation from rapidly solidified and metastable γ-TiAl toward the equilibrium state. In this study, the microstructure characteristics of gas-atomized β-solidifying Ti-44Al-6Nb-1.2Cr alloy powder, in terms of the effect of rapid solidification on microstructure evolution, were explored in comparison with cast materials. The phase constitution, morphology, and crystallographic orientation between phases were noted to be distinct. Furthermore, subsequent heat treatment was conducted at different temperatures using gas-atomized powder. The transition from the metastable to equilibrium state was observed, wherein firstly, the γ phase precipitated from the retained α₂ phase, forming an α₂/γ lamellar microstructure. In intensified heat-treatment conditions adequate for cellular reaction, β/γ cells were formed at the grain boundaries of α₂/γ lamellar colonies. The findings highlight the overall phase transformation during rapid solidification and continuous microstructural evolution from the nonequilibrium to the equilibrium state. This research can bridge the gap in understanding the effect of the solidification rate on microstructural evolution and contribute to enhanced comprehension of the microstructure in other domains involving rapid solidification, such as the additive manufacturing of γ-TiAl alloys. Full article

The paper presents a study of the phase selection and microstructure evolution of Fe₇₅B₂₅ alloy subjected to solidification at various undercoolings. The alloy invariably solidifies into a primary Fe₂B phase and α-Fe/Fe₂B eutectic at all the experimental undercoolings up to 381 K. A metastable Fe₃B phase does not precipitate, although its growth in this alloy is favored without large-scale solute diffusion involved. It is shown that the phase selection is nucleation-controlled. Solid sites existing in the alloy melt seem more favorable for the nucleation of the Fe₂B phase. As undercooling increases, primary the Fe₂B phase changes its morphology complexly. It solidifies into coarse faceted dendrites at low undercoolings, developed non-faceted dendrites at moderate undercoolings, seaweeds with dense branches at higher undercoolings, and refined granular grains at undercooling above 147 K. Full article

The prediction of the equilibrium and metastable morphologies during the solidification of Ni-based superalloys on the mesoscopic scale can be performed using phase-field modeling. In the present paper, we apply the phase-field model to simulate the evolution of solidification microstructures depending on undercooling in a quasi-binary approximation. The results of modeling are compared with experimental data obtained on samples of the alloy Inconel 718 (IN718) processed using the electromagnetic leviatation (EML) technique. The final microstructure, concentration profiles of niobium, and the interface-velocity–undercooling relationship predicted by the phase field modeling are in good agreement with the experimental findings. The simulated microstructures and concentration fields can be used as inputs for the simulation of the precipitation of secondary phases. Full article

The interest in studying the synthesis of an Al–Cr alloy system by non-equilibria processes is due to the formation of metastable or quasicrystalline phases when rapid solidification has been utilized. Similarly, the formation of quasicrystals has been reported to a much lesser extent when the mechanical alloying technique was applied. In the present research, a mixture of powders of Cr and Al (both elements with a purity of 99.99%) with compositions of Al-5 and 7.5 at. % Cr was subjected to a ball milling process. Afterwards, the powder mixture was subjected to a consolidation process, conducted by pressing and sintering processes. The X-ray diffraction analyses revealed that during 20 h of milling there was no formation of metastable or quasicrystalline second phases detected. In addition, the X-ray diffraction peaks revealed that as milling time increased, the nanometric grain size decreased, and once the sintering treatment was applied, the crystallite size decreased following the same tendency. The dislocation density was estimated using the size of nanometric grains; this computation revealed that the dislocation density grew throughout the ball milling process; even after sintering, the multiplication of dislocations prevailed following the same tendency. Full article

The formation of dissimilar weld joints, including Al/Ti joints, is an area of research supported by the need for weight reduction and corrosion resistance in automotive, aircraft, aeronautic, and other industries. Depending on the cooling rates and chemical composition, rapid solidification of Al/Ti alloys during laser welding can lead to the development of different metastable phases and the formation of brittle intermetallic compounds (IMCs). The effort to successfully join aluminum to titanium alloys is associated with demands to minimize the thickness of brittle IMC zones by selecting appropriate welding parameters or applying suitable filler materials. The paper is focused on the numerical simulation of the laser welding–brazing of 2.0 mm thick titanium Grade 2 and EN AW5083 aluminum alloy plates using 5087 aluminum filler wire. The developed simulation model was used to study the impact of laser welding–brazing parameters (laser power, welding speed, and laser beam offset) on the transient temperature fields and weld-pool characteristics. The results of numerical simulations were compared with temperatures measured during the laser welding–brazing of Al/Ti plates using a TruDisk 4002 disk laser, and macrostructural and microstructural analyses, and weld tensile strength measurements, were conducted. The ultimate tensile strength (UTS) of welded–brazed joints increases with an increase in the laser beam offset to the Al side and with an increase in welding speed. The highest UTS values at the level of 220 MPa and 245 MPa were measured for joints produced at a laser power of 1.8 kW along with a welding speed of 30 mm·s⁻¹ and a laser beam offset of 300 μm and 460 μm, respectively. When increasing the laser power to 2 kW, the UTS decreased. The results exhibited that the tensile strength of Al/Ti welded–brazed joints was dependent, regardless of the welding parameters, on the amount of melted Ti Grade 2, which, during rapid solidification, determines the thickness and morphology of the IMC layer. A simple formula was proposed to predict the tensile strength of welded–brazed joints using the computed cross-sectional Ti weld metal area. Full article

The precipitation behavior and mechanical properties for conventionally solidified Al-2.0wt.%Cu-2.0wt.%Mn alloy were studied. The supersaturated aluminum-based solid solution, CuAl₂, Al₆Mn and Al₂₀Cu₂Mn₃ phases of solidification origin were identified after casting. The high temperature ageing of as-cast samples (T5 treatment) in a temperature range of 300–350 °C led to the formation of the metastable θ′ phase and equiaxed precipitates of the quasicrystalline-structured I-phase. The θ′ phase demonstrated a high size stability in a studied temperature range with a mean length of ~300 nm and a mean thickness of ~24 nm. A mean size of the I-phase precipitates varied in a range of ~30–50 nm depending on the treatment regimes. The rod-shaped T-phase precipitates were formed with an increase in ageing temperature to 400 °C. Mechanical properties were analyzed at room temperature in a solid solution-treated state. The increased yield strength at room temperature and 200–300 °C were observed after ageing at 300 °C for 148 h. Full article

In this study, a layered composite material consisting of alternating aluminum and niobium layers and cladded on both sides with titanium plates was obtained by explosive welding. Microstructure of the composite was thoroughly studied using scanning electron microscopy (SEM) and transmission electron microscopy (TEM), as well as by energy dispersive X-ray spectroscopy (EDX) and electron backscattered diffraction (EBSD). Microhardness measurements, tensile test, and impact strength test were carried out to evaluate the mechanical properties of the composite. Formation of mixing zones observed near all interfaces was explained by local melting and subsequent rapid solidification. Mixing zones at Nb/Al interfaces consisted of metastable amorphous and ultrafine crystalline phases, as well as NbAl₃ and Nb₂Al equilibrium phases. Niobium grains near the interface were significantly elongated, while aluminum grains were almost equiaxed. Crystalline grains inside the mixing zones did not have a distinct crystallographic texture. Microhardness of Al/Nb mixing zones was in the range 546–668 HV, which significantly exceeds the microhardness of initial materials. Tensile strength and impact strength of the composite were 535 MPa and 82 J/cm², respectively. These results confirm the high bonding strength between the layers. Full article