This work presents a comprehensive study on the influence of three different processing technologies (Selective Laser Melting, Hot Pressing and conventional casting) on the microstructure, mechanical and wear behavior of an austenitic 316L Stainless Steel. A correlation between the processing technologies, the obtained microstructure and the mechanical and wear behavior was achieved. The results showed that the highest mechanical properties and tribological performance were obtained for 316L SS specimens produced by Selective Laser Melting, when compared to Hot Pressing and conventional casting. The high wear and mechanical performance of 316L Stainless Steel fabricated by Selective Laser Melting are mainly due to the finer microstructure, induced by the process. In this sense, Selective Laser Melting seems a promising method to fabricate customized 316L SS implants with improved mechanical and wear performance.

316L stainless steel mechanical and tribological behavior—A comparison between selective laser melting, hot pressing and conventional casting

Morphological evolution and growth mechanism of primary Mg2Si phase in Al–Mg2Si alloys

‘The micro/nano reinforced particle’ aluminum metal matrix composites (Al-MMCs) are widely used in manufacturing sector due to light-weight, superior strength-to-weight ratio, better fracture tough...

Developments in the aluminum metal matrix composites reinforced by micro/nano particles – A review:

A columnar-grain variant of single-crystal RENE N4 has been directionally solidified (DS) over a range of conditions in order to assess the possible benefits of the use of liquid metal-enhanced cooling for large cross-sectional castings. Castings were solidified at a rate of 2.5 mm/min using conventional radiation cooling and at rates between 2.5 and 8.5 mm/min using liquid-metal cooling (LMC) with tin as a cooling medium. Thermocouples inserted in the casting directly measured thermal gradients during solidification. The LMC process exhibited higher gradients at all withdrawal rates. The higher thermal gradients resulted in a refined structure measurable by the finer dendrite-arm spacing. Additionally, the conventionally cast material exhibited several freckle-type defects, while none were observed in the liquid-metal-cooled castings.

Directional solidification of large superalloy castings with radiation and liquid-metal cooling: A comparative assessment

In situ composites are a class of composite materials in which the reinforcement is formed within the matrix by reaction during the processing. In situ method of composite synthesis has been widely followed by researchers because of several advantages over conventional stir casting such as fine particle size, clean interface, and good wettability of the reinforcement with the matrix and homogeneous distribution of the reinforcement compared to other processes. Besides this, in situ processing of composites by casting route is also economical and amenable for large scale production as compared to other methods such as powder metallurgy and spray forming. Commonly used reinforcements for Al and its alloys which can be produced in situ are Al2O3, AlN, TiB2, TiC, ZrB2, and Mg2Si. The aim of this paper is to review the current research and development in aluminum-based in situ composites by casting route.

Aluminum-Based Cast In Situ Composites: A Review

The effects of both Li modification and cooling rate on the microstructure and tensile properties of an in situ prepared Al–15%Mg2Si composite were investigated. It was found that the addition of 0.3%Li reduces the average size of Mg2Si primary particles from ∼30 to ∼6 μm. The effect of cooling rate was investigated by the use of a mold with different section test bars. The results showed an increase in both UTS and elongation values with reduction in section thicknesses corresponding to increasing cooling rates. Adding Li also raised the tensile strength and elongation values and reduced the number of decohered particles observed in fracture surfaces thereby increasing the alloy's ductility. Data scatter and unexpected low tensile values of 3 mm sections were attributed to casting defects observed in fracture surfaces. Large clusters of Mg2Si particles and eutectic cell boundaries were found to be potential crack propagation paths in this alloy.

The effect of Li on the tensile properties of cast Al–Mg2Si metal matrix composite

Effects of conventional heat treatment on wear resistance of AISI H13 tool steel

The thermal field and the grain structure of a cored superalloy turbine blade, which has been directionally solidified with the liquid metal cooling (LMC) process, has been simulated in three dimensions using a cellular automaton (CA) coupled with finite-element (CAFE) model. The cooling induced by the liquid aluminum bath has been replaced by a heat-transfer coefficient, whose temperature- and time-dependence has been adjusted on the basis of natural convection simulations and dimensionless analyses. The simulated grain structure and crystallographic texture have been compared with the microstructure, and the electron back-scattered diffraction (EBSD) results were obtained for a real blade. In both the experiment and the simulation, it has been found that the grains do not exhibit a well-defined texture, even near the top of the blade, mainly as a result of a concave liquidus surface. In order to improve the texture and decrease the number of stray crystals, the LMC process was then optimized by changing several parameters. The baffle geometry, the liquid bath level, and the thermal conductivity of the ceramic mold were found to be the dominant parameters. Using the optimized design, the effect of the withdrawal rate on the resulting grain structure was investigated.

Thermal and Grain Structure Simulation in a Land-based Turbine Blade Directionally Solidified with the Liquid Metal Cooling Process

This paper presents the results obtained and the deductions made from a series of microstructural studies and mechanical tests involving gray cast iron which was sand cast using a variety of modules. The effect of cooling rate on the primary dendrite arm spacing (DAS), secondary dendrite arm spacing (SDAS), thickness of ferrite–cementite layer ( λ e ) and the hardness (HB) were evaluated. Results show that the both DAS and SDAS and also λ e are highly dependent on the cooling rate, and they decreases as the cooling rate increases. More attempts were also done to correlate the HB with DAS, SDAS and λ e . It was found that HB increases as DAS, SDAS and λ e decreases.

Effect of cooling rate on microstructure and mechanical properties of gray cast iron

In this study, effects of tungsten on wear resistance of high chromium white cast iron with and without tungsten in erosion–corrosion condition have been investigated. At the same time, the comparison between wear resistance of this grade of cast iron and low alloy steels with various contents of Cr which are used in industrial condition (in Sarcheshme Company, the greatest copper production company in the Middle East and with more than 4000 years historical cupper production background) was studied, while, copper concentrates have used for erosion particles. Results show that, because of higher hardness of matrix due to the tungsten, the wear resistance of high chromium cast iron increases. In addition to that, combine cutting and deformation wear mechanism and spalling mechanism were attributed in high chromium cast iron and low alloy steels, respectively. Subsequently, pitting mechanism in corrosion aspect was recognized because of inhomogeneity in chemical composition and sulfide inclusions content. Finally, the combine effects of erosion and corrosion (synergetic effect) were recognized in the high chromium white iron in industrial condition for the damaged samples.

N. Varahram

Papers

The effect of Li on the tensile properties of cast Al–Mg2Si metal matrix composite

Effects of conventional heat treatment on wear resistance of AISI H13 tool steel

Thermal and Grain Structure Simulation in a Land-based Turbine Blade Directionally Solidified with the Liquid Metal Cooling Process

Effect of cooling rate on microstructure and mechanical properties of gray cast iron

Effects of tungsten on erosion–corrosion behavior of high chromium white cast iron