Search Results (91)

In Al–Fe alloys, the mechanical properties are determined by the morphology of iron-rich phases. In this work, AA8176(Al-1Fe)-nY (n = 0, 0.3, 0.5, 0.7, and 0.9 wt.%) alloys were prepared by the cast method. The effects of yttrium (Y) addition on the microstructure and mechanical properties of AA8176 alloy were studied using various techniques including optical microscopy (OM), scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), cooling curve analysis and tensile tests. The results revealed that the optimal refinement effect was achieved when the amount of Y content was 0.5 wt.%. When the Y content increased from 0 to 0.5 wt.%, the coarse needle-like Al₁₃Fe₄ phases were gradually transformed into short rod-like morphology and some fine Al₁₀Fe₂Y phases were formed around the Al₁₃Fe₄ phases. The average length of iron-rich phases was decreased from 10.01 μm to 2.65 μm. Additionally, as the Y content increased from 0 to 0.5 wt.%, the secondary dendrite arm spacing (SDAS) of AA8176 alloy was reduced from 31.33 μm to 20.24 μm. Furthermore, the mechanical properties of the AA8176 alloy were improved due to the modified microstructure. With the addition of 0.5 wt.% Y, the ultimate tensile strength, yield strength, elongation, and Vickers hardness were improved to 96.86 MPa, 57.21 MPa, 23.1%, and 30.55 HV, respectively, compared to 84.47 MPa, 50.71 MPa, 18.6%, and 27.28 HV for the unmodified AA8176 alloy. It is proposed that the growth of α-Al dendrite and Al₁₃Fe₄ phases were effectively inhibited by segregation of Y atoms around α-Al dendrite and Al₁₃Fe₄ phases during solidification. And the Al₁₀Fe₂Y phases were formed by these Y atoms with Al and Fe elements. However, the formation of coarse Al₁₀Fe₂Y phases was promoted by excessive Y content, resulting in a substantial degradation in mechanical properties. Full article

This study investigates the presence and distribution of second phases in continuous rheo-extrusion (CRE)-processed Al-La-Ti-B grain refiners and their effect on refining A356 Al-Si alloy. Thermodynamic calculations and microstructural characterization revealed that the main second phases include α-Al, TiAl₃, TiB₂, Al₁₁La₃, LaB₆, and Ti₂AL₂₀La, with their types evolving with varying Ti/La ratios. The CRE process effectively refined and homogenized these phases. Among the tested refiners, the addition of 0.2 wt.% Al-2.5La-1Ti-1B showed the most effective refinement for A356 alloy, achieving the smallest average α-Al grain size of 221 μm and secondary dendrite arm spacing (SDAS) of 24.62 μm. This optimal refinement corresponded to superior mechanical properties: a tensile strength of 164.52 MPa and elongation of 9.0% in the as-cast state, which were further improved to be 261.13 MPa after T6 heat treatment with elongation of 5.5%. The enhancement is attributed to La’s dual role in modifying the morphology and distribution of TiB₂ and TiAl₃ phases and acting as a surface-active element to reduce nucleation work, thereby promoting heterogeneous nucleation. This work demonstrates that the CRE process is an effective route to fabricate high-performance La-bearing refiners with engineered microstructures and reveals that optimizing the Ti/La ratio is critical for maximizing grain refinement and mechanical performance in Al-Si alloys. Full article

In this study, a small core diameter single mode fiber laser was applied to weld an 8 mm thick plate of 6061-T6 aluminum alloy. The microstructural evolution and mechanical properties of the laser welded aluminum alloy specimens were investigated in detail. The results indicated that fully penetrated welded specimens, free of welding defects like porosity, melt sagging, and hot cracking could be achieved by optimizing the processing parameters through response surface methodology. The upper part of the fusion zone consisted mainly of fine equiaxed dendrites, with secondary dendrite arm spacing (SDAS) of approximately 3–5 μm. While the lower region of the fusion zone exhibited pronounced microstructural coarsening, made up mostly of coarse columnar grains, along with some localized equiaxed grains, and an SDAS ranging from 8 to 12 μm. Both the fusion zone and heat affected zone (HAZ) were characterized by a “softened” hardness profile. The fusion zone featured a narrow region with the lowest microhardness across the welded joint with the microhardness value reducing to ~72% of the base metal (BM). Meanwhile, the microhardness of the HAZ was ~87.4% of the BM. The ultimate tensile strength of laser welded specimens was ~243.6 MPa, amounting to approximately 78.3% of the base metal. This study provides a fresh approach for welding medium-thick aluminum alloy plate using a high-quality laser beam, even at the kilowatt level with a fiber laser, and it shows a strong promise for applications in light-alloy manufacturing sectors such as automotive, rail transportation, aerospace, and beyond. Full article

This study addresses the issues of coarse primary austenite dendrites and uneven graphite distribution in hypoeutectic gray cast iron. High-energy mechanical activation technology was used to prepare high-energy activated SiC particles (EASiCp), and the regulatory mechanisms of trace additions (0–0.15 wt.%) on the solidification process and microstructure properties of hypoeutectic gray cast iron were systematically investigated. The results indicate that high-energy activation treatment reduced the average particle size of SiC particles from 26.53 μm to 9.51 μm and increased their specific surface area from 0.35 m²/g to 1.78 m²/g. X-ray diffraction (XRD) analysis revealed that the grain size was refined from 55.5 nm to 17.4 nm, with significant lattice distortion. The absorption rate of EASiCp in the melt stabilized between 68–72%, with particles predominantly dispersed within the grains (78.12%) and at grain boundaries (21.88%) in sizes ranging from 0.3 to 2 μm. The addition of EASiCp enhanced the solidification undercooling from 5.3 °C to 8.4 °C and reduced the latent heat of crystallization from 162.6 J/g to 99.96 J/g due to its endothermic reaction in the melt (SiC + Fe → FeSi + C) and heterogeneous nucleation effects. In terms of microstructure, the addition of 0.15 wt.% EASiCp increased the primary austenite dendrite content by 35.29%, reduced the secondary dendrite arm spacing by 57.98%, shortened the graphite length from 0.46 mm to 0.20 mm, and refined the eutectic colony size from over 500 μm to 180 μm. The final material achieved a tensile strength of 308 MPa, an improvement of 12.82% compared to the unadded group. Mechanistic analysis showed that EASiCp facilitated direct nucleation, reaction-induced “micro-area carbon enrichment,” and a synergistic effect in suppressing grain growth, thereby optimizing the solidification microstructure and enhancing performance. This study provides a new method for the efficient nucleation control of hypoeutectic gray cast iron. Full article

Although low-silicon Al-Si alloys have been extensively studied, further improvement in their mechanical performance remains a critical challenge. This study examines the synergistic effects of scandium (Sc) and zirconium (Zr) additions on the solidification behavior, microstructural evolution, and mechanical properties of Al-5Si-Cu-Mg alloys. The Sc/Zr additions refine the α-Al grains and modify the eutectic Si morphology, with the most uniform microstructure obtained at 0.5 wt.% due to the formation of coherent Al₃(Sc,Zr) dispersoids. These additions also suppress the formation of needle-like β-Al₅FeSi phases and promote the transformation to compact α-Al₁₅(Fe,Mn)₃(Si,Zr,Sc)₂ intermetallics, optimizing the solidification process. The yield strength increases with Sc/Zr content owing to grain-boundary and precipitation strengthening. However, the alloy without Sc/Zr exhibits the highest ultimate tensile strength and elongation, likely due to its finer secondary dendrite arm spacing and the absence of casting-induced cracks in this investigation. Although Sc/Zr additions of 0.25–0.5 wt.% contribute to microstructural refinement, the concurrent formation of porosity and coarse intermetallic compounds leads to a deterioration in ductility. Excessive Sc/Zr additions further coarsen grains and degrade the overall mechanical integrity. Full article

Effective thermal management is essential in metal additive manufacturing to ensure process stability and desirable material properties. Directed energy deposition using a laser beam and wire (DED-LB/w) enables the production of large, high-performance components but remains sensitive to adverse thermal effects during multi-layer deposition due to heat accumulation. While prior studies have investigated interlayer temperature control and substrate preheating in DED modalities, including laser-powder and arc-based systems, the influence of substrate preheating in DED-LB/w has not been thoroughly examined. This study employs substrate preheating to simulate heat accumulation and assess its effects on melt pool geometry, wire–melt pool interaction, and the microstructural evolution of Alloy 718. Experimental results demonstrate that increased substrate temperatures lead to a gradual expansion of the melt pool, with a notable transition occurring beyond 400 °C. Microstructural analysis reveals that elevated preheat temperatures promote coarser secondary dendrite arm spacing and the development of wider columnar grains. Moreover, Nb-rich secondary phases, including the Laves phase, exhibit increased size but relatively unchanged area fractions. Observations from electrical conductance measurements and coaxial visual imaging show that preheat temperature significantly affects the process dynamics and microstructural evolution, providing a basis for advanced process control strategies. Full article

The suspension arm is a crucial connecting component in the automotive powertrain system, required to withstand various working condition loads, thus necessitating high mechanical performance. With the continuous development of forming processes, the forming method of suspension arms has gradually shifted from traditional gravity casting to squeeze casting. Along with the demand for automotive lightweighting, there is an urgent need for lightweight requirements in suspension arm components. This study employs a multi-condition topology optimization method, incorporating the forming requirements of the squeeze casting process, to conduct lightweight design of a certain mounting bracket. The filling and solidification processes were numerically simulated using Anycasting, followed by mechanical property testing and microstructure analysis of the product. The results revealed that the topology-optimized suspension arm met the strength and stiffness requirements under all working conditions, with a mass reduction of approximately 54.7% compared to the pre-optimized version. Based on the forming process analysis of the suspension arm, the design of its squeeze casting mold was completed. Using AnyCasting software (AnyCasting 6.7), numerical simulations of the filling and solidification processes of the suspension arm were conducted. Combined with theoretical calculations, the forming process parameters for the suspension arm were finally determined as follows: extrusion speed of 15 cm/s-10 cm/s-5 cm/s (multi-stage speed), pouring temperature of 690 °C, mold temperature of 250 °C, extrusion pressure of 81.4 MPa, and holding time of 45 s. Through T6 heat treatment, the tensile strength, yield strength, and elongation after fracture of the suspension arm reached 326.05 MPa, 276.87 MPa, and 9.68%, respectively. Metallographic analysis showed that the eutectic silicon in the T6 heat-treated specimens was primarily spherical in shape, uniformly distributed without significant clustering. The reason for this difference may be that heat treatment affects the boundary dissolution degree of alloying elements. For eutectic Al-Si alloys, the boundary dissolution and diffusion of alloying elements are accelerated, which is beneficial for improving the mechanical properties of the alloy. Finally, in order to quantitatively analyze the microstructural properties of the material after heat treatment, analyses of secondary dendrite arm spacing and porosity were conducted, leading to the conclusion that the microstructure after heat treatment is more uniform and dense. Full article

AlMg5Si2Mn alloys are widely used in the field of automotive castings. Since the morphology, size, and distribution of the primary Al dendrite and eutectic Mg₂Si have a decisive influence on the mechanical properties of the alloy, a comprehensive analysis of AlMg5Si2Mn alloys with varying Y contents was conducted using optical microscopy (OM), X-ray diffraction (XRD), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The influence of Y on the microstructural evolution and mechanical behavior of the cast hypoeutectic AlMg5Si2Mn alloy was studied. Experimental findings indicate that the addition of Y significantly refines and alters the morphology of both primary Al and eutectic Mg₂Si in AlMg5Si2Mn alloys. Specifically, in the alloy containing 0.45 wt.% Y, the primary Al undergoes a structural transformation from a coarse dendritic morphology to finer ellipsoidal grains, with a minimum secondary dendritic arm spacing (SDAS) of 18.6 ± 1.6 μm. Simultaneously, the eutectic Mg₂Si morphology transitions from a coarse lamellar structure to finer worm-like, coral-like, and fibrous forms, exhibiting a reduced average length and aspect ratio (AR) of 3.1 ± 0.4. Furthermore, the AlMg5Si2Mn alloy leads to significant improvements in mechanical performance, particularly in tensile strength. The measured average ultimate tensile strength, yield strength, and elongation are 243.3 MPa, 199.0 MPa, and 8.5%, respectively, representing increases of 19.16%, 24.6%, and 203.6% compared to the Y-free alloy. The fracture mode of the alloy fracture transitioned from brittle fracture in its unmodified condition to ductile fracture characteristics. Full article

The phase composition and morphological characteristics of eutectic carbides are key factors affecting the wear resistance and fatigue life of high-speed steel. In this study, a combination of experimental characterization and thermodynamic calculations was used to systematically reveal the dynamic regulation mechanism of cooling rate on eutectic carbides in M2Al high-speed steel. The results indicate that within a cooling rate range of 5 to 225 °C/min, the steel always contains a small amount of face-centered cubic-structured MC-type eutectic carbides and a large number of hexagonal close-packed structured M₂C-type eutectic carbides. The three-dimensional morphology of MC-type eutectic carbides is smooth and rod-like, and is insensitive to the cooling rate, while the three-dimensional morphology of M₂C-type eutectic carbides evolves from lamellar to dendritic with an increasing cooling rate. The increase in cooling rate significantly reduces the average size of eutectic carbides, increases the total area fraction, and improves the distribution uniformity. Additionally, the increase in cooling rate also promotes the significant refinement of secondary dendrites in M2Al high-speed steel, and the relationship between secondary dendrite arm spacing and cooling rate is ${\lambda }_{SDAS}=149.42\cdot {C_R}^{-0.39}$. Finally, combining thermodynamic calculations with kinetic analysis, this study found that the formation of eutectic carbides is dominated by the segregation of elements such as V, Mo, and C during the final stage of solidification, while the chemical composition and three-dimensional morphological evolution of M₂C-type eutectic carbides are synergistically controlled by the diffusion and competitive growth of elements such as W, Mo, and C in austenite. This study provides a theoretical basis for the solidification process and eutectic carbide control of M2Al high-speed steel. Full article

To address the issue that the insufficient surface hardness and wear resistance of ductile iron under harsh working conditions are likely to lead to early failure, using a cladding layer with dual hard phases is an effective method to improve the surface properties. However, the issue that a large amount of hard phases decompose under the action of a high-energy laser to generate brittle phases in the microstructure is quite troublesome. Therefore, by adding CeO₂ to the cladding layer, a TiC/WC/Co composite cladding layer containing CeO₂ is prepared on the substrate by means of a fiber laser. Through OM, SEM-EDS, XRD, and Rockwell hardness tests, the effects of the CeO₂ content on the microstructure, phase composition, and hardness of the coating were studied to determine the optimal addition amount. The results show that the secondary dendrite arm spacing (SDAS) of the γ-Co phase and the sizes of TiWC₂ and WC dendrites exhibit a non-monotonic trend of first decreasing and then increasing with the increase in the CeO₂ content, and the morphology of TiWC₂ evolves from a cross shape to a granular shape and then to a dendritic shape. When the CeO₂ content is 2 wt.%, the WC dendrites are completely inhibited, and the SDAS of γ-Co reaches the minimum value; when the content increases to 4 wt.%, WC dendrite coarsening occurs, and at the same time, the γ-Co dendrite packing density increases significantly, and the eutectic fraction decreases obviously. The hardness of the coating first increases and then decreases with the increase in the CeO₂ addition amount, and reaches a peak value of 91.4 HRC when the CeO₂ content is 4 wt.%, which is approximately 2.57 times the hardness of the substrate. Full article

Microstructure simulations of continuous casting billets are vital for understanding solidification mechanisms and optimizing process parameters. However, the commonly used CA (Cellular Automaton) model is limited by grid anisotropy, which affects the accuracy of dendrite morphology simulations. While the DCSA (Decentered Square Algorithm) reduces anisotropy, its high computational cost due to the use of fine grids and dynamic liquid/solid interface tracking hinders large-scale applications. To address this, we propose a high-performance CA-DCSA method on GPUs (Graphic Processing Units). The CA-DCSA algorithm is first refactored and implemented on a CPU–GPU heterogeneous architecture for efficient acceleration. Subsequently, key optimizations, including memory access management and warp divergence reduction, are proposed to enhance GPU utilization. Finally, simulated results are validated through industrial experiments, with relative errors of 2.5% (equiaxed crystal ratio) and 2.3% (average secondary dendrite arm spacing) in 65# steel, and 2.1% and 0.7% in 60# steel. The maximum temperature difference in 65# steel is 1.8 °C. Compared to the serial implementation, the GPU-accelerated method achieves a 1430× higher speed using two GPUs. This work has provided a powerful tool for detailed microstructure observation and process parameter optimization in continuous casting billets. Full article

In this investigation, it was found that the co-addition of Er and B causes both the modification and refinement of the Al-7Si alloy. The B element mainly forms a small amount of the AlB2 phase within the alloy, which can be used as a nucleation site for grains during casting, so the addition of B can significantly reduce the grain size of the Al-7Si alloy. However, the number density of AlB2 phase is too low, so its effect on improving the eutectic Si size and reducing the secondary dendrite arm spacing (SDAS) is not significant. The addition of 0.1 wt% Er can form a large amount of Al3Er phase within the alloy, which mainly serves as a nucleation site for eutectic Si during casting, so the addition of Er can significantly reduce the SDAS, eutectic Si size and morphology of Al-7Si alloys. However, due to the existence of a certain degree of mismatch between the Al matrix and the Al3Er phase, the relative grain refinement effect of Al3Er is not significant. In addition to this, we also observe the enrichment of Er at eutectic Si, which suggests that Er can interact with Si and thus inhibit the growth of eutectic Si. Therefore, Er can modulate eutectic Si through the Al3Er phase and the enrichment of Er. The co-addition of Er and B to Al-7Si alloys has better refining and modification effects than the addition of Er or B alone, mainly due to the modification effect of the Er element and the refining effect of the AlB2 phase. Unlike the Er-containing alloys, where the Al3Er phase plays a modifying role, the modification of the co-addition Er and B alloys is mainly caused by the enrichment of Er within the alloy. Full article

The direct energy deposition arc process is widely used for fabricating medium and large components with moderate geometric complexity but often results in coarse microstructures and inconsistent hardness. This study introduces a hybrid manufacturing approach combining the friction stir burnishing process with the direct energy deposition arc by a gas–metal arc welding technique to refine the microstructure and enhance the microhardness of components fabricated from austenitic stainless steel 316L. Our former study used an aluminum alloy (A5052) friction stir burnishing tool, demonstrating significant microhardness improvement and grain refinement. However, it also faced notable challenges under high-heat and -friction conditions, including the effect of material adherence to the workpiece during processing. Therefore, this study introduces a newly developed friction stir burnishing tool made from copper (C1100) and compares its performance with the aluminum alloy tool regarding microhardness enhancement and microstructure refinement. The results indicate that the specimen processed by direct energy deposition arc combined with the copper friction stir burnishing tool demonstrated the best overall performance in grain refinement and hardness enhancement. Specifically, it achieved the highest average microhardness of 250 HV at 50 µm depths, compared to 240 HV for the aluminum alloy tool. The statistical analysis showed that both tools led to significant improvements over specimens processed without them. The statistical analysis confirmed a notable reduction in secondary dendrite arm spacing across all depths, with the copper tool demonstrating the most refinement. Additionally, a preliminary investigation of corrosion behavior revealed tool-dependent differences. Overall, this study offers a promising approach to improving additive manufacturing, particularly for industries with less stringent surface finish requirements. It could potentially reduce post-processing time and cost. Future research should explore different process parameters and assess long-term corrosion performance to develop this hybrid technique further. Full article

This paper employed squeeze-casting (SC) technology to develop a novel Al-7Si-1.5Cu-1.2Ni-0.4Mg-0.3Mn-0.15Ti heat-resistant alloy, addressing the issue of low room/high temperature elongation in traditional gravity casting (GC). Initially, the effects of SC and GC processes on the microstructure and properties of the alloy were investigated, followed by an examination of the evolution of the microstructure and properties of the SC samples over thermal exposure time. The results indicate that the SC process significantly improves the alloy’s microstructure. Compared to the GC alloy, the secondary dendrite arm spacing of the as-cast SC alloy is refined from 50.5 μm to 18.5 μm. Meanwhile, the size and roundness of the eutectic Si phase in the T6-treated SC alloy are optimized from 11.7 μm and 0.75 μm to 9.5 μm and 0.85 μm, respectively, and casting defects such as porosity are reduced. Consequently, the ultimate tensile strengths (UTSs) at room temperature and at 250 °C of the SC alloy are 5% and 4.9% higher than that of GC alloy, respectively, and its elongation at both temperatures shows significant improvement. After thermal exposure at 250 °C for 120 h, the morphology of the residual second phase at the grain boundaries in the SC alloy becomes more rounded, but the eutectic Si and nano-precipitates undergo significant coarsening, resulting in a 49% decrease in UTS. Full article

ZG25MnCrNiMo steel samples were prepared by squeeze casting under pressure ranging from 0 to 150 MPa. The effects of pressure on the microstructure, low-temperature toughness, hardness, and impact wear performance of the prepared steels were experimentally investigated. The experimental results indicated that the samples fabricated under pressure exhibited finer grains and a significant ferrite content compared to those produced without pressure. Furthermore, the secondary dendrite arm spacing of the sample produced at 150 MPa decreased by 45.3%, and the ferrite content increased by 39.1% in comparison to the unpressurized sample. The low-temperature impact toughness of the steel at −40 °C initially increased and then decreased as the pressure varied from 0 MPa to 150 MPa. And the toughness achieved an optimal value at a pressure of 30 MPa, which was 65.4% greater than that of gravity casting (0 MPa), while the hardness decreased by only 6.17%. With a further increase in pressure, the impact work decreased linearly while the hardness increased slightly. Impact fracture analysis revealed that the fracture of the steel produced without pressure exhibited a quasi-cleavage morphology. The samples prepared by squeeze casting under 30 MPa still exhibited a large number of fine dimples even at −40 °C, indicative of ductile fracture. In addition, the impact wear performance of the steels displayed a trend of initially decreasing and subsequently increasing across the pressure range of 0–150 MPa. The wear resistance of samples prepared without pressure and at 30 MPa was superior to that at 60 MPa, and the wear resistance deteriorated when the pressure increased to 60 MPa, after which it exhibited an upward trend as the pressure continued to rise. The wear mechanisms of the samples predominantly consisted of impact wear, adhesive wear, and minimal abrasive wear, along with notable occurrences of plastic removal, furrows, and spalling. Full article