Continuous casting of non-ferrous metals has been practised for well over 100 years. It has many advantages over static ingot and book mould casting, the most important being improved yield, reduced energy consumption and reduction of manpower, with a consequent reduction in cost. This book shows how the prrocess can be used in an engineering environment for casting a wide range of copper based alloys and precious metals, including gold and silver, and selected nickel alloys.

Cast and Wrought Aluminium Bronzes: Properties, Processes and Structure

As a step forward toward the development of the next generation of nickel aluminum bronze (NAB) components using wire-arc additive manufacturing (WAAM), square bars were printed in the vertical direction. The as-built microstructure was characterized using multi-scale electron microscopy techniques, where the differences in phase formation were compared to the reference cast-NAB based on the solidification characteristics. The as-cast microstructure typically consists of Cu-rich α-matrix, and four types of intermetallic particles referred to as κ-phases. In the WAAM-NAB, the formation of κI was suppressed due to high cooling rates. The microstructure was finer and the volume fraction of intermetallic particles was significantly lower than that of the cast-NAB. Based on energy dispersive spectroscopy (EDS) technique and diffraction pattern analysis using transmission electron microscopy (TEM), the phases formed in the interdendritic regions were identified as κII (globular Fe3Al) and κIII (lamellar NiAl), whereas numerous fine (5–10 nm) Fe-rich κIV particles were precipitated uniformly within the α-matrix. Electron backscatter diffraction analysis revealed weak texture on both parallel and perpendicular planes to the building direction with (100) poles rotated away from the build direction. The WAAM-NAB sample exhibited considerably higher yield strength (˜88 MPa) and elongation (˜10%) than the cast-NAB, but the gain in the ultimate tensile strength was marginal.

Microstructural evolution and mechanical behavior of nickel aluminum bronze Cu-9Al-4Fe-4Ni-1Mn fabricated through wire-arc additive manufacturing

Wire-arc additive manufacturing of nickel aluminum bronze/stainless steel hybrid parts - Interfacial characterization, prospects, and problems

Acoustic emission during pitting corrosion of 304 stainless steel

Correlation of microstructure with cavitation erosion behaviour of a nickel-aluminum bronze in simulated seawater

Cast nickel aluminium bronze (NAB) can suffer severe selective phase corrosion in seawater by a dealuminification process similar to dezincification in brasses During the process, which occurs particularly in the heat-affected zones of weld repairs, copper is redeposited at the corroded areas thus making the phenomenon extremely difficult to detect by conventional non-destructive testing techniques It was considered likely that the different fracture modes of sound material and corroded material would result in differing forms of acoustic emission during deformation Acoustic emission monitoring was therefore carried out on tensile specimens of as-cast NAB, welded NAB and corroded NAB The failed specimens were then examined using optical and scanning electron microscopy It was apparent from the results that there were significant differences in the acoustic emission behaviour of the three types of material This was revealed in characteristic event counts, event amplitudes and rms energy outputs and by normalized amplitude analysis of the data These differences in behaviour have been correlated with the varying structures of NAB and their behaviour under stress

A. G. Foley

Papers

The detection of selective phase corrosion in cast nickel aluminium bronze by acoustic emission techniques