Showing papers in "Metallurgical and Materials Transactions A-physical Metallurgy and Materials Science in 1997"

Strain hardening regimes and microstructural evolution during large strain compression of low stacking fault energy fcc alloys that form deformation twins

Abstract: Constant true strain rate simple compression tests were conducted on annealed, polycrystalline samples of α-brass and MP35N, and the evolution of the true stress (σ)-true strain (e) response was documented. From these data, the strain hardening rate was numerically computed, normalized with shear modulus (G), and plotted against both (σ − σ 0)/G (σ0 being the initial yield strength of the alloy) and e. Such normalized plots for α-brass and MP35N were found to be almost identical to each other, and revealed four distinct stages of strain hardening: stage A, with a steadily decreasing strain hardening rate up to a true strain of about −0.08; stage B, with an almost constant strain hardening rate up to a true strain of about −0.2; stage C, with a steadily decreasing strain hardening rate up to a true strain of about −0.55; and a final stage D, again with an almost constant strain hardening rate. Optical microscopy and transmission electron microscopy (TEM) were performed on deformed samples. The results suggested that stage A corresponded to stage III strain hardening (dynamic recovery) of higher stacking fault energy (SFE) fcc metals such as copper. The onset of stage B correlated with the first observation of deformation twins in the microstructure. Further straining in stage B was found to produce clusters of parallel twins in an increasing number of grains. Stage C correlated with the development of severe inhomogeneity of deformation within most grains, and with the development of significant misorientation between the twin/matrix interface and the {111} plane in the matrix of the grain, i.e., the matrix/twin interface lost coherency with continued deformation. Stage D correlated with extensive formation of secondary twins that resulted in twin intersections in many grains. Early in stage D, some strain localization in the form of shear bands was observed. Although formation of these shear bands had no detectable effect on the macroscopic strain hardening rate, it did correlated with a marked change in texture evolution. Based on these experimental observations, we have developed and presented a physical description of the microstructural phenomena responsible for the various strain hardening stages observed in low SFE fcc alloys.

Microstructure and properties of copper and aluminum alloy 3003 heavily worked by equal channel angular extrusion

Abstract: A technique invented in the former Soviet Union and recently introduced in the United States, called equal channel angular extrusion (ECAE), produces intense and uniform deformation by simple shear and is applied to 25 × 25 × 152-mm billets of Cu 101 and Al 3003. Microcrystalline structures with a grain size of 0.2 to 0.4 µm are created during room-temperature multipass ECAE deformation for true strains lying in the range e=2.31 to 9.24. Evidence shows that intense simple shear deformation promotes dynamic or continuous recrystallization by subgrain rotation. The effects of the number of extrusion passes and deformation route for Cu 101, and the deformation route after four passes for Al 3003, are studied. Increasing the number of ECAE passes in Cu 101 causes strength to reach saturation and grain refinement stabilization after four passes (true strain of 4.68), and subgrain misorientation to increase as the number of passes increases. For multipass ECAE with billet orientation constant (route A) or rotated 90 deg between all passes (route B), two levels of structures are created inside the original grains: shear bands (first level) and very fine subgrains (second level) within the shear bands. For a billet rotation of 180 deg between passes (route C), an unusual event is observed. At each even numbered pass, shear bands nearly disappear and only subgrains are present inside the original grains. Route B gives the highest strength, whereas route C produces a more equiaxed and stable microstructure. Subsequent static recrystallization increases the average grain size to 5 to 10 µm.

Solidification structure and abrasion resistance of high chromium white irons

Abstract: Superior abrasive wear resistance, combined with relatively low production costs, makes high Cr white cast irons (WCIs) particularly attractive for applications in the grinding, milling, and pumping apparatus used to process hard materials. Hypoeutectic, eutectic, and hypereutectic cast iron compositions, containing either 15 or 26 wt pct chromium, were studied with respect to the macrostructural transitions of the castings, solidification paths, and resulting microstructures when poured with varying superheats. Completely equiaxed macrostructures were produced in thick section castings with slightly hypereutectic compositions. High-stress abrasive wear tests were then performed on the various alloys to examine the influence of both macrostructure and microstructure on wear resistance. Results indicated that the alloys with a primarily austenitic matrix had a higher abrasion resistance than similar alloys with a pearlitic/bainitic matrix. Improvement in abrasion resistance was partially attributed to the ability of the austenite to transform to martensite at the wear surface during the abrasion process.

Modeling solid solution strengthening in nickel alloys

Abstract: The yield stress of multicomponent nickel solid solution alloys has not been modeled in the past with respect to the effects of composition and temperature. There have been investigations of the effect on the yield stress of solutes in binary systems at a fixed temperature, but the effects on the yield stress of multiple solute elements and temperature changes have not been investigated. In this article, two different forms of the trough model are considered for nickel-base alloys to determine the most applicable model for solid solution strengthening in the system. The yield stresses of three binary nickel-chromium and three ternary nickel alloys were determined at a range of temperatures. The yield stress of the alloys was then modeled using the Feltham equation. The constants determined in fitting the Feltham equation to the experimental data were then applied to other experimental solid solution alloys and also to published information on commercial solid solution nickel alloys. It was found that the yield stress of the nickel solid solution alloys could be modeled successfully using the Feltham equation.

Modeling of micro- and macrosegregation and freckle formation in single-crystal nickel-base superalloy directional solidification

Abstract: The formation of macrosegregation and freckles by multicomponent thermosolutal convection during the directional solidification of single-crystal Ni-base superalloys is numerically simulated. The model links a previously developed thermodynamic phase equilibrium subroutine with an existing code for simultaneously solving the macroscopic mass, momentum, energy, and species conservation equations for solidification of a multicomponent alloy. Simulation results are presented for a variety of casting speeds and imposed thermal gradients and for two alloy compositions. It is found that for a given alloy composition, the onset of convection and freckle formation occurs at a critical primary dendrite arm spacing, which agrees well with previous experimental findings. The predicted number and shape of the freckle chains in the unstable cases also agree qualitatively with experimental observations. Finally, it is demonstrated how the onset and nature of convection and macrosegregation vary with alloy composition. It is concluded that the present model can provide a valuable tool in predicting freckle defects in directional solidification of Ni-base superalloys.

Thermodynamic study of the low-temperature phase B19′ and the martensitic transformation in near-equiatomic Ti-Ni shape memory alloys

Abstract: Experimental information on the transformation temperatures and the thermodynamic properties of the near-equiatomic TiNi alloys is analyzed. Special attention is paid to the estimation of T0 temperature from experimental Ms and Af temperatures. The properties of the TiNi low-temperature phase (B19′) are evaluated from selected experimental data by using a two-sublattice model. The Ti-Ni phase diagram including the B19′ phase is then calculated. It reveals that the equiatomic TiNi parent phase (B2) remains stable from high temperatures until 370 K, and then the B19′ phase becomes thermodynamically stable as a linear compound under 370 K. Thermodynamic quantities such as the T0 temperature and transformation enthalpy are also calculated and compared with experimental data. Further, the Ms temperature is predicted and compared with data from different sources.

Modeling the Flow Behavior of a Medium Carbon Microalloyed Steel under Hot Working Conditions

Abstract: The constitutive equations for the flow behavior of a commercial 0.34 pct C-1.5 pct Mn-0.7 pct Si-0.083 pct V-0.018 pct Ti microalloyed steel were determined. For this purpose, uniaxial hot compression tests were carried out over a wide range of strain rates (10−4 to 10 s−1) and temperatures (1123 to 1423 K). In combination with models developed in the literature, the experimental results permit the flow stress of the present steel to be predicted within ± 5 pct. It is shown that the classical constitutive equations must be modified to take the grain size into account, particularly when the latter is below 30 µm.

Supersolidus liquid-phase sintering of prealloyed powders

Abstract: A model is derived for the sintering densification of prealloyed particles that form internal liquids when heated over the solidus temperature. The model considers the powder size, composition, and microstructure, as well as the processing conditions of green density, heating rate, maximum temperature, hold time, and atmosphere. Internal liquid forms and spreads to create an interparticle capillary bond that induces densification during sintering. Densification is delayed until the particles achieve a mushy state due to grain boundary wetting by the internal liquid. This loss of rigidity and concomitant densification of the semisolid particles depends on the grain size and liquid quantity. Viscous flow is the assumed densification mechanism, where both viscosity and yield strength vary with the liquid content and particle microstructure. Densification predictions are compared to experimental data, giving agreement with previously reported rapid changes in sintered density over narrow temperature ranges. The model is tested using data from steels and tool steels of varying carbon contents, as well as boron-doped stainless steel, bronze, and two nickel-based alloys.

Phase reaction and diffusion path of the SiC/Ti system

Abstract: Bonding of SiC to SiC was conducted using Ti foil at bonding temperatures from 1373 to 1773 K in vacuum. The total diffusion path between SiC and Ti was investigated in detail at 1673 K using Ti foil with a thickness of 50 µm. At a bonding time of 0.3 ks, TiC at the Ti side and a mixture of Ti5Si3C x and TiC at the SiC side were formed, yielding the structure sequence of β-Ti/Ti+TiC/Ti5Si3C x +TiC/SiC. Furthermore, at the bonding time of 0.9 ks, a Ti5Si3C x layer phase appeared between SiC and the mixture of Ti5Si3C x and TiC. Upon the formation of Ti3SiC2 (T phase) after the bonding time of 3.6 ks, the complete diffusion path was observed as follows: β-Ti/Ti+TiC/Ti5Si3C x +TiC/Ti5Si3C x /Ti3SiC2/SiC. The activation energies for growth of TiC, Ti5Si3C x , and Ti3SiC2 were 194, 242, and 358 kJ/mol, respectively.

Friction and abrasion resistance of cast aluminum alloy-fly ash composites

Abstract: The abrasive wear properties of stir-cast A356 aluminum alloy-5 vol pct fly ash composite were tested against hard SiC p abrasive paper and compared to those of the A356 base alloy. The results indicate that the abrasive wear resistance of aluminum-fly ash composite is similar to that of aluminum-alumina fiber composite and is superior to that of the matrix alloy for low loads up to 8 N (transition load) on a pin. At loads greater than 8 N, the wear resistance of aluminum-fly ash composite is reduced by debonding and fracture of fly ash particles. Microscopic examination of the worn surfaces, wear debris, and subsurface shows that the base alloy wears primarily by microcutting, but the composite wears by microcutting and delamination caused by crack propagation below the rubbing surface through interfaces between fly ash and silicon particles and the matrix. The decreasing specific wear rates and friction during abrasion wear with increasing load have been attributed to the accumulation of wear debris in the spaces between the abrading particles, resulting in reduced effective depth of penetration and eventually changing the mechanism from two-body to three-body wear, which is further indicated by the magnitude of wear coefficient.

Discontinuous cellular precipitation in a high-refractory nickel-base superalloy

Abstract: A discontinuous precipitation reaction has been investigated in a high-refractory content nickel-base alloy. The reaction transforms the two-phase γ-γ′ parent microstructure into a three-phase cellular structure with a γ′ matrix containing Re-rich P-phase and agglomerated γ lamellae. The reaction has been studied in polycrystalline material and in bicrystals with varying degrees of boundary misorientation at temperatures in the range of T/Tm=0.78 to 0.85. The early stages of the reaction are characterized by heterogeneous nucleation of P-phase precipitates and migration of the grain boundary. At low-angle, near-tilt boundaries misoriented by less than 10 deg, nucleation of P-phase particles was observed, but the cellular reaction did not occur, due to limited boundary mobility and diffusivity. The high degree of supersaturation of Re and W in the initial γ-γ′ alloy appears to be the primary driving force for the reaction. Small amounts of creep deformation did not significantly influence the extent of the transformation. The diffusivity of Re associated with the moving boundary was calculated to be 5×10−8 cm2 s−1 at 1093 °C, which is approximately four orders of magnitude greater than the bulk lattice diffusivity of tungsten.

The role of coincidence-site-lattice boundaries in creep of Ni-16Cr-9Fe at 360 °C

Abstract: The objective of this study is to understand and quantify the role of the coincidence-site-lattice boundary (CSLB) population on creep deformation of Ni-16Cr-9Fe at 360 °C. It is hypothesized that an increase in the CSLB population decreases the annihilation rate of dislocations in the grain boundary, leading to an increase in the internal stress and a decrease in the effective stress. The result is a reduction in the creep strain rate. The role of CSLBs in deformation is, thus, to increase the internal stress by trapping run-in lattice dislocations at the grain boundaries as extrinsic grain boundary dislocations (EGBDs), creating backstresses on following dislocations rather than annihilating them, as in the case of high-angle boundaries (HABs). The hypothesis was substantiated by showing (1) that dislocation absorption kinetics differ substantially between a CSLB and an HAB, and (2) that the CSLB fraction strongly affects the internal stress in the solid. Dislocation absorption kinetics were measured by comparing EGBD density in transmission electron microscopy (TEM). Results showed that CSLBs contain an EGBD density which is 3 times higher than HABs at 1.25 pct strain. Internal stress was measured by the stress dip test and was found to be ≈ 30 MPa higher in the CSLB-enhanced sample. Steady-state creep rates of Ni-16Cr-9Fe in 360 °C argon were also found to be strongly affected by the grain boundary character distribution. Increasing the CSLB fraction by approximately a factor of 2 resulted in a decrease in steady-state creep rates by a factor of 8 to 26 in coarse-grain (330 µm) samples and a factor of 40 to 66 in small-grain (35 µm) samples. It is postulated that annihilation of EGBDs only occurs at triple lines where at least two HABs intersect. By using a geometric relationship to evaluate the probability of EGBDs annihilating at a triple line, the model predicts a non-linear dependence of the creep rate with CSLB fraction, yielding excellent correlation with measurement. The model provides a physical basis for measurements which show that increasing the CSLB fraction by only moderate amounts can greatly reduce the steady-state creep rate in Ni-16Cr-9Fe.

On the rule of additivity in phase transformation kinetics

Abstract: It is commonly held that a sufficient condition for the rule of additivity to be valid is that the transformation rate depend only on temperature and volume fraction. This is not true in general.

In Situ ceramic particle-reinforced aluminum matrix composites fabricated by reaction pressing in the TiO2 (Ti)-Al-B (B2O3) systems

Abstract: Particulate TiB2 reinforced aluminum-based metal matrix composites (MMCs) were successfully fabricated by means of the reaction processing method. TiB2 particulates were formed in situ through the reaction of Ti and B in Ti-Al-B, TiO2 and B in TiO2-Al-B, and TiO2 and B2O3 in TiO2-Al-B2O3 systems. The results showed that in situ TiB2 particulates formed in the Ti-Al-B system had a size of 5 µm and they exhibited block and rodlike structures. Moreover, coarse Al3Ti blocks several tens of micrometers in size were also formed simultaneously. On the other hand, equiaxed Al2O3 and TiB2 particulates with a size of less than 2 µm were formed in situ in the TiO2-Al-B and TiO2-Al-B2O3 systems. The Al3Ti phase was completely eliminated in the TiO2-Al-B system with increasing B content. Tensile tests revealed that the Al2O3 · TiB2/Al composite fabricated from the TiO2-Al-B system exhibits excellent mechanical properties. The yield strength of the Al2O3 · TiB2/Al composite appeared to increase with increasing TiB2 content. The yield strength of the Al2O3 · TiB2/Al composite could be further increased by introducing CuO into the TiO2-Al-B system. Such an increment in mechanical strength arose from the strengthening effect caused by the Al2Cu precipitates. The incorporation of CuO had no effect on the in situ reaction process of the TiO2-Al-B system. Finally, the effect of SiC addition on the microstructure and mechanical properties of the composites fabricated from the TiO2-Al-B and TiO2-Al-B-CuO systems was also investigated.

A thermodynamic description of the Al-Mg-Zn system

Abstract: A thermodynamic description of the Al-Mg-Zn system was developed based on critically evaluated experimental data. All binary intermetallic phases are assumed to have negligible ternary solubility except for MgZn2. Three different thermodynamic models are applied to three different types of phases in this system, i.e., disordered solution phases, stoichiometric compounds, and semistoichiometric phases. The model parameters are optimized based on the thermodynamic descriptions of the constituent binaries and experimental phase equilibrium and thermodynamic data available in the literature. The good agreement obtained between several calculated isopleths and thermodynamic values of the liquid phase and experimental data shows that the current description of this system is reasonable. The calculated phase equilibria in the Al-rich corner are believed to be reliable for practical applications, while those away from the Al-rich region are subjected to large uncertainty. Additional experimental investigations are needed to firmly establish the phase equilibrium of this system over wide ranges of composition and temperature.

Influence of the amount and morphology of retained austenite on the mechanical properties of an austempered ductile iron

Abstract: High Si contents in nodular cast irons lead to a significant volume fraction of retained austenite in the material after the austempering treatment. In the present work, the influence of the amount and morphology of this phase on the mechanical properties (proof stress, ultimate tensile strength (UTS), elongation, and toughness) has been analyzed for different austempering conditions. After 300 °C isothermal treatments at intermediate times, the austenite is plastically stable at room temperature and contributes, together with the bainitic ferrite, to the proof stress and the toughness of the material. For austenite volume fractions higher than 25 pct, the proof stress is controlled by this phase and the toughness depends mainly on the stability of γ. In these conditions (370 °C and 410 °C treatments), the present material exhibits a transformation-induced plasticity (TRIP) effect, which leads to an improvement in ductility. It is shown that the strain level necessary to initiate the martensitic transformation induced by deformation depends on the carbon content of the austenite. The martensite formed under TRIP conditions can be of two different types: “autotempered” plate martensite, which forms at room temperature from an austenite with a quasi-coherent epsilon carbide precipitation, and lath martensite nucleated at twin boundaries and twin intersections.

Trace element effects on precipitation processes and mechanical properties in an Al-Cu-Li alloy

Abstract: A study has been made of how impurities (Na and K) and trace additions of indium, magnesium, and silicon affect the microstructure and related mechanical properties of an Al-Cu-Li alloy. Transmission electron microscopy (TEM) was used to determine the size and distribution of particles in four alloys. Indium and magnesium are both seen to stimulate T 1 precipitation. Indium also modifies ϑ″ morphology, and magnesium greatly increases the number density of ϑ″ precipitates. Strain localization was observed in underaged Al-Cu-Li-In tensile samples, consistent with observed changes in precipitate structure. No superposition of the effects of indium and magnesium was seen. High-resolution analytical microscopy was used to inspect precipitates for segregation of trace elements during early stages of aging, but no segregation was found within the detection limits of the system. Variations in heat treatment were made in order to study nucleation kinetics and trace element interactions with vacancies. Indium, with a binding energy less than that of lithium, was not seen to interact with quenched-in vacancies, while magnesium, with a binding energy greater than that of lithium, had a strong interaction. Yield anisotropies and fracture toughnesses were measured. Removal of trace impurities of sodium and potassium correlated with improved fracture properties. Magnesium was observed to increase anisotropy, especially in the T8 temper. A model was used to explain the anisotropy data in terms of texture and precipitate distribution.

Deformation, fracture, and mechanical properties of low-temperature-tempered martensite in SAE 43xx steels

Abstract: Uniaxial tensile tests were performed on 4330, 4340, and 4350 steels in the as-quenched (AQ) condition and after quenching and tempering at 150 °C, 175 °C, and 200 °C for times of 10 minutes, 1 hour, and 10 hours, respectively. Strength parameters decreased and ductility parameters increased continuously with increasing tempering. Mechanical properties are presented as a function of tempering conditions and steel carbon content, and hardness and ultimate strength changes are given as a function of Hollomon—Jaffe tempering parameters. All tempered specimens, except for some lightly tempered 4350 specimens, deformed plastically through necking instability and failed by ductile fracture. The stresses required for the ductile fracture, estimated from an analysis of the interfacial stresses at particles in the neck at fracture, showed no systematic variation with carbon content or tempering conditions despite significant variations in deformation and strain hardening. The AQ specimens of the 4340 and 4350 steels, and some of the lightly tempered 4350 steels, failed by brittle mechanisms. The deformation and fracture of the low-temperature-tempered 43xx steels are discussed in terms of the changes in fine structure, namely, the formation of transition carbides and a rearranged dislocation substructure that evolve from an AQ martensitic substructure consisting of dislocations with and without carbon atom segregation.

An experimental and theoretical study of heat-affected zone austenite reformation in three duplex stainless steels

Abstract: Three duplex grades, one molybdenum-free, one 22Cr type, and one super duplex grade, have been subjected to weld simulation treatments, and the resulting microstructures have been quantified by automatic image analysis techniques. Substantial differences between the duplex grades were observed with an increased ability to reform austenite with increased alloying content. A theoretical model has been applied, based upon the paraequilibrium concept elaborated by Hillert, and the paraequilibrium compositions of individual phases were calculated as a function of temperature using the THERMOCALC database. A model based on Cahns theory of grain boundary nucleated reactions has also been utilized to calculate the kinetics of the reaction. By using this model, the grain size effects could be included in the treatment. The results of the calculations were compared with experimental data, and the experimental results were reproduced using the same parameter set for the three materials, with the exception of the diffusion coefficient values which had to be adjusted. This adjustment has in a later study been verified experimentally. The results validate the model used and the physical relevance of using the paraequilibrium model. The appropriateness of a paraequilibrium approach is also supported by experimental evidence from weld metal compositions. It is shown that the nitrogen content of the alloys plays an important role, and a higher nitrogen content results in more efficient austenite reformation. This implies that the alloy nitrogen compositions should lie close to the upper specification limits for these materials and nitrogen losses should be avoided on welding since the material properties, both mechanical and corrosive, are strongly related to the austenite-ferrite phase ratio.

Damage Effect on the Fracture Toughness of Nodular Cast Iron: Part I. Damage Characterization and Plastic Flow Stress Modeling

Abstract: After chemical, morphological, and mechanical characterization of ductile cast iron, the damage mechanisms were studied by tensile tests inside the scanning electron microscope (SEM). The evolutions of Young’s modulus and of Poisson’s ratio were measured in uniaxial tensile tests. Compression tests were used to measure the pressure sensitivity coefficient of the flow stress. The damage is produced by early initiation of cavities at the pole cap of graphite nodules by debonding of the interface, followed by the growth of cavities. The mechanical behavior was modeled in the elastic region by calculating the Hashin-Shtrickman bounds. This provided the elastic constants for the graphite nodules. The plastic behavior was modeled by considering that the graphite nodules were replaced by voids. The critical interfacial stress for debonding was determined by analytical as well as by finite-element calculations. The growth rate of cavities was deduced from the evolution of the Poisson’s ratio and was compared with predictions from Gurson’s potential. The stress-strain behavior could be modeled either by extension of the Mori-Tanaka analysis in the plastic range or by finite-element computations. This allowed a fair prediction of the observed behavior.

Ultrasonic backscattering in duplex microstructures: Theory and application to titanium alloys

Abstract: A theory is presented for the ultrasonic backscattering in duplex microstructures. Assuming single scattering described by the Born approximation, we consider a microstructure consisting of macrograins containing colonies with crystallographically related orientations. General results are presented for the backscattering coefficient, assuming that all variants occur with equal probability. These are then applied to the particular case of titanium alloys, in which the macrograins are taken to be prior beta grains and the colonies are assumed to be alpha phase produced by a martensitic transformation. Numerical results illustrate the effects of ultrasonic frequency, colony size and ellipticity, and macrograin size and ellipticity on the backscattering.

Precipitation behavior in ultra-low-carbon steels containing titanium and niobium

Abstract: This work revealed the basic mechanism for the stabilization of carbon in ultra-low-carbon (ULC) steels that contain moderate S (0.004 to 0.010 wt pct), adequate Ti (0.060 to 0.080), and low Mn (≤0.20). During cooling through the austenitic region to the ferritic, the initially formed sulfide particles (TiS) undergo an in situ transformation into carbosulfides (H-Ti4C2S2) by absorbing C and Ti. The transformation from TiS to H may be considered as a hybrid of shear and diffusion, i.e., faulted Ti8S9 (9R)+10[Ti]+9[C] → 4 1/2Ti4C2S2 (H). At low temperature (≤930 °C), the stabilization process continues through epitaxial growth of carbides on H phase, i.e., [M]+x[C]+H → epitaxial MCx (on H). This mechanism differs from the traditional view of stabilization, where the carbon is removed from solution by the formation of free-standing or independently nucleated H and/or MCN precipitates. While these two forms of carbon stabilization are now well known, this article presents a method of predicting which mechanism of stabilization will be operative in a given steel based on its bulk composition. Implications bearing upon new ULC steel design, considering the role of S, will be discussed.

Motion and Remelting of Dendrite Fragments during Directional Solidification of a Nickel-Base Superalloy

Abstract: The formation of spurious grains during the directional solidification of a Ni-base superalloy is studied by modeling the movement and remelting of dendrite fragments originating in channels inside the mush. Such channels exist because of thermosolutal convective instabilities during solidification and persist as freckle chains in the solidified material. The fragment model is linked to a phase equilibrium subroutine for multicomponent Ni-base superalloys, as well as to a previously developed solidification and convection code. A parametric study is performed to investigate the effects of initial fragment location and size on the fragment paths and survivability in the melt for one of the channels predicted in a typical directional solidification simulation. It is found that only a small window of initial conditions exists which leads to spurious grain formation. This window corresponds to medium-sized fragments originating near the mouth of the channel. Other fragments either remelt completely or sink into the channel. The need for an accurate fragment generation model is discussed.

Faceted growth of silicon crystals in Al-Si alloys

Abstract: Primary silicon crystals in hypereutectic aluminum-silicon alloy castings frozen at moderate rates have been studied metallographically. Etched growth traces parallel to external facets were used to demonstrate that the majority of the crystals, though of widely varying external shape, grow in basically octahedral form, enclosed in {111} facets. Equations are developed that predict the limits within which true octahedral or spinel-type growth can occur. The equations are tested by measurements of growth trace spacings. Outside the predicted limits, there can be accelerated corner growth, which may result in hollow hopper crystals or even a dendritic form. Alternatively, a corner may be truncated by formation of a facet other than {111}.

Fatigue and fracture behavior of a fine-grained lamellar TiAl alloy

Abstract: The fatigue and fracture resistance of a TiAl alloy, Ti-47Al-2Nb-2Cr, with 0.2 at. pct boron addition was studied by performing tensile, fracture toughness, and fatigue crack growth tests. The material was heat treated to exhibit a fine-grained, fully lamellar microstructure with approximately 150-µm grain size and 1-µm lamellae spacing. Conventional tensile tests were conducted as a function of temperature to define the brittle-to-ductile transition temperature (BDTT), while fracture and fatigue tests were performed at 25 °C and 815 °C. Fracture toughness tests were performed inside a scanning electron microscope (SEM) equipped with a high-temperature loading stage, as well as using ASTM standard techniques. Fatigue crack growth of large and small cracks was studied in air using conventional methods and by testing inside the SEM. Fatigue and fracture mechanisms in the fine-grained, fully lamellar microstructure were identified and correlated with the corresponding properties. The results showed that the lamellar TiAl alloy exhibited moderate fracture toughness and fatigue crack growth resistance, despite low tensile ductility. The sources of ductility, fracture toughness, and fatigue resistance were identified and related to pertinent microstructural variables.

Retained austenite characteristics in thermomechanically processed Si-Mn transformation-induced plasticity steels

Abstract: It is well known that a significant amount of retained austenite can be obtained in steels containing high additions (>1 pct) of Si, where bainite is the predominant microconstituent. Furthermore, retained austenite with optimum characteristics (volume fraction, composition, morphology, size, and distribution), when present in ferrite plus bainite microstructures, can potentially increase strength and ductility, such that formability and final properties are greatly improved. These beneficial properties can be obtained largely by transformation-induced plasticity (TRIP). In this work, the effect of a microalloy addition (0.035 pct Nb) in a 0.22 pct C-1.55 pct Si-1.55 pct Mn TRIP steel was investigated. Niobium was added to enable the steel to be processed by a variety of thermomechanical processing (TMP) routes, thus allowing the effects of prior austenite grain size, austenite recrystallization temperature, Nb in austenite solid solution, and Nb as a precipitate to be studied. The results, which were compared with those of the same steel without Nb, indicate that the retained austenite volume fraction is strongly influenced by both prior austenite grain size and the state of Nb in austenite. Promoting Nb(CN) precipitation by the change in TMP conditions resulted in a decrease in the V RA . These findings are rationalized by considering the effects of changes in the TMP conditions on the subsequent transformation characteristics of the parent austenite.

Wear characteristics of TiNi shape memory alloys

Abstract: The wear characteristics of TiNi shape memory alloys against Cr-steel have been studied. Experimental results indicate that the Ti49Ni51 alloy can exhibit a better wear resistance than Ti50Ni50 alloy due to their higher hardness and pseudoelastic behaviors. Four main mechanisms, adhesion, abrasion, surface fatigue, and brinelling, are found to have important contributions to the wear characteristics of TiNi alloys. The weight loss increases with increasing wear load and sliding distance but decreases with increasing sliding speed. The contact area during sliding wear will be increased due to the variant accommodation and/or pseudoelasticity and, hence, will reduce the average compressive stress and wear damage. Variant accommodation and/or pseudoelasticity can also stabilize the crack tips and hinder crack propagation, hence improving the wear characteristics of TiNi alloys.

Influence of microstructure on fracture toughness of austempered ductile iron

Abstract: An investigation was carried out to examine the influence of microstructure on the plane strain fracture toughness of austempered ductile iron. Austempered ductile iron (ADI) alloyed with nickel, copper, and molybdenum was austenitized and subsequently austempered over a range of temperatures to produce different microstructures. The microstructures were characterized through optical microscopy and X-ray diffraction. Plane strain fracture toughness of all these materials was determined and was correlated with the microstructure. The results of the present investigation indicate that the lower bainitic microstructure results in higher fracture toughness than upper bainitic microstructure. Both volume fraction of retained austenite and its carbon content influence the fracture toughness. The retained austenite content of 25 vol pct was found to provide the optimum fracture toughness. It was further concluded that the carbon content of the retained austenite should be as high as possible to improve fracture toughness.

Mechanically activated carbothermic reduction of ilmenite

Abstract: A systematic study of the effect of milling conditions on the low-temperature carbothermic reduction of the mineral ilmenite has been carried out. It was found that after ball milling of an ilmenite-carbon mixture at room temperature, the ilmenite was reduced to rutile and metallic iron during subsequent low-temperature annealing (760 °C for 30 minutes). A longer milling time results in a lower reduction temperature and a higher reduction rate. Higher milling intensity also leads to a lower reduction temperature. This enhanced reduction reaction induced by ball milling mainly results from the intimate mixing and large contact area between milled ilmenite and carbon particles.

Microstructure of Ti-48.2 at. Pct Ni shape memory thin films

Abstract: Amorphous thin films of Ti-48.2 at. pct Ni formed by sputtering were annealed at 773 K for 5 minutes, 1 hour, and 10 hours. It was found by transmission electron microscopy (TEM) that the microstructure changes in the sequence of (1) Guinier-Preston (GP) zones for 5 minutes, (2) GP zones and Ti2Ni precipitates for 1 hour, and (3) Ti2Ni precipitates for 10 hours. A high-resolution electron microscope (HREM) revealed that Ti2Ni precipitates have partial coherency with the TiNi matrix.