Abstract: The refractory alloys are crucial for high-temperature applications to improve performance and reduce cost. They are used in several applications such as aerospace, outer space, military and defense, nuclear powerplants, automobiles, and industry. The conventional refractory alloys show greater stability at high temperatures and in contrast they have operational limitations due to their low melting temperatures. However, there is a huge requirement to improve the refractory alloys’ operational temperatures and replace the conventional alloys. The newly emerging refractory high entropy alloys (RHEAs) could be alternative materials for conventional refractory alloys and fulfill the demands and requirements of various practical applications in the future. The RHEA TaHfNbZrTi was prepared through an arc melting process. The annealing behavior of severely deformed equiatomic RHEATaHfNbZrTi has been investigated. To obtain deformed condition, the alloy is cold-rolled to 90% thickness reduction and then subjected to an annealing process to observe recrystallization and microstructural evolution in the range of 800 °C to 1400 °C temperatures. The cold-rolled – 90% condition shows the presence of microstructural heterogeneity. The annealing microstructure of 800 °C temperature reveals that partial recrystallization and further annealing treatment carried out annealing treatment in the range of 850 °C to 1400 °C temperatures exhibits completely recrystallized microstructures, followed by coarsening with a degree of annealing temperature. The deformed and annealed conditions featured the development of body-centered cubic (BCC) fiber textures. The experimental investigation of heavy deformation and followed by high-temperature annealing up to 1400 °C temperature will contribute to the understanding of microstructure and texture evolution of emerging RHEAs.
Abstract: In this investigation, a hypoeutectic AlSi11Cu alloy was printed. This alloy was obtained in powder form with an average particle size of 40 µm. Bars 20 mm in diameter and 100 mm in length were printed with the building direction parallel to the bars' longitudinal direction. The microstructural characterization demonstrated an Al matrix surrounded by a Si network forming a coral-like pattern. The microstructure of the alloy showed a heterogeneous behavior with a mixture of columnar and equiaxed grains. Likewise, the texture indicated that the columnar grains were preferentially oriented towards the building direction, while the equiaxed followed a texture dominated by the cube component. On the other hand, the as-printed material strength showed higher values than those obtained in the same alloy using conventional processes such as casting. In addition, strength and ductility differences were found in the printed material, depending on the measurement direction. The highest values were obtained in the radial direction (565 MPa maximum strength and 4.8% elongation to failure). The lowest values corresponded to the transverse direction (508 MPa maximum strength and 3.2 elongation to failure), which corroborate the material anisotropy.
Abstract: The deformation behaviour of additively manufactured AlSi10Mg alloy under low strains, high strain rates and elevated temperature conditions is essential to analyse and predict its response against dynamic loading such as impact and thermomechanical fatigue. The constitutive relation of Johnson-Cook is used to capture the strain rate sensitivity and thermal softening effect in AlSi10Mg alloy. Johnson-Cook failure model is widely used for exploring damage mechanics and predicting the fracture in many materials. In this present work, Johnson-Cook material and damage model parameters for additively manufactured AlSi10Mg alloy have been determined numerically from four types of uniaxial tensile test. Three different uniaxial tensile tests with dynamic strain rates (0.1, 1, 10, 50, and 100 s-1) and elevated temperature tensile test with three different temperature conditions (450 K, 500 K and 550 K) were performed on 3D printed AlSi10Mg alloy in ABAQUS/Explicit. Hexahedral elements are used to discretize tensile specimens and fracture energy value of 43.6 kN/m was used for damage initiation. Levenberg Marquardt optimization method was used for the evaluation of Johnson-Cook model parameters. It was observed that additively manufactured AlSi10Mg alloy has shown relatively higher strain rate sensitivity and lower thermal stability as compared to the other Al alloys.
Abstract: In this study, the Si-aluminide coating was prepared on gamma-TiAl [Ti-45Al-2Nb-2Mn-1B (at. %)] via liquid-phase slurry procedure. The high temperature oxidation resistance of this diffusion coating was evaluated at 1100 °C for 400 hours. The results of the isothermal oxidation showed that the formation of Si-aluminide coating can remarkably improve the high temperature oxidation of bare gamma-TiAl alloy. The identification of oxide scale microstructure showed that the formation of protective Al2O3+SiO2 mixed oxide scale along with a continuous, compact and uniform layer of Ti5Si3 beneath the surface oxide scale can act as an oxygen diffusion barrier during the high temperature oxidation. The other possible mechanisms related to the formation of Si-aluminide coating and oxide scales were also discussed.
Abstract: The objective of this paper is to investigate the formation and adhesion of a protective aluminum-oxide (Al2O3, alumina) layer on the surface of Iron-Chromium-Aluminum Alloy (Fe-Cr-Al) sintered-metal-fibers. The oxide-scale layer was developed via multi-stage thermal oxidation at 930 oC for 1 hour, followed by 1 hour at 960 oC, and finally at 990 oC for 2 hours. Scanning Electron Microscope (SEM) images show that the multi-stage thermal oxidation resulted in the formation of predominantly Al2O3 platelets-like and whiskers. SEM images also reveal non-uniform oxide-scale growth on the surface of the fibers. Furthermore, peeling/spalling of the alumina protective layer occurred after minimum handling, which indicates weak adhesion forces between the protective layer and the base metal alloy. Energy Dispersive Spectroscopy (EDS) analysis of the heat-treated Fe-Cr-Al sintered-metal-fibers confirmed the high aluminum content on the surface of the protective layer, and the low aluminum content on the exposed base metal alloy surface. In conclusion, the failure of the oxide-scale protective layer exposes the base metal alloy to further oxidation, and the fragile non-uniform oxide-scale is not suitable as a support for catalysts.
Abstract: By using a combination of new technologies together with an unconventional use of different types of materials, specific mechanical properties and structures of the material can be achieved. Some possibilities are enabled by a combination of powder metallurgy in the preparation of a metal matrix with dispersed stable particles achieved by mechanical alloying and hot consolidation. This paper explains the thermomechanical properties of new generation of Oxide Dispersion Strengthened alloys (ODS) within three ranges of temperature with specified deformation profiles. The results show that the mechanical properties of new ODS alloys are significantly affected by the thermomechanical treatment.
Abstract: Friction stir welding is the new-fangled and cutting-edge technique in welding applications; it is widely used in the fields of transportation, aerospace, defense, etc. For thriving significant welding joints and properties of friction stir welded components, it is essential to carry out this advanced process in a prescribed systematic procedure. At this moment, Underwater Friction Stir Welding (UFSW) Process is the field of interest to do research work. In the continuous assessment, the study of UFSW process is to comprehend problems occurred in the past and the structure through which the mechanical properties of the welded joints can be value-added and contributes to conclude results an acceptable and resourceful joint. A meticulous criticism is given on how to modify the experimental setup from NFSW to UFSW. It can discern the influence of tool materials, feeds, spindle angle, load, rotational speeds and mechanical properties. By expending the DEFORM-3D simulation software, the achieved outcomes are validated.
Abstract: In this study, Ti-5Al-2.5Fe alloy was prepared by powder metallurgy. The elemental titanium, aluminum, and iron powders were mechanically alloyed for 10 h in a vacuum atmosphere. A stainless steel jar and stainless steel balls were used for mechanical alloying. The alloyed powders were then sintered by vacuum hot pressing at 950 °C for a soaking time of 30 minutes. Pure titanium was also sintered at the same conditions for comparison of mechanical properties and microstructural behavior. The samples were investigated by scanning electron microscopy, XRD analysis, and optical microscopy. Results showed that, after mechanical alloying, a homogeneous distribution of the elements was obtained, and desired a-b structure was determined. Ti-5Al-2.5Fe alloy was successfully produced, and the alloy showed enhanced mechanical properties compared to the commercial pure titanium.
Abstract: The sintering step in powder metallurgy (P/M) processes is very sensitive as it determines to a large extent the properties of the final component produced. Spark plasma sintering over the past decade has been extensively used in consolidating a wide range of materials including metallic alloy powders. This novel, non-conventional sintering method has proven to be advantageous offering full densification of materials, high heating rates, low sintering temperatures, and short sintering cycles over conventional sintering methods. Ti6Al4V has been adjudged the most widely used α+β alloy due to its impressive mechanical performance in service environments, especially in the aerospace and automobile industries being a light metal alloy with the capacity for fuel efficiency needed in these industries. The P/M route has been a promising method for the fabrication of parts made from Ti6Al4V alloy due to its cost and material loss reductions and the ability to produce near net and intricate shapes. However, the use of this alloy has been largely limited owing to its relatively poor hardness and wear properties. The effect of sintering temperature on the densification, hardness, and wear behaviors of spark plasma sintered Ti6Al4V powders was investigated in this present study. Sintering of the alloy powders was performed in the 650–850°C temperature range at a constant heating rate, applied pressure and holding time of 100°C/min, 50 MPa and 5 min, respectively. Density measurements were carried out according to Archimedes’ principle and microhardness tests were performed on sectioned as-polished surfaces at a load of 100gf and dwell time of 15 s. Dry sliding wear tests were performed at varied sliding loads of 5, 15, 25 and 35 N using the ball-on-disc tribometer configuration with WC as the counterface material. Microstructural characterization of the sintered samples and wear tracks were carried out using SEM and EDX techniques. The density and hardness characteristics of sintered samples increased with increasing sintering temperature. Near full densification (99.6% of the theoretical density) and Vickers’ micro-indentation hardness of 360 HV were attained at 850°C. The coefficient of friction (COF) and wear depth improved significantly with increased sintering temperature under all the loading conditions examined, except at 25 N indicating better mechanical properties at high sintering temperatures. Worn surface analyses showed the wear mechanism was a synergy of adhesive and abrasive wears, although the former was prevalent.
Abstract: This paper focuses on the mathematical modeling for
solidification of Al alloy in a cube mold cavity to study the
solidification behavior of casting process. The parametric
investigation of solidification process inside the cavity was
performed by using computational solidification/melting model
coupled with Volume of fluid (VOF) model. The implicit filling
algorithm is used in this study to understand the overall process from
the filling stage to solidification in a model metal casting process.
The model is validated with past studied at same conditions. The
solidification process is analyzed by including the effect of pouring
velocity as well as natural convection from the wall and geometry of
the cavity. These studies show the possibility of various defects
during solidification process.
Abstract: This paper reports the viability of developing Zn-27Al
alloy matrix hybrid composites reinforced with alumina, graphite and
fly ash (solid waste bye product of coal in thermal power plants).
This research work was aimed at developing low cost-high
performance Zn-27Al matrix composite with low density. Alumina
particulates (Al2O3), graphite added with 0, 2, 3, 4 and 5 wt% fly ash
were utilized to prepare 10wt% reinforcing phase with Zn-27Al alloy
as matrix using two-step stir casting method. Density measurement,
estimated percentage porosity, tensile testing, micro hardness
measurement and optical microscopy were used to assess the
performance of the composites produced. The results show that the
hardness, ultimate tensile strength, and percent elongation of the
hybrid composites decrease with increase in fly ash content. The
maximum decrease in hardness and ultimate tensile strength of
13.72% and 15.25% respectively were observed for composite grade
containing 5wt% fly ash. The percentage elongation of composite
sample without fly ash is 8.9% which is comparable with that of the
sample containing 2wt% fly ash with percentage elongation of 8.8%.
The fracture toughness of the fly ash containing composites was
however superior to those of composites without fly ash with 5wt%
fly ash containing composite exhibiting the highest fracture
toughness. The results show that fly ash can be utilized as
complementary reinforcement in ZA-27 alloy matrix composite to
reduce cost.
Abstract: A novel chromium-free protective coating films based
on a zeolite coating was growing onto a FeCrAlloy metal using in –
situ hydrothermal method. The zeolite film was obtained using in-situ
crystallization process that is capable of coating large surfaces with
complex shape and in confined spaces has been developed. The
zeolite coating offers an advantage of a high mechanical stability and
thermal stability. The physicochemical properties were investigated
using X-ray diffraction (XRD), Electron Microscopy (SEM), Energy
Dispersive X–ray Analysis (EDX) and Thermogravimetric Analysis
(TGA). The transition from oxide-on-alloy wires to hydrothermally
synthesised uniformly zeolite coated surfaces was followed using
SEM and XRD. In addition, the robustness of the prepared coating
was confirmed by subjecting these to thermal cycling (ambient to
550oC).
Abstract: The aim of this study is to investigate formability of
Al based closed cell metallic foams at high temperature. The foam
specimens with rectangular section were produced from
AlMg1Si0.6TiH20.8 alloy preform material. Bending and free
bending tests based on gravity effect were applied to foam specimens
at high temperatures. During the tests, the time-angular deformation
relationships with various temperatures were determined.
Deformation types formed in cell walls were investigated by means
of Scanning Electron Microscopy (SEM) and optical microscopy.
Bending deformation about 90° was achieved without any defect at
high temperatures. The importance of a critical temperature and
deformation rate was emphasized in maintaining the deformation.
Significant slip lines on surface of cell walls at tensile zones of
bending specimen were observed. At high strain rates, the microcrack
formation in boundaries of elongated grains was determined.
Abstract: This article presents modeling studies of NiAl alloy
under solid-particle erosion and liquid-drop erosion. In the
solid-particle erosion simulation, attention is paid to the oxide scale
thickness variation on the alloy in high-temperature erosion
environments. The erosion damage is assumed to be deformation wear
and cutting wear mechanisms, incorporating the influence of the oxide
scale on the eroded surface; thus the instantaneous oxide thickness is
the result of synergetic effect of erosion and oxidation. For liquid-drop
erosion, special interest is in investigating the effects of drop velocity
and drop size on the damage of the target surface. The models of
impact stress wave, mean depth of penetration, and maximum depth of
erosion rate (Max DER) are employed to develop various maps for
NiAl alloy, including target thickness vs. drop size (diameter), rate of
mean depth of penetration (MDRP) vs. drop impact velocity, and
damage threshold velocity (DTV) vs. drop size.
Abstract: The temperature dependence of wettability (wetting
angle, Θ (T)) for Ag-based melts on graphite and Al2O3 substrates is
compared. Typical alloying effects are found, as the Ag host metal is
gradually replaced by various metallic elements. The essence of
alloying lies in the change of the electron/atom (e/a) ratio. This ratio
is also manifested in the shift of wetting angles on the same substrate.
Nevertheless, the effects are partially smeared by other
(metallurgical) factors, like the interaction between the oxygenalloying
elements and by the graphite substrate-oxygen interaction. In
contrast, such effects are not pronounced in the case of Al2O3
substrates. As a consequence, Θ(T) exhibits an opposite trend in the
case of two substrates. Crossovers of the Θ(T) curves were often
found. The positions of crossovers depend on the chemical character
and concentration of solute atoms. Segregation and epitaxial texture
formation after solidification were also observed in certain alloy
drops, especially in high concentration range. This phenomenon is
not yet explained in every detail.
Abstract: The current study investigated the influence of milling
time and ball-to-powder (BPR) weight ratio on the microstructural
constituents and mechanical properties of bulk nanocrystalline Al;
Al-10%Cu; and Al-10%Cu-5%Ti alloys. Powder consolidation was
carried out using a high frequency induction heat sintering where the
processed metal powders were sintered into a dense and strong bulk
material. The powders and the bulk samples were characterized using
XRD and FEGSEM techniques. The mechanical properties were
evaluated at various temperatures of 25°C, 100°C, 200°C, 300°C and
400°C to study the thermal stability of the processed alloys. The
processed bulk nanocrystalline alloys displayed extremely high
hardness values even at elevated temperatures. The Al-10%Cu-5%Ti
alloy displayed the highest hardness values at room and elevated
temperatures which are related to the presence of Ti-containing
phases such as Al3Ti and AlCu2Ti. These phases are thermally stable
and retain the high hardness values at elevated temperatures up to
400ºC.
Abstract: In the present study, M2 high speed steels were
fabricated by using electro-slag rapid remelting process. Carbide
structure was analysed and the fracture toughness and hardness were
also measured after austenitization treatment at 1190 and 1210oC
followed by tempering treatment at 535oC for billets with various
diameters from 16 to 60 mm. Electro-slag rapid remelting (ESRR)
process is an advanced ESR process combined by continuous casting
and successfully employed in this study to fabricate a sound M2 high
speed ingot. Three other kinds of commercial M2 high speed steels,
produced by traditional method, were also analysed for comparison.
Distribution and structure of eutectic carbides of the ESRR billet were
found to be comparable to those of commercial alloy and so was the
fracture toughness.
Abstract: High temperature deformation behavior of cast
Fe-20Cr-5Al alloy has been investigated in this study by performing
tensile and compression tests at temperatures from 1100 to 1200oC.
Rectangular ingots of which the dimensions were 300×300×100 in
millimeter were cast using vacuum induction melting. Phase
equilibrium was calculated using the FactSage®, thermodynamic
software and database. Tensile strength of cast Fe-20Cr-5Al alloy was
4 MPa at 1200oC. With temperature decreased, tensile strength
increased rapidly and reached up to 13 MPa at 1100oC. Elongation
also increased from 18 to 80% with temperature decreased from
1200oC to 1100oC. Microstructure observation revealed that M23C6
carbide was precipitated along the grain boundary and within the
matrix.
Abstract: Joining of 1mm thick aluminum 6061 to titanium TC4
was conducted using Bypass-current MIG welding-brazed, and stable
welding process and good bead appearance were obtained. The Joint
profile and microstructure of Ti/Al joints were observed by optical
microscopy and SEM and then the structure of the interfacial reaction
layers were analyzed in details. It was found that the intermetallic
compound layer at the interfacial top is in the form of columnar
crystal, which is in short and dense state. A mount of AlTi were
observed at the interfacial layer near the Ti base metal while
intermetallic compound like Al3Ti, TiSi3 were formed near the Al base
metal, and the Al11Ti5 transition phase was found in the center of the
interface layer due to the uneven distribution inside the weld pool
during the welding process. Tensile test results show that the average
tensile strength of joints is up to 182.6 MPa, which reaches about
97.6% of aluminum base metal. Fracture is prone to occur in the base
metal with a certain amount of necking.
Abstract: Sand cast samples of the as-received 66/34Mg-Al alloy were first homogenized at 4900C and then divided into three groups on which annealing, normalising and artificial ageing were respectively carried out. Thermal ageing of the samples involved treatment at 5000C, soaked for 4 hours and quenched in water at ambient temperature followed by tempering at 2000C for 2 hours. Test specimens were subjected to microstructure and mechanical analyses and the results compared. Precipitation of significant volume of stable Mg17Al12 crystals in the aged specimen’s matrix conferred superior mechanical characteristics compared with the annealed, normalized and as-cast specimens. The ultimate tensile strength was 93.4MPa with micro-hardness of 64.9HRC and impact energy (toughness) of 4.05J. In particular, its Young modulus was 10.4GPa which compared well with that of cortical (trabecule) bone’s modulus that varies from 12-17GPa.