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American Society for Testing and Materials

Recent advances in friction-stir welding : Process, weldment structure and properties

The metallurgy of zinc-coated steel

Welding Metallurgy of

Wire-feed additive manufacturing (AM) is a promising alternative to traditional subtractive manufacturing for fabricating large expensive metal components with complex geometry. The current research focus on wire-feed AM is trying to produce complex-shaped functional metal components with good geometry accuracy, surface finish and material property to meet the demanding requirements from aerospace, automotive and rapid tooling industry. Wire-feed AM processes generally involve high residual stresses and distortions due to the excessive heat input and high deposition rate. The influences of process conditions, such as energy input, wire-feed rate, welding speed, deposition pattern and deposition sequences, etc., on thermal history and resultant residual stresses of AM-processed components needs to be further understood. In addition, poor accuracy and surface finish of the process limit the applications of wire-feed AM technology. In this paper, after an introduction of various wire-feed AM technologies and its characteristics, an in depth review of various process aspects of wire-feed AM, including quality and accuracy of wire-feed AM processed components, will be presented. The overall objective is to identify the current challenges for wire-feed AM as well as point out the future research direction.

Wire-feed additive manufacturing of metal components: technologies, developments and future interests

Electrodeposited metal matrix/metal particle composite (EMMC) coatings were produced with a nickel matrix and aluminum particles. By optimizing the process parameters, coatings were deposited with 20 volume percent aluminum particles. Coating morphology and composition were characterized using light optical microscopy (LOM), scanning electron microscopy (SEM), and electron probe microanalysis (EPMA). Differential thermal analysis (DTA) was employed to study reactive phase formation. The effect of heat treatment on coating phase formation was studied in the temperature range 415 to 1,000 C. Long-time exposure at low temperature results in the formation of several intermetallic phases at the Ni matrix/Al particle interfaces and concentrically around the original Al particles. Upon heating to the 500--600 C range, the aluminum particles react with the nickel matrix to form NiAl islands within the Ni matrix. When exposed to higher temperatures (600--1,000 C), diffusional reaction between NiAl and nickel produces ({gamma})Ni{sub 3}Al. The final equilibrium microstructure consists of blocks of ({gamma}{prime})Ni{sub 3}Al in a {gamma}(Ni) solid solution matrix, with small pores also present. Pore formation is explained based on local density changes during intermetallic phase formation and microstructural development is discussed with reference to reaction synthesis of bulk nickel aluminides.

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Reaction synthesis of Ni-Al based particle composite coatings

Metallographic preparation technique for hot-dip galvanized and galvannealed coatings on steel

Characterization of Thermal Spray Coatings

A study was conducted on the effect of a uniform oxide layer on the galvanizing reaction in 0.20 wt pct Al-Zn and pure Zn baths at 450 °C. In the 0.20 wt pct Al-Zn bath, poor wettability of the oxide layer was observed. No significant liquid Zn penetration of the oxide occurred and, therefore, attack of the steel substrate to form localized Fe-Zn growth did not occur. It was found that the iron oxide acted as a physical barrier or inhibition layer in the pure Zn bath, similar to the Fe2Al5 inhibition layer that forms at the steel interface in Al-Zn baths. The inhibition effect of the oxide in the pure Zn bath was temporary, since cracks and other macrodefects in the oxide acted as fast diffusion paths for Zn. Localized Fe-Zn growth (outbursts) formed at the steel/coating interface, and the number of outbursts was generally inversely proportional to the oxide layer thickness at constant immersion times. Increased immersion time for a constant oxide layer thickness led to an increase in the number of outbursts. These results simulate the diffusion short circuit mechanisms for Fe2Al5 inhibition layer breakdown in Al-containing Zn baths.

The effect of iron oxide as an inhibition layer on iron-zinc reactions during Hot-Dip galvanizing

A method is proposed for calculating the variation in fraction liquid with distance in the mushy zone as an aid to determining the effect of alloy additions on solidification cracking susceptibility. The model combines the general liquidus equation of a multicomponent system, solute redistribution relations, and temperature gradient information. Calculations are presented for a range of niobium bearing superalloys and the results were found to reveal important relations between alloy composition, variation in fraction liquid with distance in the mushy zone, and cracking susceptibility as measured by the Varestraint test. In particular, the results directly show that the addition of carbon to these alloys is generally beneficial because it reduces the size of the crack susceptible mushy zone and limits the amount of terminal liquid available for the low temperature L → γ + Laves reaction. The modelling results and experimental data are also used to describe the influence of other alloy additions.

Arnold R. Marder

Papers

Reaction synthesis of Ni-Al based particle composite coatings

Metallographic preparation technique for hot-dip galvanized and galvannealed coatings on steel

Characterization of Thermal Spray Coatings

The effect of iron oxide as an inhibition layer on iron-zinc reactions during Hot-Dip galvanizing

Modelling mushy zones in welds of multicomponent alloys : implications for solidification cracking