Sample records for solidification modes grain

  1. Alternating grain orientation and weld solidification cracking

    Kou, S.; Le, Y.


    A new mechanism for reducing weld solidification cracking was proposed, based on the concept of the crack path and resistance to crack propagation, and its effectiveness was verified in magnetically oscillated GTA welds of a rather crack susceptible material 2014 aluminum alloy. This mechanism, i.e., alternating grain orientation, was most pronounced in welds made with transverse arc oscillation of low frequency and high amplitude, and solidification cracking was dramatically reduced in these welds. The effect of the arc oscillation pattern, amplitude, and frequency on the formation of alternating columnar grains and the reduction of solidification cracking in GTA welds of 2014 aluminum alloy was examined and explained. The present study demonstrated for the first time that columnar grains can, in fact, be very effective in reducing solidification cracking, provided that they are oriented favorably.

  2. Effect of solidification rate on competitive grain growth in directional solidification of a nickel-base superalloy

    ZHOU YiZhou; SUN XiaoFeng


    The mechanism of grain structure evolution during directional solidification is a fundamental subject in material science.Within the published research there exist conflicting views on the mechanism of grain overgrowth.To study the effect of solidification rate on grain structure evolution,bi-crystals samples were produced in a nickel-base superalloy at different solidification rates.It was found that at the convergent grain boundaries those grains better aligned with respect to the heat flux more readily overgrew neighbouring grains with misaligned orientations and the effect became more pronounced as solidification rate was increased.However,at diverging grain boundaries the rate of overgrowth was invariant to the solidification rate.These experimental results were compared with models in the literature.Thus,a better insight into competitive grain growth in directional solidification processes was obtained.

  3. Solidification Based Grain Refinement in Steels


    likely to form, the author conducted a Schiel solidification analysis using Thermo-Calc. Table 2 lists the steel chemistry used based on the actual...the phases present during freezing were calculated. Table 3 Steel chemistry used fur Schiel analysis. C (wt. %) Mn (wt %) AKwt. %) Ti(wt. %) N(wt...0.4 0.6 0.8 Mole fraction of all solid phases Figure 23 Schiel solidification analysis for 0.1 % Ti containing 1030 steel. Figure 25 depicts the

  4. Competitive growth of high purity aluminum grains in directional solidification

    ZHANG Jiao; SHU Da; WANG De-lin; SUN Bao-de; CHEN Gang


    A self-made directional solidification setup was used to prepare high purity aluminum ingots of 100mm in diameter. The morphology of the growth interface was detected by SEM and AFM, and the grain lattice orientation was detected by XRD. The results indicate that the grains suffer competitive growth under any conditions in experiments. The lattice orientation of the preferred grains is determined by the flow field above the solid-liquid interface. The horizontal lattice position does not change during the growth process. However, the lattice orientation in the growth direction varies with the growth velocity and approaches to [100]gradually during the growth process.

  5. Understanding Solidification Based Grain Refinement in Steels


    interatomic spacing along [uvw]s, and 0 = the angle between the [uvwjjand [uvw]n.^’ Work on the grain refinement of aluminum and magnesium alloys has found...chemistry ternary plot from ASPEX system. The author found some evidence of reactions occurring with some rare earth oxide or sulfide inclusions and... sulfide .^^"^^ Another approach would be to react a sample of misch metal or rare earth silicide at elevated temperatures to form the desired oxide or

  6. Solidification of Suspended Sediments with Two Characteristic Grain Sizes

    Zarski, G.; Borja, R. I.


    We use mixture theory to formulate the problem of solidification of sediments with two characteristic grain sizes in a suspension. The formulation involves a mixture of larger grains in a thick fluid, where the thick fluid is a mixture of smaller particles in a host fluid. This mixture within a mixture description resembles a double porosity representation in unsaturated soil mechanics. Two independent variables of interest include the volume fraction of the larger grains relative to the total volume of the mixture, and the volume fraction of the smaller grains relative to the volume of the thick fluid. The two volume fractions are coupled by a constitutive law based on the Richardson-Zaki equation. The governing partial differential equations describing the settling velocities of the two solid groups are solved simultaneously in space and time using the finite element method.

  7. Evolution of grain structures during directional solidification of silicon wafers

    Lin, H. K.; Wu, M. C.; Chen, C. C.; Lan, C. W.


    The evolution of grain structures, especially the types of grain boundaries (GBs), during directional solidification is crucial to the electrical properties of multicrystalline silicon used for solar cells. To study this, the electric molten zone crystallization (EMZC) of silicon wafers at different drift speeds from 2 to 6 mm/min was considered. It was found that orientation was dominant at the lower drift velocity, while orientation at the higher drift velocity. Most of the non-∑GBs tended to align with the thermal gradient, but some tilted toward the unfavorable grains having higher interfacial energies. On the other hand, the tilted ∑3GBs tended to decrease during grain competition, except at the higher speed, where the twin nucleation became frequent. The competition of grains separated by ∑GBs could be viewed as the interactions of GBs that two coherent ∑3n GBs turned into one ∑3nGB following certain relations as reported before. On the other hand, when ∑ GBs met non-∑ GBs, the non-∑ GBs remained which explained the decrease of ∑ GBs at the lower speed.

  8. Phase-field model of isothermal solidification with multiple grain growth

    Feng Li; Wang Zhi-Ping; Zhu Chang-Sheng; Lu Yang


    This paper develops a new phase-field model for equiaxed dendrite growth of multiple grains in multicomponent alloys based on the Ginzberg-Landau theory and phase-field model of a single grain. Taking Al-Cu and Al-Cu-Mg alloys for example, it couples the concentration field and simulates the dendrite growth process of multiple grains during isothermal solidification. The result of the simulation shows dendrite competitive growth of multiple grains, and is reapplied to the process of dendrite growth in practical solidification.

  9. Effect of strontium and solidification rate on eutectic grain structure in an AI-13 wt% Si alloy

    Liao Hengcheng; Bi Juanjuan; Zhang Min; Ding Ke; Jiang Yunfeng; Cai Mingdong


    The influence of strontium addition and solidification rate on eutectic grain structure in a near-eutectic AI-Si alloy was investigated. The characteristic temperature of eutectic nucleation (TN),minimum temperature prior to recalescence (TM),and the growth temperature (TG) during cooling were determined by quantitative thermal analysis. All characteristic temperatures were found to decrease continuously with increasing Sr content and solidification rate. Microstructural analysis also revealed that the eutectic grain size decreases with increasing Sr content and solidification rate. Such eutectic grain refinement is attributed to the increased actual under-cooling ahead of the liquid/solid interface during solidification.

  10. Phase field modeling of grain structure evolution during directional solidification of multi-crystalline silicon sheet

    Lin, H. K.; Lan, C. W.


    Evolution of grain structures and grain boundaries (GBs), especially the coincident site lattice GBs, during directional solidification of multi-crystalline silicon sheet are simulated by using a phase field model for the first time. Since the coincident site lattice GBs having lower mobility, tend to follow their own crystallographic directions despite thermal gradients, the anisotropic energy and mobility of GBs are considered in the model. Three basic interactions of GBs during solidification are examined and they are consistent with experiments. The twinning process for new grain formation is further added in the simulation by considering twin nucleation. The effect of initial distribution of GB types and grain orientations is also investigated for the twinning frequency and the evolution of grain size and GB types.

  11. Macrosegregation and Grain Formation Caused by Convection Associated with Directional Solidification Through Cross-Section Increase

    Ghods, Masoud; Lauer, Mark; Tewari, Surendra; Poirier, David; Grugel, Richard


    Cylindrical Al-7 wt% Silicon, Al-19 wt% Copper and Lead-6 wt% Antimony alloy samples were directionally solidified (DS) with liquid above, solid below, and gravity pointing down, in graphite crucibles having an abrupt cross-sectional increase. These alloys have similar solidification shrinkage but are expected to have different degrees of thermosolutal convection during solidification. Microstructures in the DS samples in the vicinity of the section change have been studied in order to examine the effect of convection associated with the combined influence of thermosolutal effects and solidification shrinkage. Extensive radial and axial macrosegregation associated with cross-section change is observed. It also appears that steepling and local primary alpha-phase remelting resulting from convection are responsible for stray grain formation at the reentrant corners. Preliminary results from a numerical model, which includes solidification shrinkage and thermosolutal convection in the mushy zone, indicate that these regions are prone to solutal remelting of dendrites.

  12. DEM simulation of dendritic grain random packing: application to metal alloy solidification

    Olmedilla, Antonio; Založnik, Miha; Combeau, Hervé


    The random packing of equiaxed dendritic grains in metal-alloy solidification is numerically simulated and validated via an experimental model. This phenomenon is characterized by a driving force which is induced by the solid-liquid density difference. Thereby, the solid dendritic grains, nucleated in the melt, sediment and pack with a relatively low inertia-to-dissipation ratio, which is the so-called Stokes number. The characteristics of the particle packed porous structure such as solid packing fraction affect the final solidified product. A multi-sphere clumping Discrete Element Method (DEM) approach is employed to predict the solid packing fraction as function of the grain geometry under the solidification conditions. Five different monodisperse noncohesive frictionless particle collections are numerically packed by means of a vertical acceleration: a) three dendritic morphologies; b) spheres and c) one ellipsoidal geometry. In order to validate our numerical results with solidification conditions, the sedimentation and packing of two monodisperse collections (spherical and dendritic) is experimentally carried out in a viscous quiescent medium. The hydrodynamic similarity is respected between the actual phenomenon and the experimental model, that is a low Stokes number, o(10-3). In this way, the experimental average solid packing fraction is employed to validate the numerical model. Eventually, the average packing fraction is found to highly depend on the equiaxed dendritic grain sphericity, with looser packings for lower sphericity.

  13. Large-grained copper indium diselenide crystal growth by computer-controlled high-pressure liquid-encapsulated directional solidification

    Schwerdtfeger, C. R.; Ciszek, T. F.


    Large-grained copper indium diselenide crystal growth by computer-controlled high-pressure liquid-encapsulated directional solidification is presented. A supply of good quality angle crystals is essential to characterization of the fundamental material properties. [AIP

  14. Numerical Simulation of Solidification Microstructure and Effects of Phase-field Parameters on Grain Growth Morphologies

    Jingfeng LIU; Ruixiang LIU; Liliang CHEN


    By a simple phase field model, a series of numerical simulations of solidification microstructure was performed to show a rich variety of dendritic patterns. At the same time, the relation between the morphology of grain growth and some parameters including the strength of anisotropy, dimensionless latent heat and the size of initial solid zone was studied. It is for the first time that patterns of grain growth were associated with the size of initial solid zone,which is an interesting issue. The possible reason for this may be that variation in the size of initial solid zone may bring about fluctuation of the interface energy, making the interface unstable.

  15. Effect of current and atomized grain size distribution on the solidification of Plasma Transferred Arc coatings

    Danielle Bond


    Full Text Available Plasma Transferred Arc (PTA is the only thermal spray process that results in a metallurgical bond, being frequently described as a hardfacing process. The superior properties of coatings have been related to the fine microstructures obtained, which are finer than those processed under similar heat input with welding techniques using wire feedstock. This observation suggests that the atomized feedstock plays a role on the solidification of coatings. In this study a model for the role of the powders grains in the solidification of PTA coatings is put forward and discussed. An experiment was setup to discuss the model which involved the deposition of an atomized Co-based alloy with different grain size distributions and deposition currents. X ray diffraction showed that there were no phase changes due to the processing parameters. Microstructure analysis by Laser Confocal Microscopy, dilution with the substrate steel and Vickers microhardness were used the characterized coatings and enriched the discussion confirming the role of the powdered feedstock on the solidification of coatings.

  16. Orientation-field models for polycrystalline solidification: Grain coarsening and complex growth forms

    Korbuly, Bálint; Pusztai, Tamás; Tóth, Gyula I.; Henry, Hervé; Plapp, Mathis; Gránásy, László


    We compare two versions of the phase-field theory for polycrystalline solidification, both relying on the concept of orientation fields: one by Kobayashi et al. [Physica D 140 (2000) 141] [15] and the other by Henry et al. [Phys. Rev. B 86 (2012) 054117] [22]. Setting the model parameters so that the grain boundary energies and the time scale of grain growth are comparable in the two models, we first study the grain coarsening process including the limiting grain size distribution, and compare the results to those from experiments on thin films, to the models of Hillert, and Mullins, and to predictions by multiphase-field theories. Next, following earlier work by Gránásy et al. [Phys. Rev. Lett. 88 (2002) 206105; Phys. Rev. E 72 (2005) 011605] [17,21], we extend the orientation field to the liquid state, where the orientation field is made to fluctuate in time and space, and employ the model for describing of multi-dendritic solidification, and polycrystalline growth, including the formation of "dizzy" dendrites disordered via the interaction with foreign particles.

  17. Effect of a Transverse Magnetic Field on Stray Grain Formation of Ni-Based Single Crystal Superalloy During Directional Solidification

    Xuan, Weidong; Liu, Huan; Lan, Jian; Li, Chuanjun; Zhong, Yunbo; Li, Xi; Cao, Guanghui; Ren, Zhongming


    The effect of a transverse magnetic field on stray grain formation during directional solidification of superalloy was investigated. Experimental results indicated that the transverse magnetic field effectively suppressed the stray grain formation on the side the primary dendrite diverges from the mold wall. Moreover, the quenched experimental results indicated that the solid/liquid interface shape was obviously changed in a transverse magnetic field. The effect of a transverse magnetic field on stray grain formation was discussed.

  18. Nonequilibrium Solidification, Grain Refinements, and Recrystallization of Deeply Undercooled Ni-20 At. Pct Cu Alloys: Effects of Remelting and Stress

    Xu, Xiaolong; Hou, Hua; Zhao, Yuhong; Liu, Feng


    Grain refinement phenomena during the microstructural evolution upon nonequilibrium solidification of deeply undercooled Ni-20 at. pct Cu melts were systematically investigated. The dendrite growth in the bulk undercooled melts was captured by a high-speed camera. The first kind of grain refinement occurring in the low undercooling regimes was explained by a current grain refinement model. Besides, for the dendrite melting mechanism, the stress originating from the solidification contraction and thermal strain in the FMZ during rapid solidification could be a main mechanism causing the second kind of grain refinement above the critical undercooling. This internal stress led to the distortion and breakup of the primary dendrites and was semiquantitatively described by a corrected stress accumulation model. It was found that the stress-induced recrystallization could make the primary microstructures refine substantially after recalescence. A new method, i.e., rapidly quenching the deeply undercooled alloy melts before recalescence, was developed in the present work to produce crystalline alloys, which were still in the cold-worked state and, thus, had the driven force for recrystallization.

  19. Molecular dynamics simulations investigating consecutive nucleation, solidification and grain growth in a twelve-million-atom Fe-system

    Okita, Shin; Verestek, Wolfgang; Sakane, Shinji; Takaki, Tomohiro; Ohno, Munekazu; Shibuta, Yasushi


    Continuous processes of homogeneous nucleation, solidification and grain growth are spontaneously achieved from an undercooled iron melt without any phenomenological parameter in the molecular dynamics (MD) simulation with 12 million atoms. The nucleation rate at the critical temperature is directly estimated from the atomistic configuration by cluster analysis to be of the order of 1034 m-3 s-1. Moreover, time evolution of grain size distribution during grain growth is obtained by the combination of Voronoi and cluster analyses. The grain growth exponent is estimated to be around 0.3 from the geometric average of the grain size distribution. Comprehensive understanding of kinetic properties during continuous processes is achieved in the large-scale MD simulation by utilizing the high parallel efficiency of a graphics processing unit (GPU), which is shedding light on the fundamental aspects of production processes of materials from the atomistic viewpoint.

  20. The Production of Material with Ultrafine Grain Structure in Al-Zn Alloy in the Process of Rapid Solidification

    Szymaneka M.


    Full Text Available In the aluminium alloy family, Al-Zn materials with non-standard chemical composition containing Mg and Cu are a new group of alloys, mainly owing to their high strength properties. Proper choice of alloying elements, and of the method of molten metal treatment and casting enable further shaping of the properties. One of the modern methods to produce materials with submicron structure is a method of Rapid Solidification. The ribbon cast in a melt spinning device is an intermediate product for further plastic working. Using the technique of Rapid Solidification it is not possible to directly produce a solid structural material of the required shape and length. Therefore, the ribbon of an ultrafine grain or nanometric structure must be subjected to the operations of fragmentation, compaction, consolidation and hot extrusion.

  1. Two-dimensional phase-field study of competitive grain growth during directional solidification of polycrystalline binary alloy

    Takaki, Tomohiro; Ohno, Munekazu; Shibuta, Yasushi; Sakane, Shinji; Shimokawabe, Takashi; Aoki, Takayuki


    Selections of growing crystals during directional solidification of a polycrystalline binary alloy were numerically investigated using two-dimensional phase-field simulations. To accelerate the simulations, parallel graphics processing unit (GPU) simulations were performed using the GPU-rich supercomputer TSUBAME2.5 at the Tokyo Institute of Technology. Twenty simulations with a combination of five sets of different seed orientation distributions and four different temperature gradients covering dendritic and cellular growth regions were performed. The unusual grain selection phenomenon, in which the unfavorably oriented grains preferentially grow instead of the favorably oriented grains, was observed frequently. The unusual selection was more remarkable in the cellular structure than in the dendritic structure.

  2. High temperature phase chemistries and solidification mode prediction in nitrogen-strengthened austenitic stainless steels

    Ritter, Ann M.; Henry, Michael F.; Savage, Warren F.


    Nitronic 50 and Nitronic 50W, two nitrogen-strengthened stainless steels, were heat treated over a wide range of temperatures, and the compositions of the ferrite and austenite at each temperature were measured with analytical electron microscopy techniques. The compositional data were used to generate the (γ + δ phase field on a 58 pct Fe vertical section. Volume fractions of ferrite and austenite were calculated from phase chemistries and compared with volume fractions determined from optical micrographs. Weld solidification modes were predicted by reference to the Cr and Ni contents of each alloy, and the results were compared with predictions based on the ratios of calculated Cr and Ni equivalents for the alloys. Nitronic 50, which contained ferrite and austenite at the solidus temperature of 1370 °C, solidified through the eutectic triangle, and the weld microstructure was similar to that of austenitic-ferritic solidification. Nitronic 50W was totally ferritic at 1340 °C and solidified as primary delta ferrite. During heat treatments, Nitronic 50 and Nitronic 50W precipitated secondary phases, notably Z-phase (NbCrN), sigma phase, and stringered phases rich in Mn and Cr.

  3. Grain Refinement and Improvement of Solidification Defects in Direct-Chill Cast Billets of A4032 Alloy by Melt Conditioning

    Li, Hu-Tian; Zhao, Pizhi; Yang, Rongdong; Patel, Jayesh B.; Chen, Xiangfu; Fan, Zhongyun


    Melt-conditioned, direct-chill (MC-DC) casting is an emerging technology to manipulate the solidification process by melt conditioning via intensive shearing in the sump during DC casting to tailor the solidification microstructure and defect formation. When using MC-DC casting technology in an industrial scale DC cast billet of an A4032 aluminum alloy, significant grain refinement and uniform microstructure can be achieved in the primary α-Al phase with fine secondary dendritic arm spacing (SDAS). Improved macrosegregation is quantitatively characterized and correlated with the suppression of channel segregation. The mechanisms for the prevention of channel segregation are attributed to the increased local cooling rate in the liquid-solid phase region in the sump and the formation of fine equiaxed dendritic grains under intensive melt shearing during MC-DC casting. A critical cooling rate has been identified to be around 0.5 to 1 K/s (°C/s) for the channel segregation to happen in the investigated alloy based on quantitative metallographic results of SDAS. Reduction and refinement of microporosity is attributed to the improved permeability in the liquid-solid phase region estimated by the Kozeny-Carman relationship. The potential improvement in the mechanical properties achievable in MC-DC cast billets is indicated by the finer and more uniform forging streamline in the forgings of MC-DC cast billet.

  4. Mode-converted ultrasonic scattering in polycrystals with elongated grains.

    Arguelles, Andrea P; Kube, Christopher M; Hu, Ping; Turner, Joseph A


    Elastic wave scattering is used to study polycrystalline media for a wide range of applications. Received signals, which include scattering from the randomly oriented grains comprising the polycrystal, contain information from which useful microstructural parameters may often be inferred. Recently, a mode-converted diffuse ultrasonic scattering model was developed for evaluating the scattered response of a transverse wave from an incident longitudinal wave in a polycrystalline medium containing equiaxed single-phase grains with cubic elastic symmetry. In this article, that theoretical mode-converted scattering model is modified to account for grain elongation within the sample. The model shows the dependence on scattering angle relative to the grain axis orientation. Experimental measurements were performed on a sample of 7475-T7351 aluminum using a pitch-catch transducer configuration. The results show that the mode-converted scattering can be used to determine the dimensions of the elongated grains. The average grain shape determined from the experimental measurements is compared with dimensions extracted from electron backscatter diffraction, an electron imaging technique. The results suggest that mode-converted diffuse ultrasonic scattering has the potential to quantify detailed information about grain microstructure.

  5. Evolution of Grain Selection in Spiral Selector during Directional Solidification of Nickel-base Superalloys

    Xiangbin Meng; Jinguo Li; Tao Jin; Xiaofeng Sun; Changbo Sun; Zhuangqi Hu


    The process of grain selection in the spiral selector was investigated by both a ProCAST simulation based on a cellular automaton finite element (CAFE) model and experimental confirmation. The results show that the height of starter block, the spiral diameter and initial angle play an important role in grain selection. The dimension of selector should be maintained in a stable range to optimize the grain orientation and select a single crystal efficiently. A selector which can efficiently select a single crystal had been successfully designed. Grain orientation fluctuation in the spiral part was also studied by means of the variation of thermal condition.

  6. Modelling directional solidification

    Wilcox, William R.; Regel, Liya L.


    This grant, NAG8-831, was a continuation of a previous grant, NAG8-541. The long range goal of this program has been to develop an improved understanding of phenomena of importance to directional solidification, in order to enable explanation and prediction of differences in behavior between solidification on Earth and in space. Emphasis in the recently completed grant was on determining the influence of perturbations on directional solidification of InSb and InSb-GaSb alloys. In particular, the objective was to determine the influence of spin-up/spin-down (ACRT), electric current pulses and vibrations on compositional homogeneity and grain size.

  7. Solidification and casting

    Cantor, Brian


    INDUSTRIAL PERSPECTIVEDirect chillcasting of aluminium alloysContinuous casting of aluminium alloysContinuous casting of steelsCastings in the automotive industryCast aluminium-silicon piston alloysMODELLING AND SIMULATIONModelling direct chill castingMold filling simulation of die castingThe ten casting rulesGrain selection in single crystal superalloy castingsDefects in aluminium shape castingPattern formation during solidificationPeritectic solidificationSTRUCTURE AND DEFECTSHetergeneous nucleation in aluminium alloysCo

  8. Solidification and transformation behavior of Cr-Ni stainless steel weld metals with ferritic single phase solidification mode. Report 4. Study on solidification and subsequent transformation of Cr-Ni stainless steel weld metals; Feraito tanso de gyokosuru Cr-Ni kei sutenresu ko yosetsu kinzoku no gyoko/hendo kyodo. 4. Cr-Ni kei sutenresu ko yosetsu kinzoku no gyoko/hentai ni kansuru kenkyu

    Inoue, H.; Koseki, T.; Okita, S.; Fuji, M. [Nippon Steel Corp., Tokyo (Japan)


    The solidification modes of {gamma} stainless steel that solidifies at initial crystal {delta} are classified into FA mode where solidification at two phase of {delta}+{gamma} takes place after crystallization at {gamma} phase during solidification and F mode where solidification is completed at {delta} single phase, and solidification transformation behaviors of weld metal of FA mode are reported in the previous paper. Hereupon, in this report, solidification and transformation behaviors of stainless steel weld metal of F mode are studied. Cr-Ni stainless steel of F mode consists of two phase stainless steel with two phase base metal structure of {delta}+{gamma} besides {gamma} stainless steel. Further, two phase stainless steel with higher alloy compared to conventional one has been developed. In this report, not only the {gamma} stainless steel but also two phase stainless weld metals with varied amount of alloying metal are studied. The welding method and welding conditions are same as that of previous paper. Observation of structure was carried out by optical microscope, and crystal orientation and element distribution were measured by EBSP and CMA respectively. 11 refs., 18 figs., 1 tab.

  9. Fatigue Failure Modes of the Grain Size Transition Zone in a Dual Microstructure Disk

    Gabb, Timothy P.; Kantzos, Pete T.; Palsa, Bonnie; Telesman, Jack; Gayda, John; Sudbrack, Chantal K.


    Mechanical property requirements vary with location in nickel-based superalloy disks. In order to maximize the associated mechanical properties, heat treatment methods have been developed for producing tailored grain microstructures. In this study, fatigue failure modes of a grain size transition zone in a dual microstructure disk were evaluated. A specialized heat treatment method was applied to produce varying grain microstructure in the bore to rim portions of a powder metallurgy processed nickel-based superalloy disk. The transition in grain size was concentrated in a zone of the disk web, between the bore and rim. Specimens were extracted parallel and transversely across this transition zone, and multiple fatigue tests were performed at 427 C and 704 C. Grain size distributions were characterized in the specimens, and related to operative failure initiation modes. Mean fatigue life decreased with increasing maximum grain size, going out through the transition zone. The scatter in limited tests of replicates was comparable for failures of uniform gage specimens in all transition zone locations examined.

  10. Influence of nano-inclusions' grain boundaries on crack propagation modes in materials

    Karakasidis, T.E., E-mail: [Department of Civil Engineering, University of Thessaly, Pedion Areos, 38834 Volos (Greece); Charitidis, C.A. [National Technical University of Athens, School of Chemical Engineering, 9 Heroon Polytechniou st., Zografos, 157 80 Athens (Greece)


    The effect of nano-inclusions on materials' strength and toughness has attracted great interest in recent years. It has been shown that tuning the morphological and microstructural features of materials can tailor their fracture modes. The existence of a characteristic size of inclusions that favours the fracture mode (i.e. transgranular or intergranular) has been experimentally observed but also predicted by a 2D model based on energetic arguments which relates the crack propagation mode to the ratio of the interface area between the crystalline inclusion and the matrix with the area of the crystallite inclusion in a previous work. In the present work, a 3D model is proposed in order to extend the 2D model and take into account the influence of the size of grain boundary zone on the toughening/hardening behavior of the material as it was observed experimentally in the literature. The model relates crack propagation mode to the ratio of the volume of the grain boundary zone between the crystalline inclusion and the matrix with the volume of the nano-inclusion. For a ratio below a critical value, transgranular propagation is favoured while for larger values, intergranular propagation is favoured. We also demonstrate that the extent of the grain boundary region also can significantly affect this critical value. The results of the model are in agreement with the literature experimental observations related to the toughening/hardening behavior as a function of the size of crystalline inclusions as well as the width of the grain boundary regions.

  11. A visualization of the eutectic solidification process

    E. Olejnik


    Full Text Available The study presents a visualization of the sequence of formation of eutectic grains during solidification in volume and directional solidification of model organic materials from the system of salol (faceted phase - camphor (non-faceted phase and carbon tetrabromide (non-faceted phase - hexachloroethane (non-faceted phase. It has been proved that the faceted phase may act as a substrate for nucleation of the non-faceted phase, while the non-faceted phase in a eutectic grain is of polycrystalline character. The directional solidification of non-faceted/non-faceted eutectic enabled disclosing various structural defects, while solidification in volume explained in what way the, so called, halo effect is formed.

  12. Depositional and Immersion-Mode Ice Nucleation of Fine-Grained Volcanic Ash Samples

    Cloer, S.; Woods, T.; Genareau, K. D.


    Volcanic lightning is a common phenomenon during explosive eruptions; occurring as vent discharges, near-vent discharges, and plume lightning. Plume lightning is most similar to thunderstorm lightning, where volcanic ash may act as ice nuclei. Volcanic ash samples derived from eight volcanoes: Augustine, Crater Peak, Katmai, Okmok, Redoubt (Alaska, U.S.A.), Lathrop Well (Nevada, U.S.A.), Taupo (New Zealand), and Valles Caldera (New Mexico, U.S.A.); were used to determine what roles ash mineralogy, particularly Fe-oxide-bearing minerals and silica-enriched minerals, grain shape, and grain size have in the nucleation of ice, which can generate plume lightning. Depositional and immersion-mode ice nucleation experiments were performed using a Nicolet Almega XR Dispersive Raman spectrometer, following the methods of Schill et al. (2015), where samples were shaken for 24 h prior to experiments in ultra-pure water, then nebulized to super micron droplets. Depositional nucleation experiments were conducted from 225-235 K, and immersion-mode nucleation experiments were conducted from 233-278 K. A JEOL JSM 6010 Plus/LA scanning electron microscope (SEM), along with Image-J freeware, was used to quantify the number density of Fe-oxide mineral phases in backscattered electron images, with an x-ray diffractometer (XRD) used to determine bulk mineral abundance and an x-ray fluorescence (XRF) spectrometer to determine bulk ash composition. Based on previous studies, we hypothesize that all ash samples will efficiently form depositional ice nuclei; however, certain mineral phases will dictate the efficiency of immersion-mode ice nucleation including K or Na / Ca feldspars, which have been shown to be efficient nuclei, and Fe-oxide-bearing minerals. These results will shed new light on volcanic cloud dynamics and add new parameters for atmospheric models, which currently only address effects of mineral dust as ice nuclei and overlook the potential role of volcanic ash.

  13. Non-equilibrium solidification of undercooled Ni-31.44%Pb monotectic alloy melts

    郑红星; 谢辉; 郭学锋


    By using the method of molten glass denucleating combined with superheating cycling, solidification behavior of the bulk undercooled Ni-31.44%Pb monotectic alloy melts was systematically investigated. The results indicated that the undercooled monotectic alloy solidifies in form of dendrite essentially during the stage of rapid solidification and after recalescence, the residual melts between the dendrites solidify in the equilibrium mode. Within the achieved undercooling range, the solidification structures are classified into three categories. When the undercooling is less than 50K, the structures are composed of coarse dendrites and interdendritic lead phase. With the undercooling increasing into the range of 70~232K, the dendrite clusters are refined and fine lead particles separate out from the supersaturated primary dendrite arms because of solute trapping. When the undercooling exceeds 242K, the granular grains form and fine lead particles homogeneously distribute in the whole sample. Based on the observation of the solidification structures and the calculated results with BCT model, it is found that the granulation mechanism of the granular grains is owing to the primary dendrite disintegration and recrystallization.

  14. Effects of Pulse Current on Solidification Structure of Austenitic Stainless Steel

    FAN Jin-hui; CHEN Yu; LI Ren-xing; ZHAI Qi-jie


    The 1Cr18Ni9Ti specimens were treated respectively with pulse current under 520 V and 2 600 V during solidification and the solidification structure was observed. The results showed that pulse current can refine solidification grains, cut primary dentrities remarkably and reduce second dentritic arm spacing. The mechanism and effect are changed with operation parameters.

  15. Evolution of solidification texture during additive manufacturing.

    Wei, H L; Mazumder, J; DebRoy, T


    Striking differences in the solidification textures of a nickel based alloy owing to changes in laser scanning pattern during additive manufacturing are examined based on theory and experimental data. Understanding and controlling texture are important because it affects mechanical and chemical properties. Solidification texture depends on the local heat flow directions and competitive grain growth in one of the six preferred growth directions in face centered cubic alloys. Therefore, the heat flow directions are examined for various laser beam scanning patterns based on numerical modeling of heat transfer and fluid flow in three dimensions. Here we show that numerical modeling can not only provide a deeper understanding of the solidification growth patterns during the additive manufacturing, it also serves as a basis for customizing solidification textures which are important for properties and performance of components.

  16. Evaluation of microstructure of A356 aluminum alloy casting prepared under vibratory conditions during the solidification



    The objective of this investigation was to evaluate the effect of vibrations (during solidification) on the metallurgical properties of A356 aluminum casting. Mechanical vibrations were applied to A356 aluminum alloy through set up. A356 melt has been subjected to mechanical vibration with the frequency range from 0 to 400 Hz with constant amplitude 5 lm. Grain refinement was obtained through mold vibration. Metallurgical properties were examined through optical microstructure, tensile fracture scanning electron microscope (SEM) and SEM image of test specimens prepared under different conditions of solidification. Results indicate that mold vibration effectively modified the microstructure of A356 casting and it has uniform and smaller grain sizewith fibrous silicon particle than nonvibrated casting. Grain refinement results increase in mechanical properties with increase in frequency of vibration of mold during the solidification. SEM micrograph of tensile fracture surface was carried out to study the influence of microstructure on fracture mode. SEM image of tensile fractured surface shows transgranular cleavage facets due to fracture of primary silicon particles. Fractures are brittle in nature so observation indicates low ductility and brittle fracture.

  17. Direct numerical simulation of solidification microstructures affected by fluid flow

    Juric, D.


    The effects of fluid flow on the solidification morphology of pure materials and solute microsegregation patterns of binary alloys are studied using a computational methodology based on a front tracking/finite difference method. A general single field formulation is presented for the full coupling of phase change, fluid flow, heat and solute transport. This formulation accounts for interfacial rejection/absorption of latent heat and solute, interfacial anisotropies, discontinuities in material properties between the liquid and solid phases, shrinkage/expansion upon solidification and motion and deformation of the solid. Numerical results are presented for the two dimensional dendritic solidification of pure succinonitrile and the solidification of globulitic grains of a plutonium-gallium alloy. For both problems, comparisons are made between solidification without fluid flow and solidification within a shear flow.

  18. Directional Solidification of Ledeburite

    M. Trepczyńska-Łent


    Full Text Available Directional solidification of ledeburite was realised out using a Bridgman’s device. The growth rate for movement sample v=83.3 μm/s was used. In one sample the solidification front was freezing. The value of temperature gradient in liquid at the solidification front was determined. Interfacial distance λ on the samples was measured with NIS-Elements application for image analysis.

  19. Solidification control in continuous casting of steel

    S Mazumdar; S K Ray


    An integrated understanding of heat transfer during solidification, friction/lubrication at solid-liquid interface, high temperature properties of the solidifying shell etc. is necessary to control the continuous casting process. The present paper elaborates upon the knowledge developed in the areas of initial shell formation, mode of mould oscillation, and lubrication mechanism. The effect of these issues on the caster productivity and the quality of the product has been discussed. The influence of steel chemistry on solidification dynamics, particularly with respect to mode of solidification and its consequence on strength and ductility of the solidifying shell, has been dealt with in detail. The application of these basic principles for casting of stainless steel slabs and processing to obtain good quality products have been covered.




    Full Text Available In this research solidification characteristic of metal matrix composites consisted of titanium carbide particulate reinforced aluminium-11.8% silicon alloy matrix is performed. Vortex mixing and permanent casting method are used as the manufacturing method to produce the specimens. Temperature measurements during the casting process are captured and solidification graphs are plotted to represent the solidification characteristic. The results show, as volume fraction of particulate reinforcement is increased, solidification time is faster. Particulate reinforcement promotes rapid solidification which will support finer grain size of the casting specimen. Hardness test is performed and confirmed that hardness number increased as more particulate are added to the system.

  1. Novel aspect in grain size control of nanocrystalline diamond film for thin film waveguide mode resonance sensor application.

    Lee, Hak-Joo; Lee, Kyeong-Seok; Cho, Jung-Min; Lee, Taek-Sung; Kim, Inho; Jeong, Doo Seok; Lee, Wook-Seong


    Nanocrystalline diamond (NCD) thin film growth was systematically investigated for application for the thin film waveguide mode resonance sensor. The NCD thin film was grown on the Si wafer or on the SiO2-coated sapphire substrate using the hot filament chemical vapor deposition (HFCVD). The structural/optical properties of the samples were characterized by the high-resolution scanning electron microscopy (HRSEM), high-resolution transmission electron microscopy (HRTEM), energy dispersive X-ray spectroscopy (EDS), near edge X-ray absorption fine structure (NEXAFS), X-ray diffraction (XRD), and ultraviolet-visible (UV-vis) spectroscopy. The waveguide modes of the NCD layer were studied by prism coupler technique using laser (wavelength: 632.8 nm) with varying incident angle. A novel aspect was disclosed in the grain size dependence on the growth temperature at the relatively low methane concentration in the precursor gas, which was important for optical property: the grain size increased with decreasing growth temperature, which was contrary to the conventional knowledge prevailing in the microcrystalline diamond (MCD) domain. We have provided discussions to reconcile such observation. An optical waveguide mode resonance was demonstrated in the visible region using the microstructure-controlled transparent NCD thin film waveguide, which provided a strong potential for the waveguide mode resonance sensor applications.

  2. Fundamental Metallurgy of Solidification

    Tiedje, Niels


    The text takes the reader through some fundamental aspects of solidification, with focus on understanding the basic physics that govern solidification in casting and welding. It is described how the first solid is formed and which factors affect nucleation. It is described how crystals grow from ...

  3. Relation between feeding mechanisms and solidification mode in 380 aluminium alloy with different iron contents; Relacion entre los mecanismos de alimentacion y el modo de solidificacion en una aleacion de aluminio 380 con distintos contenidos de hierro

    Tovio, D. O.; Gonzalez, A.C.; Mugica, G. W.; Cuyas, J. C.


    In the present work the effect of iron (0.15, 0.42 and 0.86%) content in feeding mechanisms for 380 aluminium alloy has been studied. The feeding capacity has been evaluated by a device that produces a barrier removable to allowing the movement of the inter dendritic liquid. The results show the flow of different quantity of liquid, it depends of the temperature of operating the device and of the iron content. For minimum and maximum iron content, the inter dendritic and bursts feeding mechanisms are fundamentally involved, for 0.42% of iron the feeding mechanisms was the inter dendritic. The authors establish this behavior by the solidification mode of alloy, which promotes the presence of particles of Si or plates of b-Al{sub 3}FeDi phase, in the inter dendritic channels and produce the different feeding mechanisms. (Author) 15 refs.

  4. Coarse grained normal mode analysis vs. refined Gaussian Network Model for protein residue-level structural fluctuations.

    Park, Jun-Koo; Jernigan, Robert; Wu, Zhijun


    We investigate several approaches to coarse grained normal mode analysis on protein residual-level structural fluctuations by choosing different ways of representing the residues and the forces among them. Single-atom representations using the backbone atoms C(α), C, N, and C(β) are considered. Combinations of some of these atoms are also tested. The force constants between the representative atoms are extracted from the Hessian matrix of the energy function and served as the force constants between the corresponding residues. The residue mean-square-fluctuations and their correlations with the experimental B-factors are calculated for a large set of proteins. The results are compared with all-atom normal mode analysis and the residue-level Gaussian Network Model. The coarse-grained methods perform more efficiently than all-atom normal mode analysis, while their B-factor correlations are also higher. Their B-factor correlations are comparable with those estimated by the Gaussian Network Model and in many cases better. The extracted force constants are surveyed for different pairs of residues with different numbers of separation residues in sequence. The statistical averages are used to build a refined Gaussian Network Model, which is able to predict residue-level structural fluctuations significantly better than the conventional Gaussian Network Model in many test cases.

  5. Coarse-Grained Langevin Equation for Protein Dynamics: Global Anisotropy and a Mode Approach to Local Complexity.

    Copperman, J; Guenza, M G


    We utilize a multiscale approach where molecular dynamic simulations are performed to obtain quantitative structural averages used as input to a coarse-grained Langevin equation for protein dynamics, which can be solved analytically. The approach describes proteins as fundamentally semiflexible objects collapsed into the free energy well representing the folded state. The normal-mode analytical solution to this Langevin equation naturally separates into global modes describing the fully anisotropic tumbling of the macromolecule as a whole and internal modes which describe local fluctuations about the folded structure. Complexity in the configurational free-energy landscape of the macromolecule leads to a renormalization of the internal modes, while the global modes provide a basis set in which the dipolar orientation and global anisotropy can be accounted for when comparing to experiments. This simple approach predicts the dynamics of both global rotational diffusion and internal motion from the picosecond to the nanosecond regime and is quantitative when compared to time correlation functions calculated from molecular dynamic simulations and in good agreement with nuclear magnetic resonance relaxation experiments. Fundamental to this approach is the inclusion of internal dissipation, which is absent in any rigid-body hydrodynamical modeling scheme.

  6. Parabolic aircraft solidification experiments

    Workman, Gary L. (Principal Investigator); Smith, Guy A.; OBrien, Susan


    A number of solidification experiments have been utilized throughout the Materials Processing in Space Program to provide an experimental environment which minimizes variables in solidification experiments. Two techniques of interest are directional solidification and isothermal casting. Because of the wide-spread use of these experimental techniques in space-based research, several MSAD experiments have been manifested for space flight. In addition to the microstructural analysis for interpretation of the experimental results from previous work with parabolic flights, it has become apparent that a better understanding of the phenomena occurring during solidification can be better understood if direct visualization of the solidification interface were possible. Our university has performed in several experimental studies such as this in recent years. The most recent was in visualizing the effect of convective flow phenomena on the KC-135 and prior to that were several successive contracts to perform directional solidification and isothermal casting experiments on the KC-135. Included in this work was the modification and utilization of the Convective Flow Analyzer (CFA), the Aircraft Isothermal Casting Furnace (ICF), and the Three-Zone Directional Solidification Furnace. These studies have contributed heavily to the mission of the Microgravity Science and Applications' Materials Science Program.

  7. Transient convective instabilities in directional solidification

    Meca, Esteban


    We study the convective instability of the melt during the initial transient in a directional solidification experiment in a vertical configuration. We obtain analytically the dispersion relation, and perform an additional asymptotic expansion for large Rayleigh number that permits a simpler analytical analysis and a better numerical behavior. We find a transient instability, i.e. a regime in which the system destabilizes during the transient whereas the final unperturbed steady state is stable. This could be relevant to growth mode predictions in solidification.

  8. Advances in Solidification Processing

    Hugo F. Lopez


    Full Text Available Melt solidification is the shortest and most viable route to obtain components, starting from the design to the finished products. Hence, a sound knowledge of the solidification of metallic materials is essential for the development of advanced structural metallic components that drive modern technological societies. As a result, there have been innumerable efforts and full conferences dedicated to this important subject [1–6]. In addition, there are various scientific journals fully devoted to investigating the various aspects which give rise to various solidification microstructures [7–9]. [...

  9. Time-of-Flight Three Dimensional Neutron Diffraction in Transmission Mode for Mapping Crystal Grain Structures.

    Cereser, Alberto; Strobl, Markus; Hall, Stephen A; Steuwer, Axel; Kiyanagi, Ryoji; Tremsin, Anton S; Knudsen, Erik B; Shinohara, Takenao; Willendrup, Peter K; da Silva Fanta, Alice Bastos; Iyengar, Srinivasan; Larsen, Peter M; Hanashima, Takayasu; Moyoshi, Taketo; Kadletz, Peter M; Krooß, Philipp; Niendorf, Thomas; Sales, Morten; Schmahl, Wolfgang W; Schmidt, Søren


    The physical properties of polycrystalline materials depend on their microstructure, which is the nano- to centimeter scale arrangement of phases and defects in their interior. Such microstructure depends on the shape, crystallographic phase and orientation, and interfacing of the grains constituting the material. This article presents a new non-destructive 3D technique to study centimeter-sized bulk samples with a spatial resolution of hundred micrometers: time-of-flight three-dimensional neutron diffraction (ToF 3DND). Compared to existing analogous X-ray diffraction techniques, ToF 3DND enables studies of samples that can be both larger in size and made of heavier elements. Moreover, ToF 3DND facilitates the use of complicated sample environments. The basic ToF 3DND setup, utilizing an imaging detector with high spatial and temporal resolution, can easily be implemented at a time-of-flight neutron beamline. The technique was developed and tested with data collected at the Materials and Life Science Experimental Facility of the Japan Proton Accelerator Complex (J-PARC) for an iron sample. We successfully reconstructed the shape of 108 grains and developed an indexing procedure. The reconstruction algorithms have been validated by reconstructing two stacked Co-Ni-Ga single crystals, and by comparison with a grain map obtained by post-mortem electron backscatter diffraction (EBSD).

  10. Solidification Based Grain Refinement in Steels


    and a coarser microstructure forms (See Figure 17). ROLE OF COBALT ALUMINATE CoAI204 produced very different results in the 1010 and 1030 TA...determine what role CoAl204 played in both steels. Other researchers have observed refinement with cobalt aluminate .2"󈧙 Their work has been using...produced in this work. The one unexplained result for CoAl204 is the different undercooling behavior found. Cobalt aluminate reduced undercooling in the

  11. Solidification microstructure development

    G Phanikumar; K Chattopadhyay


    In the present article, evolution of microstructure during solidification, as a function of various parameters, is discussed. Macrosegregation is described as being due to insufficient diffusivity of solute in the solid. Pattern formation is discussed in the light of instabilities at the solidification growth front. An overview of the scaling relations for various microstructures is given. Metastable extensions to equilibrium phase diagrams and corrections to equilibrium quantities are described.

  12. Time-of-Flight Three Dimensional Neutron Diffraction in Transmission Mode for Mapping Crystal Grain Structures

    Cereser, Alberto; Strobl, Markus; Hall, Stephen A.


    constituting the material. This article presents a new non-destructive 3D technique to study centimeter-sized bulk samples with a spatial resolution of hundred micrometers: time-of-flight three-dimensional neutron diffraction (ToF 3DND). Compared to existing analogous X-ray diffraction techniques, ToF 3DND...... enables studies of samples that can be both larger in size and made of heavier elements. Moreover, ToF 3DND facilitates the use of complicated sample environments. The basic ToF 3DND setup, utilizing an imaging detector with high spatial and temporal resolution, can easily be implemented at a time....... The reconstruction algorithms have been validated by reconstructing two stacked Co-Ni-Ga single crystals, and by comparison with a grain map obtained by post-mortem electron backscatter diffraction (EBSD)....

  13. Time-of-Flight Three Dimensional Neutron Diffraction in Transmission Mode for Mapping Crystal Grain Structures

    Cereser, Alberto; Strobl, Markus; Hall, Stephen A.


    constituting the material. This article presents a new non-destructive 3D technique to study centimeter-sized bulk samples with a spatial resolution of hundred micrometers: time-of-flight three-dimensional neutron diffraction (ToF 3DND). Compared to existing analogous X-ray diffraction techniques, ToF 3DND......-of-flight neutron beamline. The technique was developed and tested with data collected at the Materials and Life Science Experimental Facility of the Japan Proton Accelerator Complex (J-PARC) for an iron sample. We successfully reconstructed the shape of 108 grains and developed an indexing procedure...... enables studies of samples that can be both larger in size and made of heavier elements. Moreover, ToF 3DND facilitates the use of complicated sample environments. The basic ToF 3DND setup, utilizing an imaging detector with high spatial and temporal resolution, can easily be implemented at a time...

  14. Solidification of Al alloys under electromagnetic field



    New theories and technology in the electromagnetic field were put forward about DC casting of Al alloys, including the fundamental research works, I.e, effects of the electromagnetic field on solidus and liquidus, macrosegregation of the main alloying elements, microstructures, content of alloying elements in grains and grain size after solidification under electromagnetic field, and also including a new process-DC casting under low frequency electromagnetic field(LFEMC), which can refine microstructure, eliminate macrosegregation, increase the content of alloying elements within grains, decrease the residual stress, avoid cracks and improve surface quality, and another new process-DC casting under low frequency electromagnetic vibration(LFEVC), which is a high effective method for grain refining.

  15. Effect of low temperature melt on solidification structure of A356 alloy with melt thermal treatment

    何树先; 王俊; 孙宝德; 周尧和


    The influence of the low temperature melt (LTM) structure on solidification structure of the sample with melt thermal treatment (MTT) process was studied. And the mechanism of the MTT process was analyzed with cluster theory. It is shown that the final solidification structure is dependent mainly on the structure of LTM. Dendrites will appear in the solidification structure if the structure of LTM is dendritic before MTT. Otherwise, non-dendritic grains will appear in the solidification structure. And the lower the temperature of LTM, the more remarkable the effect of the LTM structure is.

  16. Models of Rapid Solidification

    Gilmer, G. H.; Broughton, J. Q.


    Laser annealing studies provide much information on various consequences of rapid solidification, including the trapping of impurities in the crystal, the generation of vacancies and twins, and on the fundamental limits to the speed of the crystal-melt interface. Some results obtained by molecular dynamics methods of the solidification of a Lennard-Jones liquid are reviewed. An indication of the relationship of interface speed to undercooling for certain materials can be derived from this model. Ising model simulations of impurity trapping in silicon are compared with some of the laser annealing results. The consequences of interface segregation and atomic strain are discussed.

  17. Grain refinement, hardening and metastable phase formation by high current pulsed electron beam (HCPEB) treatment under heating and melting modes

    Grosdidier, T., E-mail: Thierry.grosdidier@univ-metz.f [Laboratoire d' Etude des Textures et Applications aux Materiaux (LETAM, CNRS 3143), Universite Paul Verlaine-Metz, Ile du Saulcy, 57045 Metz (France); Lab of Materials Modification by Laser, Ion and Electron Beams and School of Materials Science and Engineering, Dalian University of Technology, Dalian 116024 (China); Zou, J.X. [Laboratoire d' Etude des Textures et Applications aux Materiaux (LETAM, CNRS 3143), Universite Paul Verlaine-Metz, Ile du Saulcy, 57045 Metz (France); Bolle, B. [Laboratoire d' Etude des Textures et Applications aux Materiaux (LETAM, CNRS 3143), ENIM, Ile du Saulcy, 57045 Metz (France); Hao, S.Z.; Dong, C. [Lab of Materials Modification by Laser, Ion and Electron Beams and School of Materials Science and Engineering, Dalian University of Technology, Dalian 116024 (China)


    High current pulsed electron beam is a recently developed technique for surface modification. The pulsed electron irradiation introduces concentrated energy depositions in the thin surface layer of the treated materials, giving rise to an extremely fast heating and subsequent rapid cooling of the surface together with the formation of dynamic stress waves. Improved surface properties (hardness, corrosion resistance) can be obtained under the 'melting' mode when the top surface is melted and rapidly solidified (10{sup 7} K/s). In steels, this is essentially the result of nanostructures formed from the highly undercooled melt, melt surface purification, strain hardening induced by the thermal stress waves as well as metastable phase selections in the rapidly solidified melted layers. The use of the 'heating' mode is less conventional, combining effects of the heavy deformation and recrystallization/recovery mechanisms. A detailed analysis of a FeAl alloy demonstrates grain size refinement, hardening, solid-state enhanced diffusion and texture modification without modification of the surface geometry.

  18. Solidification modeling: Status and outlook

    Dantzig, J. A.


    Solidification modeling is a complex and highly advanced field. This article examines the state of the art in solidification modeling, including physical phenomena of solidification such as heat extraction, transport processes within a casting, and dimensional changes in the casting and mold during solidification. Also examined are current efforts to model these phenomena and the strengths and weaknesses of these efforts. Finally, obstacles to solidification modeling, such as speed and cost of the process, are considered, along with the likelihood those obstacles will be overcome.

  19. Effect of Mould Wall Thickness on Rate of Solidification of Centrifugal Casting



    Full Text Available In Centrifugal Casting process the centrifugal force presses the metal against the inner wall of the metal mould, resulting in rapid solidification of the molten metal. However the solidification structures like structural uniformity and structural character of the solidified metal of centrifugal casting is of great importance, regarding to its mechanical properties. The solidification time of the casting is dependent upon the various parameters like speed ofrotation of the mold, mould wall temperature, heat transfer coefficient at the metal-mold interface, mould wall thickness, material of the mould and so on. In this paper experimental study of effect of mould wall thickness on solidification of the centrifugal casting has been discussed. As the mould wall thickness increases, due to the chilling effect, the solidification time decreases. Fine grains are observed in castings produced in thick walled mould and coarse grains are observed in thin walled moulds. Brinel Hardness of the casting was measured.

  20. Mode of inheritance and combining abilities for kernel row number, kernel number per row and grain yield in maize (Zea mays L.)

    Bocanski, J.; Sreckov, Z.; Nastasic, A.; Ivanovic, M.; Djalovic, I.; Vukosavljev, M.


    Bocanski J., Z. Sreckov, A. Nastasic, M. Ivanovic, I.Djalovic and M. Vukosavljev (2010): Mode of inheritance and combining abilities for kernel row number, kernel number per row and grain yield in maize (Zea mays L.) - Genetika, Vol 42, No. 1, 169- 176. Utilization of heterosis requires the study of

  1. Mode of inheritance and combining abilities for kernel row number, kernel number per row and grain yield in maize (Zea mays L.)

    Bocanski, J.; Sreckov, Z.; Nastasic, A.; Ivanovic, M.; Djalovic, I.; Vukosavljev, M.


    Bocanski J., Z. Sreckov, A. Nastasic, M. Ivanovic, I.Djalovic and M. Vukosavljev (2010): Mode of inheritance and combining abilities for kernel row number, kernel number per row and grain yield in maize (Zea mays L.) - Genetika, Vol 42, No. 1, 169- 176. Utilization of heterosis requires the study of

  2. Strength, corrosion resistance, and biocompatibility of ultrafine-grained Mg alloys after different modes of severe plastic deformation

    Dobatkin, S. V.; Lukyanova, E. A.; Martynenko, N. S.; Anisimova, N. Yu; Kiselevskiy, M. V.; Gorshenkov, M. V.; Yurchenko, N. Yu; Raab, G. I.; Yusupov, V. S.; Birbilis, N.; Salishchev, G. A.; Estrin, Y. Z.


    The effect of severe plastic deformation on the structure, mechanical properties, corrosion resistance, and biocompatibility of the WE43 (Mg-Y-Nd-Zr) alloy earmarked for applications as bioresorbable material has been studied. The alloy was deformed by rotary swaging (RS), equal channel angular pressing (ECAP), and multiaxial deformation (MAD). The microstructure examination by transmission electron microscopy showed that all SPD modes lead to the formation of ultrafine-grained structure with a structural element size of 0.5-1 µm and the Mg12Nd phase particles 0.3 µm in size. The microstructure refinement by all three treatments resulted in strengthening of the alloy. ECAP and MAD also raised ductility to up to 12-17%, while RS increased the ultimate tensile strength to up to 415 MPa. The study of the corrosion properties showed that SPD does not affect the electrochemical corrosion of the alloy. Its biocompatibility in vitro was estimated after incubation of the samples with red blood cells (hemolysis study), white blood cells (cell viability assay), and mesenchymal stromal cells (cell proliferation analysis). The biodegradation rate in fetal bovine serum was also evaluated. ECAP and MAD were found to cause some deceleration of biodegradation by slowing down the gas formation in the biological fluid and, compared to MSC, to improve the biocompatibility of the WE43 alloy.

  3. Construction and analysis of dynamic solidification curves for non-equilibrium solidification process in lost-foam casting hypo-eutectic gray cast iron

    Ming-guo Xie


    Full Text Available Most lost-foam casting processes involve non-equilibrium solidification dominated by kinetic factors, while construction of a common dynamic solidification curve is based on pure thermodynamics, not applicable for analyses and research of non-equilibrium macro-solidification processes, and the construction mode can not be applied to non-equilibrium solidification process. In this study, the construction of the dynamic solidification curve (DSC for the non-equilibrium macro-solidification process included: a modified method to determine the start temperature of primary austenite precipitation (TAL and the start temperature of eutectic solidification (TES; double curves method to determine the temperature of the dendrite coherency point of primary austenite (TAC and the temperature of eutectic cells collision point (TEC; the “technical solidus” method to determine the end temperature of eutectic reaction (TEN. For this purpose, a comparative testing of the non-equilibrium solidification temperature fields in lost-foam casting and green sand mold casting hypoeutectic gray iron was carried out. The thermal analysis results were used to construct the DSCs of both these casting methods under non-equilibrium solidification conditions. The results show that the transformation rate of non-equilibrium solidification in hypoeutectic gray cast iron is greater than that of equilibrium solidification. The eutectic solidification region presents a typical mushy solidification mode. The results also indicate that the primary austenite precipitation zone of lost-foam casting is slightly larger than that of green sand casting. At the same time, the solid fraction (fs of the dendrite coherency points in lost-foam casting is greater than that in the green sand casting. Therefore, from these two points, lost-foam casting is more preferable for reduction of shrinkage and mechanical burnt-in sand tendency of the hypoeutectic gray cast iron. Due to the fact that

  4. MPS Solidification Model. Volume 2: Operating guide and software documentation for the unsteady model

    Maples, A. L.


    The operation of solidification Model 2 is described and documentation of the software associated with the model is provided. Model 2 calculates the macrosegregation in a rectangular ingot of a binary alloy as a result of unsteady horizontal axisymmetric bidirectional solidification. The solidification program allows interactive modification of calculation parameters as well as selection of graphical and tabular output. In batch mode, parameter values are input in card image form and output consists of printed tables of solidification functions. The operational aspects of Model 2 that differ substantially from Model 1 are described. The global flow diagrams and data structures of Model 2 are included. The primary program documentation is the code itself.

  5. Numerical simulation on directional solidification of Al-Ni-Co alloy based on FEM

    Yang Zhili


    Full Text Available The ratio, of the temperature gradient at the solidification front to the solidification rate of solid-liquid interface, plays a large part in columnar grain growth. The transient temperature fields of directional solidification of Al-Ni-Co alloy were studied by employing a finite element method. The temperature gradient at the solidification front and the solidification rate were analyzed for molten steels pouring at different temperatures. The results show that with different initial pouring temperatures, the individual ratio of the temperature gradient at solidification front to the solidification rate soars up in the initial stage of solidification, then varies within 2,000-6,000 ℃·s·cm-2, and finally goes down rapidly and even tend to be closed to each other when the solidification thickness reaches 5-6 cm. The simulation result is consistent with the practical production which can provide an available reference for process optimization of directional solidified Al-Ni-Co alloy.

  6. Weld solidification cracking in 304 to 204L stainless steel

    Hochanadel, Patrick W [Los Alamos National Laboratory; Lienert, Thomas J [Los Alamos National Laboratory; Martinez, Jesse N [Los Alamos National Laboratory; Johnson, Matthew Q [Los Alamos National Laboratory


    A series of annulus welds were made between 304 and 304L stainless steel coaxial tubes using both pulsed laser beam welding (LBW) and pulsed gas tungsten arc welding (GTAW). In this application, a change in process from pulsed LBW to pulsed gas tungsten arc welding was proposed to limit the possibility of weld solidification cracking since weldability diagrams developed for GTAW display a greater range of compositions that are not crack susceptible relative to those developed for pulsed LBW. Contrary to the predictions of the GTAW weldability diagram, cracking was found.This result was rationalized in terms of the more rapid solidification rate of the pulsed gas tungsten arc welds. In addition, for the pulsed LBW conditions, the material compositions were predicted to be, by themselves, 'weldable' according to the pulsed LBW weldability diagram. However, the composition range along the tie line connecting the two compositions passed through the crack susceptible range. Microstructurally, the primary solidification mode (PSM) of the material processed with higher power LBW was determined to be austenite (A), while solidification mode of the materials processed with lower power LBW apparently exhibited a dual PSM of both austenite (A) and ferrite-austenite (FA) within the same weld. The materials processed by pulsed GTAW showed mostly primary austenite solidification, with some regions of either primary austenite-second phase ferrite (AF) solidification or primary ferrite-second phase austenite (FA) solidification. This work demonstrates that variations in crack susceptibility may be realized when welding different heats of 'weldable' materials together, and that slight variations in processing can also contribute to crack susceptibility.

  7. Weld solidification cracking in 304 to 304L stainless steel

    Hochanadel, Patrick W [Los Alamos National Laboratory; Lienert, Thomas J [Los Alamos National Laboratory; Martinez, Jesse N [Los Alamos National Laboratory; Martinez, Raymond J [Los Alamos National Laboratory; Johnson, Matthew Q [Los Alamos National Laboratory


    A series of annulus welds were made between 304 and 304L stainless steel coaxial tubes using both pulsed laser beam welding (LBW) and pulsed gas tungsten arc welding (GTAW). In this application, a change in process from pulsed LBW to pulsed gas tungsten arc welding was proposed to limit the possibility of weld solidification cracking since weldability diagrams developed for GTAW display a greater range of compositions that are not crack susceptible relative to those developed for pulsed LBW. Contrary to the predictions of the GTAW weldability diagram, cracking was found. This result was rationalized in terms of the more rapid solidification rate of the pulsed gas tungsten arc welds. In addition, for the pulsed LBW conditions, the material compositions were predicted to be, by themselves, 'weldable' according to the pulsed LBW weldability diagram. However, the composition range along the tie line connecting the two compositions passed through the crack susceptible range. Microstructurally, the primary solidification mode (PSM) of the material processed with higher power LBW was determined to be austenite (A), while solidification mode of the materials processed with lower power LBW apparently exhibited a dual PSM of both austenite (A) and ferrite-austenite (FA) within the same weld. The materials processed by pulsed GT A W showed mostly primary austenite solidification, with some regions of either primary austenite-second phase ferrite (AF) solidification or primary ferrite-second phase austenite (FA) solidification. This work demonstrates that variations in crack susceptibility may be realized when welding different heats of 'weldable' materials together, and that slight variations in processing can also contribute to crack susceptibility.

  8. Phase field modeling of multiple dendrite growth of AI-Si binary alloy under isothermal solidification

    Sun Qiang; Zhang Yutuo; Cui Haixia; Wang Chengzhi


    Phase field method offers the prospect of being able to perform realistic numerical experiments on dendrite growth in metallic systems. In this study, the growth process of multiple dendrites in Ai-2-mole-%-Si binary alloy under isothermal solidification was simulated using phase field model. The simulation results showed the impingement of arbitrarily oriented crystals and the competitive growth among the grains during solidification. With the increase of growing time, the grains begin to coalesce and impinge the adjacent grains. When the dendrites start to impinge, the dendrite growth is obviously inhibited.

  9. Anisotropic growth of multigrain in equiaxial solidification simulated with the phase field method

    Li Mei-E; Xiao Zhi-Ying; Yang Gen-Cang; Zhou Yao-He


    The phase field method has been mainly used to simulate the growth of a single crystal in the past. But polycrystalline materials predominate in engineering. In this work, a phase field model for multigrain solidification is developed, which takes into account the random crystallographic orientations of crystallites and preserves the rotational invariance of the free energy. The morphological evolution of equiaxial multigrain solidification is predicted and the effect of composition on transformation kinetics is studied. The numerical results indicate that due to the soft impingement of grains the Avrami exponent varies with the initial melt composition and the solidification fraction.

  10. Solidification zoning and metallographic cooling rates of chondrites

    Willis, J.; Goldstein, J. I.


    The cooling rates of chondrites have been determined according to the cooling rate method of Wood (1967) which involves the measurement of the concentration of nickel in the interiors of taenite grains of various sizes. The present paper presents an investigation of the effect of zoning produced during solidification on the use of the Wood method. Cooling rate curves were obtained in a computer simulation based on a model of kamacite formation on the outer edge of a taenite sphere of uniform initial composition, followed by the inward radial progression of the kamacite-taenite interface. When a concentration gradient produced by solidification is present in the initial conditions, deviations from the cooling rate curves for uniform 10% Ni are obtained only at cooling rates greater than 1000 K/million years, which would result in an overestimation of the cooling rates based on observed Ni gradients in grains of radius greater than 20 microns.

  11. Solidification under microgravity

    B K Dhindaw


    The paper outlines the broad areas where studies are being conducted under microgravity conditions worldwide viz., biotechnology, combustion science, materials science and fluid physics. The paper presents in particular a review on the various areas of research being pursued in materials science. These include studies on immiscibles, eutectics, morphology development during solidification or pattern formation, nucleation phenomena, isothermal dendrite growth, macrosegregation and the behaviour of insoluble particles ahead of the solidifying interface. The latter studies are given in detail with description of case studies of experiments conducted by the author on space shuttles. In particular, the technology and the science issues are addressed. Lastly, based on the presentations, some salient features enumerating the advantages of conducting experiments under conditions of microgravity are highlighted in terms of science returns.

  12. Combined effect of non-equilibrium solidification and thermal annealing on microstructure evolution and hardness behavior of AZ91 magnesium alloy

    Zhou, Z.Z.; Yang, W., E-mail:; Chen, S.H.; Yu, H.; Xu, Z.F.


    Non-equilibrium solidification of commercial AZ91 magnesium alloy was performed by copper mold spray-casting technique and the thermal stability property of as-formed meta-stable microstructure was investigated by subsequent annealing at different temperatures and times. Remarkable grain refinement appears with increasing cooling rate during solidification process, which is accompanied by a visible cellular/dendrite transition for the grain morphology of primary phase. Moreover, the non-equilibrium solidified alloy exhibits obvious precipitation hardening effect upon annealing at 200 °C, and the precipitation mode of β-Mg{sub 17}Al{sub 12} phase changes from discontinuous to continuous with extending isothermal time from 4 h to 16 h, which generates an increase of resultant micro-hardness value. After solid solution treatment at the elevated temperature of 420 °C, the volume fraction of β-Mg{sub 17}Al{sub 12} phase decreases and a notable grain growth phenomenon occurs, which give rise to a reduction of hardness in comparison with that of as-quenched alloy.

  13. Influence of sub-rapid solidification on microstructure and mechanical properties of AZ61A magnesium alloy


    The microstructure of sub-rapid solidification processed AZ61A magnesium alloy was presented and discussed. The results show that the grain size of the foil is significantly refined, and the grain morphology is cellular or globular. The eutectic transformation L→α-Mg+β-Mg17Al12 and microsegregation in conventionally solidified AZ61A alloy are suppressed to a great extent.The β-Mg17Al12 phases located in the α-Mg grain boundaries are largely decreased due to high solidification cooling rate. As a consequence, the alloying elements Al, Zn, Mn show much higher solid solubility and the sub-rapid solidification microstructure dominantly consists of supersaturated α-Mg solid solution. The mechanical properties and fractographic analysis reveal that the fracture mechanism and corresponding morphology of the rapture surface of tensile bars are linked to the microstructure obtained and depend on the sub-solidification processes.

  14. Effect of process parameters on hardness, temperature profile and solidification of different layers processed by direct metal laser sintering (DMLS)

    Ahmed, Sazzad Hossain; Mian, Ahsan; Srinivasan, Raghavan


    In DMLS process objects are fabricated layer by layer from powdered material by melting induced by a controlled laser beam. Metallic powder melts and solidifies to form a single layer. Solidification map during layer formation is an important route to characterize micro-structure and grain morphology of sintered layer. Generally, solidification leads to columnar, equiaxed or mixture of these two types grain morphology depending on solidification rate and thermal gradient. Eutectic or dendritic structure can be formed in fully equiaxed zone. This dendritic growth has a large effect on material properties. Smaller dendrites generally increase ductility of the layer. Thus, materials can be designed by creating desired grain morphology in certain regions using DMLS process. To accomplish this, hardness, temperature distribution, thermal gradient and solidification cooling rate in processed layers will be studied under change of process variables by using finite element analysis, with specific application to Ti-6Al-4V.

  15. Effect of process parameters on hardness, temperature profile and solidification of different layers processed by direct metal laser sintering (DMLS)

    Ahmed, Sazzad Hossain; Mian, Ahsan, E-mail:; Srinivasan, Raghavan [Department of Mechanical and Materials Engineering, Wright State University, Dayton, Ohio 45435 (United States)


    In DMLS process objects are fabricated layer by layer from powdered material by melting induced by a controlled laser beam. Metallic powder melts and solidifies to form a single layer. Solidification map during layer formation is an important route to characterize micro-structure and grain morphology of sintered layer. Generally, solidification leads to columnar, equiaxed or mixture of these two types grain morphology depending on solidification rate and thermal gradient. Eutectic or dendritic structure can be formed in fully equiaxed zone. This dendritic growth has a large effect on material properties. Smaller dendrites generally increase ductility of the layer. Thus, materials can be designed by creating desired grain morphology in certain regions using DMLS process. To accomplish this, hardness, temperature distribution, thermal gradient and solidification cooling rate in processed layers will be studied under change of process variables by using finite element analysis, with specific application to Ti-6Al-4V.

  16. Inversion Solidification Cladding of H90-Steel

    LI Bao-mian; XU Guang-ming; CUI Jian-zhong


    The variation law of cladding thickness as well as the structures and properties of H90-steel clad strip produced by inversion solidification was studied.The interface bonding mechanisms were approached.It is found that the thickness of H90 cladding goes sequentially through the solidification growth stage,holding stage,and remelting stage,with an increase in immersion time.The higher the preheating temperature of the steel coil,the thicker is the maximum cladding thickness.Observation by using optical microscopy (OM) and the electron probe microanalyzer (EPMA) shows that the microstrueture of H90 cladding is composed of equiaxed grains,and that interdiffusion between Cu and Fe at interface occurs but obvious diffusion of Zn and the intermetallic layer are not observed.The diffusion layer is thin and about 4 μm.Multipass small reduction cold rolling and repeated bending tests show that the interface is firmly bonded.Tensile test shows that the mechanical properties of the as-clad strips can meet the requirements of GB5213-2001 for the F-grade deep-drawing steel plate though there is a slight difference in the mechanical properties among the clad strips with different cladding thickness.

  17. Modeling fluid interactions with the rigid mush in alloy solidification

    Plotkowski, Alexander J.

    Macrosegregation is a casting defect characterized by long range composition differences on the length scale of the ingot. These variations in local composition can lead to the development of unwanted phases that are detrimental to mechanical properties. Unlike microsegregation, in which compositions vary over the length scale of the dendrite arms, macrosegregation cannot be removed by subsequent heat treatment, and so it is critical to understand its development during solidification processing. Due to the complex nature of the governing physical phenomena, many researchers have turned to numerical simulations for these predictions, but properly modeling alloy solidification presents a variety of challenges. Among these is the appropriate treatment of the interface between the bulk fluid and the rigid mushy zone. In this region, the non-linear and coupled behavior of heat transfer, fluid mechanics, solute transport, and alloy thermodynamics has a dramatic effect on macrosegregation predictions. This work investigates the impact of numerical approximations at this interface in the context of a mixture model for alloy solidification. First, the numerical prediction of freckles in columnar solidification is investigated, and the predictive ability of the model is evaluated. The model is then extended to equiaxed solidification, in which the analogous interface is the transition of free-floating solid particles to a rigid dendritic network. Various models for grain attachment are investigated, and found to produce significant artifacts caused by the discrete nature of their implementation on the numerical grid. To reduce the impact of these artifacts, a new continuum grain attachment model is proposed and evaluated. The differences between these models are compared using uncertainty quantification, and recommendations for future research are presented.

  18. Experimental study on directional solidification of Al-Si alloys under the influence of electric currents

    Räbiger, D.; Zhang, Y.; Galindo, V.; Franke, S.; Willers, B.; Eckert, S.


    The application of electric currents during solidification can cause grain refinement in metallic alloys. However, the knowledge about the mechanisms underlying the decrease in grain size remains fragmentary. This study considers the solidification of Al-Si alloys under the influence of electric currents for the configuration of two parallel electrodes at the free surface. Solidification experiments were performed under the influence of both direct currents (DC) and rectangular electric current pulses (ECP). The interaction between the applied current and its own induced magnetic field causes a Lorentz force which produces an electro-vortex flow. Numerical simulations were conducted to calculate the Lorentz force, the Joule heating and the induced melt flow. The numerical predictions were confirmed by isothermal flow measurements in eutectic GaInSn. The results demonstrate that the grain refining effect observed in our experiments can be ascribed solely to the forced melt flow driven by the Lorentz force.

  19. Investigation of Melting and Solidification of Thin Polycrystalline Silicon Films via Mixed-Phase Solidification

    Wang, Ying

    Melting and solidification constitute the fundamental pathways through which a thin-film material is processed in many beam-induced crystallization methods. In this thesis, we investigate and leverage a specific beam-induced, melt-mediated crystallization approach, referred to as Mixed-Phase Solidification (MPS), to examine and scrutinize how a polycrystalline Si film undergoes the process of melting and solidification. On the one hand, we develop a more general understanding as to how such transformations can transpire in polycrystalline films. On the other hand, by investigating how the microstructure evolution is affected by the thermodynamic properties of the system, we experimentally reveal, by examining the solidified microstructure, fundamental information about such properties (i.e., the anisotropy in interfacial free energy). Specifically, the thesis consists of two primary parts: (1) conducting a thorough and extensive investigation of the MPS process itself, which includes a detailed characterization and analysis of the microstructure evolution of the film as it undergoes MPS cycles, along with additional development and refinement of a previously proposed thermodynamic model to describe the MPS melting-and-solidification process; and (2) performing MPS-based experiments that were systematically designed to reveal more information on the anisotropic nature of Si-SiO2 interfacial energy (i.e., sigma Si-SiO2). MPS is a recently developed radiative-beam-based crystallization technique capable of generating Si films with a combination of several sought-after microstructural characteristics. It was conceived, developed, and characterized within our laser crystallization laboratory at Columbia University. A preliminary thermodynamic model was also previously proposed to describe the overall melting and solidification behavior of a polycrystalline Si film during an MPS cycle, wherein the grain-orientation-dependent solid-liquid interface velocity is identified

  20. Solidification microstructure formation in HK40 and HH40 alloys

    Ding, Xian-fei; Liu, Dong-fang; Guo, Pei-liang; Zheng, Yun-rong; Feng, Qiang


    The microstructure formation processes in HK40 and HH40 alloys were investigated through JmatPro calculations and quenching performed during directional solidification. The phase transition routes of HK40 and HH40 alloys were determined as L → L + γ → L + γ + M7C3 → γ + M7C3 → γ + M7C3 + M23C6→ γ + M23C6 and L → L + δ → L + δ + γ→ L + δ + γ + M23C6 δ + γ + M23C6, respectively. The solidification mode was determined to be the austenitic mode (A mode) in HK40 alloy and the ferritic-austenitic solidification mode (FA mode) in HH40 alloy. In HK40 alloy, eutectic carbides directly precipitate in a liquid and coarsen during cooling. The primary γ dendrites grow at the 60° angle to each other. On the other hand, in HH40 alloy, residual δ forms because of the incomplete transformation from δ to γ. Cr23C6 carbide is produced in solid delta ferrite δ but not directly in liquid HH40 alloy. Because of carbide formation in the solid phase and no rapid growth of the dendrite in a non-preferential direction, HH40 alloy is more resistant to cast defect formation than HK40 alloy.

  1. Solidification in a Supercomputer: From Crystal Nuclei to Dendrite Assemblages

    Shibuta, Yasushi; Ohno, Munekazu; Takaki, Tomohiro


    Thanks to the recent progress in high-performance computational environments, the range of applications of computational metallurgy is expanding rapidly. In this paper, cutting-edge simulations of solidification from atomic to microstructural levels performed on a graphics processing unit (GPU) architecture are introduced with a brief introduction to advances in computational studies on solidification. In particular, million-atom molecular dynamics simulations captured the spontaneous evolution of anisotropy in a solid nucleus in an undercooled melt and homogeneous nucleation without any inducing factor, which is followed by grain growth. At the microstructural level, the quantitative phase-field model has been gaining importance as a powerful tool for predicting solidification microstructures. In this paper, the convergence behavior of simulation results obtained with this model is discussed, in detail. Such convergence ensures the reliability of results of phase-field simulations. Using the quantitative phase-field model, the competitive growth of dendrite assemblages during the directional solidification of a binary alloy bicrystal at the millimeter scale is examined by performing two- and three-dimensional large-scale simulations by multi-GPU computation on the supercomputer, TSUBAME2.5. This cutting-edge approach using a GPU supercomputer is opening a new phase in computational metallurgy.

  2. Multi-crystalline silicon solidification under controlled forced convection

    Cablea, M.; Zaidat, K.; Gagnoud, A.; Nouri, A.; Chichignoud, G.; Delannoy, Y.


    Multi-crystalline silicon wafers have a lower production cost compared to mono-crystalline wafers. This comes at the price of reduced quality in terms of electrical properties and as a result the solar cells made from such materials have a reduced efficiency. The presence of different impurities in the bulk material plays an important role during the solidification process. The impurities are related to different defects (dislocations, grain boundaries) encountered in multi-crystalline wafers. Applying an alternative magnetic field during the solidification process has various benefits. Impurities concentration in the final ingot could be reduced, especially metallic species, due to a convective term added in the liquid that reduces the concentration of impurities in the solute boundary layer. Another aspect is the solidification interface shape that is influenced by the electromagnetic stirring. A vertical Bridgman type furnace was used in order to study the solidification process of Si under the influence of a travelling magnetic field able to induce a convective flow in the liquid. The furnace was equipped with a Bitter type three-phase electromagnet that provides the required magnetic field. A numerical model of the furnace was developed in ANSYS Fluent commercial software. This paper presents experimental and numerical results of this approach, where interface markings were performed.

  3. Effect of vacuum on solidification process and microstructure of LFC magnesium alloy

    LIU Zi-li; LIU Xi-qin; XU Jiang; GUO Hua-ming; PAN Qing-lin; ZHOU Hai-tao


    Lost foam casting (LFC) is regarded as a cost-effective, environment-friendly vital option to the conventional casting process for production of near-net shape castings with high quality. Effect of vacuum on the solidification process and microstructure of LFC magnesium alloy were explored. The results indicate that vacuum plays a very important role in the heat transfer during mould filling and solidification periods, it increases the cooling rate of the filling melt, but greatly decreases the cooling rate of the casting during solidification period, and the solidification time of the casting is greater than that without vacuum. The microstructure of LFC magnesium alloy is rather coarse. Compared with that without vacuum, the microstructure of the LFC magnesium alloy under vacuum is more refined and has less precipitated β-phase, which is formed at the grain boundry and around the Al-Mn compound particle.

  4. Effect of Electrode Types on the Solidification Cracking Susceptibility of Austenitic Stainless Steel Weld Metal

    J. U. Anaele


    Full Text Available The effect of electrode types on the solidification cracking susceptibility of austenitic stainless steel weld metal was studied. Manual metal arc welding method was used to produce the joints with the tungsten inert gas welding serving as the control. Metallographic and chemical analyses of the fusion zones of the joints were conducted. Results indicate that weldments produced from E 308-16 (rutile coated, E 308-16(lime-titania coated electrodes, and TIG welded joints fall within the range of 1.5≤Creq./Nieq.≤1.9 and solidified with a duplex mode and were found to be resistant to solidification cracking. The E 308-16 weld metal had the greatest resistance to solidification cracking. Joints produced from E 310-16 had Creq./Nieq. ratio 1.9 and solidified with ferrite mode. It had a low resistance to solidification cracking.

  5. Solidification Microstructure, Fracture Behavior and In-Situ Toughening of TiC-TiB2 Fine-grained Composite Ceramics%TiC-TiB2细晶陶瓷凝固组织、断裂行为与原位增韧

    赵忠民; 张龙; 宋义刚; 何建强


    Solidification structure and crystal growth of the TiC-TiBz fine-grained ceramics which was prepared by combustion synthesis under high gravity were investigated, and the relationship between microstructure and fracture behavior as well as toughening mechanism was analyzed by XRD (X-ray diffraction) , FESEM (field emission scanning electron microscope) and EDS (energy dispersive spectrometer). The results show that the composite ceramics matrix is composed of a lot of fine TiB2 platelets and irregular TiC grain surrounded the TiBz platelets. The formation of TiB2 platelets is resulted from faceted crystal growth while irregular TiC grains are the results of non-faceted crystal growth and high growth velocity. Relative density, Vickers hardness, bending strength and fracture toughness of the ceramics reach 98. 6% , 21. 8 Gpa, 650MPa and 12. 5 Mpa · m1/2, respectively. Ceramic toughening mechanism is attributed to the co-operation of crack deflection, crack-bridging and pull-up by small-size TiBz platelets and frictionally-interlocking in-situ toughening effects.%通过采用超重力下燃烧合成制备TiC-TiB2细晶陶瓷,研究了陶瓷凝固组织与晶体生长特征,探讨了陶瓷显微组织与断裂行为、增韧机制的关系.XRD、FESEM与EDS分析表明,TiC-TiB2复合陶瓷基体主要由大量细小的TiB2片晶及分布其周围的形状不规则的TiC相构成,TiB2片晶的形成是因其小平面晶体生长特性所致,而不规则TiC的晶体形貌则是因非小平面晶体生长特性及高的生长速率所造成的.陶瓷相对密度、硬度(HV)、弯曲强度及断裂韧度分别为98.6%、21.8 GPa、650MPa、12.5 MPa ·m1/2,并且陶瓷增韧是小尺寸TiB片晶的裂纹偏转、裂纹桥接、片晶拔出及摩擦互锁原位增韧机制协同作用的结果.

  6. Nanoparticle Capture During Directional Solidification of Nano-Sized SiC Particle-Reinforced AZ91D Composites.

    Zhu, Qiaobo; Liu, Hongchang; Li, Wenzhen; Gao, Weiming; Li, Qiushu


    The capture/push behavior of a particle in front of a solidification interface was analyzed theoretically and experimentally in this work. Van der Waals force, viscous force, and force due to interfacial energy played important roles in the particle capture/push process. Directional solidification experiments were conducted with nano-sized SiC particle-reinforced AZ91D composites to observe the distribution of nanoparticles in different solidification morphologies under varied cooling rates. When the composite solidified with plane manner, the nanoparticles could be captured by the solidification front and distributed uniformly in the matrix. When solidified with columnar or equiaxial manners, the nanoparticles could be captured by the solidification front but distributed uniformly only in the grain boundary as a result of the difference in interfacial energy and wettability between SiC/α-Mg and SiC/eutectic phase. Theoretical prediction of particle capture was in agreement with the experiment results.

  7. Kinetic model of ductile iron solidification with experimental verification

    W. Kapturkiewicz


    Full Text Available A solidification model for ductile iron, including Weibull formula for nodule count has been presented. From this model, the following can be determined: cooling curves, kinetics of austenite and eutectic nucleation, austenite and eutectic growth velocity, volume fraction, distribution of Si and P both in austenite and eutectic grain with distribution in casting section.In the developed model of nodular graphite iron casting solidification, the correctness of the mathematical model has been experimentally verified in the range of the most significant factors, which include temperature field, the value of maximum undercooling, and the graphite nodule count interrelated with the casting cross-section. Literature offers practically no data on so confronted process model and simulation program.

  8. Well-Hidden Grain Boundary in the Monolayer MoS2 Formed by a Two-Dimensional Core-Shell Growth Mode.

    Zhang, Wenting; Lin, Yue; Wang, Qi; Li, Weijie; Wang, Zhifeng; Song, Jiangluqi; Li, Xiaodong; Zhang, Lijie; Zhu, Lixin; Xu, Xiaoliang


    Guided by the hexagonal lattice symmetry, triangles and hexagons are the most basic morphological units for two-dimensional (2D) transition metal dichalcogenides (TMDs) synthesized by chemical vapor deposition (CVD). Also, it is widely acknowledged that these units start from the single nucleation site and then grow epitaxially. Accordingly, the triangular monolayer (ML) samples are generally considered as single crystals. Here, we report a 2D core-shell growth mode in the CVD process for ML-MoS2, which leads to one kind of "pseudo" single-crystal triangles containing triangular outline grain boundaries (TO-GBs). It is difficult to be optically distinguished from the "true" single-crystal triangles. The weakening of Raman peaks and the remarkable enhancement of photoluminescence (PL) are found at the built-in TO-GBs, which could be useful for high-performance optoelectronics. In addition, the electrical measurements indicate that the TO-GBs are conductive. Furthermore, TO-GBs and the common grain boundaries (CO-GBs) can coexist in a single flake, whereas their optical visibility and optical modifications (Raman and PL) are quite different. This work is helpful in further understanding the growth mechanism of 2D TMD materials and may also play a significant role in related nanodevices.

  9. Substrate recognition and motion mode analyses of PFV integrase in complex with viral DNA via coarse-grained models.

    Jianping Hu

    Full Text Available HIV-1 integrase (IN is an important target in the development of drugs against the AIDS virus. Drug design based on the structure of IN was markedly hampered due to the lack of three-dimensional structure information of HIV-1 IN-viral DNA complex. The prototype foamy virus (PFV IN has a highly functional and structural homology with HIV-1 IN. Recently, the X-ray crystal complex structure of PFV IN with its cognate viral DNA has been obtained. In this study, both Gaussian network model (GNM and anisotropy network model (ANM have been applied to comparatively investigate the motion modes of PFV DNA-free and DNA-bound IN. The results show that the motion mode of PFV IN has only a slight change after binding with DNA. The motion of this enzyme is in favor of association with DNA, and the binding ability is determined by its intrinsic structural topology. Molecular docking experiments were performed to gain the binding modes of a series of diketo acid (DKA inhibitors with PFV IN obtained from ANM, from which the dependability of PFV IN-DNA used in the drug screen for strand transfer (ST inhibitors was confirmed. It is also found that the functional groups of keto-enol, bis-diketo, tetrazole and azido play a key role in aiding the recognition of viral DNA, and thus finally increase the inhibition capability for the corresponding DKA inhibitor. Our study provides some theoretical information and helps to design anti-AIDS drug based on the structure of IN.

  10. Solidification Structure of Low Carbon Steel Strips with Different Phosphorus Contents Produced by Strip Casting

    Na LI; Zhenyu LIU; Yiqing QIU; Zhaosen LIN; Xianghua LIU; Guodong WANG


    In the present paper, low carbon steel strips with different phosphorus contents were produced using a twin roll strip casting process. The solidification structure was studied and its features were analyzed in detail. It was found that the strips possessed a fine microstructure compared with the mould cast steels. With increasing phosphorus content more ferrite has been formed with finer grains.

  11. In-situ observation of porosity formation during directional solidification of Al-Si casting alloys

    Zhao Lei


    Full Text Available In-situ observation of porosity formation during directional solidification of two Al-Si alloys (7%Si and 13%Si was made by using of micro-focus X-ray imaging. In both alloys, small spherical pores initially form in the melt far away from the eutectic solid-liquid (S/L interface and then grow and coagulate during solidification. Some pores can float and escape from the solidifying melt front at a relatively high velocity. At the end of solidification, the remaining pores maintain spherical morphology in the near eutectic alloy but become irregular in the hypoeutectic alloy. This is attributed to different solidification modes and aluminum dendrite interactions between the two alloys. The mechanism of the porosity formation is briefly discussed in this paper.

  12. A combined enthalpy / front tracking method for modelling melting and solidification in laser welding

    Duggan, G.; Mirihanage, W. U.; Tong, M.; Browne, D. J.


    The authors present an integrated meso-scale 2D numerical model for the simulation of laser spot welding of a Fe-Cr-Ni steel. The melting of the parent materials due to the applied heating power is an important phenomenon, leading to the formation of the weld pool and the subsequent conditions from which solidification proceeds. This model deals with the dynamic formation of the weld pool whereby melting may be occurring at a given location while solidification has already commenced elsewhere throughout the weld pool. Considering both melting and possible simultaneous solidification in this manner ensures a more accurate simulation of temperature distribution. A source based enthalpy method is employed throughout the calculation domain in order to integrate the melting model with the UCD front tracking model for alloy solidification. Melting is tracked via interpolation of the liquidus isotherm, while solidification is treated via both the tracking of the advancing columnar dendritic front, and the nucleation and growth of equiaxed dendrites using a volume-averaging formulation. Heterogeneous nucleation is assumed to take place on TiN grain refiner particles at a grain refiner density of 1000 particles per mm2. A mechanical blocking criterion is used to define dendrite coherency, and the columnar-to-equiaxed transition within the weld pool is predicted.

  13. Solidification Structure of Continuous Casting Large Round Billets under Mold Electromagnetic Stirring

    Tao SUN; Feng YUE; Hua-jie WU; Chun GUO; Ying LI; Zhong-cun MA


    The solidification structure of a continuous casting large round billet was analyzed by a cellular-automaton-finite-element coupling model using the ProCAST software.The actual and simulated solidification structures were compared under mold electromagnetic stirring (MEMS)conditions (current of 300 A and frequency of 3 Hz).There-after,the solidification structures of the large round billet were investigated under different superheats,casting speeds,and secondary cooling intensities.Finally,the effect of the MEMS current on the solidification structures was obtained under fixed superheat,casting speed,secondary cooling intensity,and MEMS frequency.The model accurately simulated the actual solidification structures of any steel,regardless of its size and the parameters used in the continuous casting process.The ratio of the central equiaxed grain zone was found to increase with decreasing su-perheat,increasing casting speed,decreasing secondary cooling intensity,and increasing MEMS current.The grain size obviously decreased with decreasing superheat and increasing MEMS current but was less sensitive to the casting speed and secondary cooling intensity.

  14. Ab initio studies of two Al grain boundaries subjected to mixed tension/shear mode loading: how shear may promote breakage

    Ehlers, F. J. H.; Seydou, M.; Tingaud, D.; Maurel, F.; Queyreau, S.; Charles, Y.


    Using the framework of density functional theory, the structural and energetic response of two face-centred cubic (fcc) Al grain boundaries (GBs) to combined tension and shear loadings has been examined. It is shown that tension will serve to inhibit the Σ5 [100] 36.87° twist GB response to shear in a mixed-mode loading scenario, by increasing the difference in structural environments for inequivalent atoms at the GB plane. We propose that the presence of such atoms, rather than the full structural details of the GB structure, is instrumental in triggering this tension-shear interplay. As support for this hypothesis, we compute the Σ3 [-110] (111) 60° symmetric tilt GB mixed-mode loading response. Here, all atoms at the GB plane are equivalent, and the qualitative shear energy variation is unaffected by tension. Our findings indicate that general fcc Al GBs may display a stronger shear energy variation at larger levels of tension, contrasting general expectations. The implications to GB breakage are discussed.

  15. Solidification at the High and Low Rate Extreme

    Meco, Halim [Iowa State Univ., Ames, IA (United States)


    The microstructures formed upon solidification are strongly influenced by the imposed growth rates on an alloy system. Depending on the characteristics of the solidification process, a wide range of growth rates is accessible. The prevailing solidification mechanisms, and thus the final microstructure of the alloy, are governed by these imposed growth rates. At the high rate extreme, for instance, one can have access to novel microstructures that are unattainable at low growth rates. While the low growth rates can be utilized for the study of the intrinsic growth behavior of a certain phase growing from the melt. Although the length scales associated with certain processes, such as capillarity, and the diffusion of heat and solute, are different at low and high rate extremes, the phenomena that govern the selection of a certain microstructural length scale or a growth mode are the same. Consequently, one can analyze the solidification phenomena at both high and low rates by using the same governing principles. In this study, we examined the microstructural control at both low and high extremes. For the high rate extreme, the formation of crystalline products and factors that control the microstructure during rapid solidification by free-jet melt spinning are examined in Fe-Si-B system. Particular attention was given to the behavior of the melt pool at different quench-wheel speeds. Since the solidification process takes place within the melt-pool that forms on the rotating quench-wheel, we examined the influence of melt-pool dynamics on nucleation and growth of crystalline solidification products and glass formation. High-speed imaging of the melt-pool, analysis of ribbon microstructure, and measurement of ribbon geometry and surface character all indicate upper and lower limits for melt-spinning rates for which nucleation can be avoided, and fully amorphous ribbons can be achieved. Comparison of the relevant time scales reveals that surface-controlled melt

  16. Instabilities in rapid solidification of multi-component alloys

    Altieri, Anthony L.; Davis, Stephen H.


    Rapid solidification of multi-component liquids occurs in many modern applications such as additive manufacturing. In the present work the interface departures from equilibrium consist of the segregation coefficient and liquidus slope depending on front speed, the one-sided, frozen-temperature approximation, and the alloy behaving as the superposition of individual components. Linear-stability theory is applied, showing that the cellular and oscillatory instabilities of the binary case are modified. The addition of components tends to destabilize the interface while the addition of a single large-diffusivity material can entirely suppress the oscillatory mode. Multiple minima in the neutral curve for the cellular mode occur.

  17. Cellular instability in rapid directional solidification - Bifurcation theory

    Braun, R. J.; Davis, S. H.


    Merchant and Davis performed a linear stability analysis on a model for the directional solidification of a dilute binary alloy valid for all speeds. The analysis revealed that nonequilibrium segregation effects modify the Mullins and Sekerka cellular mode, whereas attachment kinetics has no effect on these cells. In this paper, the nonlinear stability of the steady cellular mode is analyzed. A Landau equation is obtained that determines the amplitude of the cells. The Landau coefficient here depends on both nonequilibrium segregation effects and attachment kinetics. This equation gives the ranges of parameters for subcritical bifurcation (jump transition) or supercritical bifurcation (smooth transition) to cells.

  18. Rapid solidification in thermal spary deposition: Microstructure and modelling

    Guo-Xiang Wang; V Prasad; S Sampath


    Mechanical, thermal, and adhesive properties of thermal spray coatings are primarily determined by the phase and microstructure of single splats, which ultimately depend on rapid solidification of each splat and on the interactions between the splats and between the splat and the substrate. Significant efforts are being made to develop a better understanding of the physical mechanisms underlying these phenomena. This paper reviews a series of work in the area of mathematical modelling of phase and microstructure formation during the rapid solidification of single splats and coatings. The model development has been complimented by special experiments. Conditions under which plariar interface solidification occurs, columnar cellular or dendriric growth takes place, or banded structure forms, have been identified. A microstructure map can therefore be built using the model presented here. The process parameters that promote crystalline nucleation and grain structure formation can be isolated and the effect of interfacial heat transfer, splat substrate temperature difference, and substrate melting and resolidification can be examined using the model. The model predictions agree qualitatively well with the experimental data for alumina, yttria, partially-stabilized zirconia, and molybdenum.

  19. Solidification of sediment contaminated with volatile chlorinated hydrocarbons

    Schwarz, E.J. [Anchor QEA LLC, Portland, OR (United States)


    A series of bench-scale treatability tests were used to evaluate the effectiveness of various solidification reagents in treating sediments contaminated with high concentrations of chlorinated hydrocarbons. The effectiveness of Portland cement, cement kiln dust, lime kiln dust, fly ash, and a combination of silica and lime were was assessed relative to their ability to reduce the leaching of contaminants, increase the strength of the contaminated sediment, and reduce the hydraulic conductivity of the sediments. The aim of the study was to develop a design for treating sediments in a stagnant water body located on the grounds of an industrial facility. The sediments were predominantly fine-grained and high in organic content. Preliminary tests identified Portland cement and the silica and lime mixture as achieving the desired strength and resistance to leaching. The solidification reagents were used to solidify more than 11,000 cubic yards of sediment with a mixture of 2 fly ashes. The full-scale solidification project surpassed the required standards for strength and permeability. 10 refs., 4 tabs., 3 figs.

  20. Cavitation-aided grain refinement in aluminium alloys

    Atamanenko, T.V.


    This thesis deals with grain refinement under the influence of ultrasonic-driven cavitation in aluminium casting processes. Three major goals of this research were: (1) to identify the mechanism of the cavitation-aided grain refinement at different stages of solidification; (2) to reveal the

  1. Cavitation-aided grain refinement in aluminium alloys

    Atamanenko, T.V.


    This thesis deals with grain refinement under the influence of ultrasonic-driven cavitation in aluminium casting processes. Three major goals of this research were: (1) to identify the mechanism of the cavitation-aided grain refinement at different stages of solidification; (2) to reveal the conditi

  2. Investigation of the Solidification Behavior of NH4Cl Aqueous Solution Based on a Volume-Averaged Method

    Li, Ri; Zhou, Liming; Wang, Jian; Li, Yan


    Based on solidification theory and a volume-averaged multiphase solidification model, the solidification process of NH4Cl-70 pct H2O was numerically simulated and experimentally verified. Although researchers have investigated the solidification process of NH4Cl-70 pct H2O, most existing studies have been focused on analysis of a single phenomenon, such as the formation of channel segregation, convection types, and the formation of grains. Based on prior studies, by combining numerical simulation and experimental investigation, all phenomena of the entire computational domain of the solidification process of an NH4Cl aqueous solution were comprehensively investigated for the first time in this study. In particular, the sedimentation of equiaxed grains in the ingot and the induced convection were reproduced. In addition, the formation mechanism of segregation was studied in depth. The calculation demonstrated that the equiaxed grains settled from the wall of the mold and gradually aggregated at the bottom of the mold; when the volume fraction reached a critical value, the columnar grains stopped growing, thus completing the columnar-to-equiaxed transition (CET). Because of solute partitioning, negative segregation occurred at the bottom region of the ingot concentrated with grains, whereas a wide range of positive segregation occurred in the unsolidified, upper part of the ingot. Experimental investigation indicated that the predicted results of the sedimentation of the equiaxed grains in the ingot and the convection types agreed well with the experimental results, thus revealing that the sedimentation of solid phase and convection in the solidification process are the key factors responsible for macrosegregation.

  3. Rapid Solidification of AB{sub 5} Hydrogen Storage Alloys

    Gulbrandsen-Dahl, Sverre


    thesis the changes of the crystal structure and the grain structure of La{sub 0.60}Ce{sub 0.29}Pr{sub 0.04}Nd{sub 0.07}Ni{sub 3.37}Co{sub 0.79}Mn{sub 0.25}Al{sub 0.7}= cooling rate during chill-block melt spinning are described. Totally, the material was rapidly solidified at 9 different cooling rates. The grain structure, crystallographic texture and the lattice parameters were studied by means of electron microscopy and powder X-ray diffraction. Additionally, the density of the rapidly solidified materials was measured by a gas pycnometer. All these properties were found to change with increasing cooling rate. The grain size decreased continuously with increasing cooling rate and was in the range of 1-5 {mu}m. The strength of the crystallographic texture first increased and then decreased with increasing cooling rate. Transmission electron microscopy studies revealed that the grains contained a large amount of crystallographic twins and that the solidification morphology changed from cellular to plane front at a cooling rate during solidification of approximately 6*10{sup 4} Ks{sup -1}. The unit cell volume and the density followed the same pattern with increasing cooling rate and decreased within each solidification morphology, but at the cooling rate from which the morphology changed, both these parameters suddenly increased. The identical variations in the unit cell volume and the density is explained by formation of excess lattice vacancies during rapid solidification. In Part IV of the thesis rapid solidification of the materials La{sub 0.60}Ce{sub 0.27}Pr{sub 0.04}Nd{sub 0.09}Ni{sub 4.76}Sn{sub 0.24} and LaNi{sub 4.76}Sn different cooling rates are described. The materials were analysed by means of electron microscopy and powder X-ray diffraction. The grain structures of both alloys were found to be in the nanometer range, and the grain sizes were almost invariant with increasing cooling rate. Furthermore, the lattice parameters of these materials were almost

  4. Solidification microstructures in a short fiber reinforced alloy composite containing different fiber fractions

    JING Qing-xiu


    Full Text Available The solidification microstructures and micro-segregation of a fiber reinforced Al-9 Cu alloy, containing different volume fractions of Al2O3 short fibers about 6 μm diameter and made by squeeze casting have been studied. The results indicate that as volume fraction of fiber Vf increases, the size of final grains becomes finer in the matrix. If λf /λ>1, the fibers have almost no influence on the solidification behavior of the matrix, so the final grains grow coarse, where λf is the average inter-fiber spacing and λ is the secondary dendrite arm spacing. While if λf /λ<1, the growth of crystals in the matrix is affected significantly by the fibers and the grain size is reduced to the value of the inter-fiber spacing. The fibers influence the average length of a solidification volume element L of the matrix and also influence the solidification time θt of the matrix. As a result of fibers influencing L and θt, the micro-segregation in the matrix is improved when the composite contains more fibers, although the level of the improvement is slight. The Clyne-Kurz model can be used to semi-quantitatively analyze the relationship between Vf and the volume fraction fe of the micro-segregation eutectic structure.

  5. Solidification microstructures in a short fiber reinforced alloy composite containing different fiber fractions


    The solidification microstructures and micro-segregation of a fiber reinforced Al-9 Cu alloy, containing different volurne fractions of Al2O3 short fibers about 6μm diameter and made by squeeze casting have been studied. The results indicate that as volume fraction of fiber Vf increases, the size of final grains becomes finer in the matrix. If λf/λ> 1, the fibers have almost no influence on the solidification behavior of the matrix, so the final grains grow coarse, where λf is the average inter-fiber spacing and λ is the secondary dendrite arm spacing. While if λf/λ< 1, the growth of crystals in the matrix is affected significantly by the fibers and the grain size is reduced to the value of the inter-fiber spacing. The fibers influence the average length of a solidification volume element L of the matrix and also influence the solidification time θt of the matrix. As a result of fibers influencing L and θt, the micro-segregation in the matrix is improved when the composite contains more fibers, although the level of the improvement is slight. The Clyne-Kurz model can be used to semi-quantitatively analyze the relationship between Vf and the volume fraction fe of the micro-segregation eutectic structure.

  6. Simulation of Microstructure during Laser Rapid Forming Solidification Based on Cellular Automaton

    Zhi-jian Wang


    Full Text Available The grain microstructure of molten pool during the solidification of TC4 titanium alloy in the single point laser cladding was investigated based on the CAFE model which is the cellular automaton (CA coupled with the finite element (FE method. The correct temperature field is the prerequisite for simulating the grain microstructure during the solidification of the molten pool. The model solves the energy equation by the FE method to simulate the temperature distribution in the molten pool of the single point laser cladding. Based on the temperature field, the solidification microstructure of the molten pool is also simulated with the CAFE method. The results show that the maximum temperature in the molten pool increases with the laser power and the scanning rate. The laser power has a larger influence on the temperature distribution of the molten pool than the scanning rate. During the solidification of the molten pool, the heat at the bottom of the molten pool transfers faster than that at the top of the molten pool. The grains rapidly grow into the molten pool, and then the columnar crystals are formed. This study has a very important significance for improving the quality of the structure parts manufactured through the laser cladding forming.

  7. Skaergaard vs Sudbury: Solidification Times and Crystal Sizes

    Marsh, B. D.; Mittal, T.; Currier, R. M.; Jordon, E.


    The overall cooling time of a batch of magma is intimately reflected in the nature of the crystal sizes. The thinner are dikes and sills the finer grained are the crystals they display. And the spatial variations in crystal size and abundance record the spatial progression of solidification. Chilled margins are fine grained because of rapid solidification, and a progressive inward increase in crystal size is perfectly predictable by coupling a law of crystal growth with a suitable solidification front-based cooling model. When observed crystal sizes are much larger than predicted, as in finding phenocrysts near or in chilled margins, this is a clear indication of crystals grown and entrained prior to final emplacement and solidification. This is exactly the process exhibited by volcanics carrying swarms of large crystals. But in plutonic rocks there is frequent confusion over what crystal sizes to expect, especially when the pluton size and shape is poorly known, and there is often an unexpressed feeling that fine grained (i.e., non-phenocryst bearing) bodies almost regardless of size somehow cool fundamentally different than large bodies, especially layered intrusions. An invaluable standard state body to which to compare the crystal sizes of other large bodies is the Sudbury impact melt sheet. Formed in a few minutes, the 3km thick 200 km wide superheated melt sheet cooled and crystallized to produce a systematic and predictable internal variation in crystal size and abundance (Zieg & Marsh, 2002, JPet). Buried by 3km of fallback debris, the sheet took about 100,000 to solidify. The Skaergaard intrusion is of a similar thickness (3.4-4 km), but is much less extensive, being more like a thin-edged elliptical laccolith (Norton et. al., 1984, JGR) or a fault-bounded loaf of bread (7.75 x 10.55 x 3.7 km; Nielsen, 2004, JPet). In spite of its limited extent, the extent is large enough for solidification of the thickest parts time to approach that of an infinite sheet

  8. Effect of thermosolutal convection on directional solidification

    Suresh V Garimella; James E Simpson


    The impact of thermosolutal convection during directional solidification is explored via results of numerical investigations. Results from fully transient numerical simulations of directional solidification in a differentially heated cavity under terrestrial conditions and Bridgman crystal growth in space are discussed. The pivotal role of both thermal and solutal convection in the solidification process is illustrated by examining these two cases. In particular, radial and longitudinal macrosegregation resulting from this thermosolutal convection is discussed.

  9. Micro-macroscopic coupling in the cellular automaton model of solidification

    Vinicius Bertolazzi Biscuola


    Full Text Available A cellular automaton (CA model to predict the formation of grain macrostructure during solidification has been implemented and the coupling between the microscopic and the macroscopic submodels has been investigated. The microscopic submodel simulates the nucleation and growth of grains, whereas the macroscopic solves the heat conduction equation. The directional solidification of an Al-7 wt. (% Si alloy was simulated, enabling the calculation of the temperature and solid fraction profiles. The calculated temperature was used to obtain the solid fraction profile by an application of Scheil equation. This solid fraction disagrees with that calculated in the micro-macro coupling of the model, although this coupling is completely based on Scheil equation. Careful examination of the discrepancies shows that it is a result of the undercoolings for nucleation and growth of grains and also of the interpolations of enthalpy change and temperature from the finite volume mesh to the CA cell mesh.

  10. On the hot cracking susceptibility of a semisolid aluminium 6061 weld: Application of a coupled solidification- thermomechanical model

    Zareie Rajani, H. R.; Phillion, A. B.


    A coupled solidification-thermomechanical model is presented that investigates the hot tearing susceptibility of an aluminium 6061 semisolid weld. Two key phenomena are considered: excessive deformation of the semisolid weld, initiating a hot tear, and the ability of the semisolid weld to heal the hot tear by circulation of the molten metal. The model consists of two major modules: weld solidification and thermomechanical analysis. 1) By means of a multi-scale model of solidification, the microstructural evolution of the semisolid weld is simulated in 3D. The semisolid structure, which varies as a function of welding parameters, is composed of solidifying grains and a network of micro liquid channels. The weld solidification module is utilized to obtain the solidification shrinkage. The size of the micro liquid channels is used as an indicator to assess the healing ability of the semisolid weld. 2) Using the finite element method, the mechanical interaction between the weld pool and the base metal is simulated to capture the transient force field deforming the semisolid weld. Thermomechanical stresses and shrinkage stresses are both considered in the analysis; the solidification contractions are extracted from the weld solidification module and applied to the deformation simulation as boundary conditions. Such an analysis enables characterization of the potential for excessive deformation of the weld. The outputs of the model are used to study the effect of welding parameters including welding current and speed, and also welding constraint on the hot cracking susceptibility of an aluminium alloy 6061 semisolid weld.

  11. Progress on modeling and simulation of directional solidification of superalloy turbine blade casting

    Xu Qingyan


    Full Text Available Directional solidified turbine blades of Ni-based superalloy are widely used as key parts of the gas turbine engines. The mechanical properties of the blade are greatly influenced by the final microstructure and the grain orientation determined directly by the grain selector geometry of the casting. In this paper, mathematical models were proposed for three dimensional simulation of the grain growth and microstructure evolution in directional solidification of turbine blade casting. Ray-tracing method was applied to calculate the temperature variation of the blade. Based on the thermo model of heat transfer, the competitive grain growth within the starter block and the spiral of the grain selector, the grain growth in the blade and the microstructure evolution were simulated via a modified Cellular Automaton method. Validation experiments were carried out, and the measured results were compared quantitatively with the predicted results. The simulated cooling curves and microstructures corresponded well with the experimental results. The proposed models could be used to predict the grain morphology and the competitive grain evolution during directional solidification.

  12. A Multiscale Transient Modeling Approach for Predicting the Solidification Structure in VAR-Processed Alloy 718 Ingots

    Nastac, Laurentiu


    This paper describes the development and validation of a comprehensive multiscale modeling approach capable of predicting at the mesoscopic scale level the ingot solidification structure and solidification-related defects commonly occurring during the vacuum arc remelting (VAR) process. The approach consists of a coupling between a fully transient macroscopic code and a mesoscopic solidification structure code. The predictions from the multiscale model, including grain morphology and size and columnar-to-equiaxed transition, were validated against experimental measurements for a 20-inch (508 mm) diameter VAR alloy 718 ingots. The validated model was then used to investigate the effects of melting rate and ingot diameter on the solidification structure of VAR processed 718 ingots.

  13. Towards a Map of Solidification Cracking Risk in Laser Welding of Austenitic Stainless Steels

    Bermejo, María-Asunción Valiente; DebRoy, Tarasankar; Hurtig, Kjell; Karlsson, Leif; Svensson, Lars-Erik

    In this work, two series of specimens with Hammar and Svensson's Cr- and Ni-equivalents (Creq+Nieq) = 35 and 45 wt% were used to cover a wide range of austenitic grades. These were laser welded with different energy inputs achieving cooling rates in the range of 103 °C/s to 104 °C/s. As high cooling rates and rapid solidification conditions could favour fully austenitic solidification and therefore raise susceptibility to solidification cracking, the solidification modes of the laser welded specimens were compared to the ones experienced by the same alloys under arc welding conditions. It was found that high cooling rates experienced in laser welding promoted fully austenitic solidification for a wider range of compositions, for example specimens with (Creq+Nieq) = 35% under arc welding cooling conditions at 10 °C/s showed fully austenitic solidification up to Creq/Nieq = 1.30, whilst the same specimens laser cooled at 103 °C/s showed fully austenitic solidification up to Creq/Nieq = 1.50 and those cooled at 104 °C/s showed it up to Creq/Nieq = 1.68. Therefore, high cooling rates extended the solidification cracking risk to a wider range of Creq/Nieq values. This work also compares the cooling rates experimentally determined by thermocouples to the computed cooling rates calculated by a highly-advanced computational model. The distance between the thermocouple's wires and the thermal resistance of thermocouples together with the small size of the weld pools proved to be practical limitations in the experimental determination of cooling rates. However, an excellent agreement was found between computed and experimental solidus isotherms at high energy input settings. For low energy input settings cooling rate was in the order of magnitude of 104 °C/s, whilst for high energy input settings cooling rate was found to be in the order of magnitude of 103 °C/s.

  14. In Situ Observation of Solidification Process of AISI 304 Austenitic Stainless Steel

    HUANG Fu-xiang; WANG Xin-hua; ZHANG Jiong-ming; JI Chen-xi; FANG Yuan; YU Yan


    The solidification process of AISI 304 stainless steel during cooling at a rate of 0.05 K/s has been observed in situ using a confocal scanning laser microscope(CSLM).The results show that the δ phase appeared first in liquid steel,as the temperature decreased,the γ phase precipitated prior at δ-grain boundary at 1452.2℃,the liquid steel disappeared at 1431.3℃,and then theγphase precipitated on the δ ferrite.Based on the Scheil-GulliVer solidification model,the solidification processes of AISI 304 stainless steel are simulated using the Scheil model in Thermo-Calc.and the simulation results agree well with the results observed in the experiment.

  15. Solidification Structure Refining of 430 Ferrite Stainless Steel With TiN Nucleation

    SHI Cai-xia; CHENG Guo-guang; LI Zhan-jun; ZHAO Pei


    The thermodynamics of TiN precipitation in liquid steel of 430 ferrite stainless steel has been calculated to find out the condition of TiN precipitation during the initial solidification stage. The difference in the solidification structure of 430 ferrite stainless steel has been discussed through comparative tests of vacuum induction furnace melt-ing with different contents of Ti. It has been found that the equiaxed grain proportion can be increased from 20% to 69% as the content of Ti from 0.1% up to 0.4%. The size of the TiN particles precipitated is 1--3 μm and the number of TiN particles is about (200--300)/μm2. It is found that the effect of using TiN to refine the solidification structure has been confirmed under the strict process condition used for 430 ferrite stainless steel.

  16. A 3-phase model for mixed columnar-equiaxed solidification in DC casting of bronze

    Hao, J.; Grasser, M.; Wu, M.; Ludwig, A.; Riedle, J.; Eberle, R.


    A three-phase Eulerian approach is used to model the columnar-to-equiaxed transition (CET) during solidification in DC casting of technical bronze. The three phases are the melt, the solidifying columnar dendrites and the equiaxed grains. They are considered as spatially interpenetrating and interacting continua by solving the conservation equations of mass, momentum, species and enthalpy for all three phases. The so defined solidification model is applied to a binary CuSn6 DC casting process as a benchmark to demonstrate the model potentials. Two cases are studied: one considering only feeding flow and one including both feeding flow and equiaxed sedimentation. The simulated results of mixed columnar and equiaxed solidification are presented and discussed including the occurrence of CET, phase distribution, feeding flow, equiaxed sedimentation and their influence on macrosegregation.

  17. Solidification Features of Ti45Al Alloys with Different Boron Addition

    Weidong Wang; Yingche Ma; Bo Chen; Ming Gao; Kui Liu; Yiyi Li


    The effects of boron on the solidification behaviors of Ti45AlxB alloys were studied by high temperature samples. These samples were melted at 1823 K, followed by cooling to the designated temperature, and then quickly water-quenched to preserve the solidification features. Optical microscopy and scanning electron microscopy analysis shows that the solidus temperature of Ti45AI was really reduced by 20 K when adding 0.8 at. pct B, and it was also observed that boride precipitated before the appearance of β phase. Besides, solidification structure confirmed that B addition does not obviously refine β phase, α grain refinement by certain amount of B in alloy probably clarifies the mechanism of B refining lamellar microstructure at room temperature.

  18. Solidification Structure and Macrosegregation of Billet Continuous Casting Process with Dual Electromagnetic Stirrings in Mold and Final Stage of Solidification: A Numerical Study

    Jiang, D.; Zhu, M.


    Coupling macroscale heat transfer and fluid flow with microscale grain nucleation and crystal growth, a mixed columnar-equiaxed solidification model was established to study the SWRT82B steel solidification structure and macrosegregation in 160 mm × 160 mm billet continuous casting with dual electromagnetic stirrings in mold and final stage of solidification (M-EMS and F-EMS). In the model, the phases of liquid, columnar, and equiaxed were treated separately and the initial growing equiaxed phase, which could move freely with liquid, was regarded as slurry. To obtain the equiaxed grains nucleation and columnar front evolution, the unit tracking method and the columnar front tracking model were built. The model was validated by magnetic induction intensity of stirrer, billet surface temperature, and carbon segregation. The equiaxed phase evolution and the solute transport with effect of fluid flow and grains transport were described in this article. The results show that the equiaxed phase ratio will not increase obviously with higher current intensity of M-EMS, while the negative segregation near the strand surface becomes more serious. The negative segregation zone near the billet center and the center positive segregation come into being with the effect of equiaxed grains sedimentation and liquid thermosolutal flow. It is also found that the liquid solute transport in the F-EMS zone becomes the main factor with higher current intensity rather than the solidification rate, and therefore, the final billet center segregation decreases first and then turns to rise with the current intensity. The optimal current intensities of M-EMS and F-EMS proposed for SWRT82B billet continuous casting are 200 and 400 A, respectively.

  19. Solidification Structure and Macrosegregation of Billet Continuous Casting Process with Dual Electromagnetic Stirrings in Mold and Final Stage of Solidification: A Numerical Study

    Jiang, D.; Zhu, M.


    Coupling macroscale heat transfer and fluid flow with microscale grain nucleation and crystal growth, a mixed columnar-equiaxed solidification model was established to study the SWRT82B steel solidification structure and macrosegregation in 160 mm × 160 mm billet continuous casting with dual electromagnetic stirrings in mold and final stage of solidification (M-EMS and F-EMS). In the model, the phases of liquid, columnar, and equiaxed were treated separately and the initial growing equiaxed phase, which could move freely with liquid, was regarded as slurry. To obtain the equiaxed grains nucleation and columnar front evolution, the unit tracking method and the columnar front tracking model were built. The model was validated by magnetic induction intensity of stirrer, billet surface temperature, and carbon segregation. The equiaxed phase evolution and the solute transport with effect of fluid flow and grains transport were described in this article. The results show that the equiaxed phase ratio will not increase obviously with higher current intensity of M-EMS, while the negative segregation near the strand surface becomes more serious. The negative segregation zone near the billet center and the center positive segregation come into being with the effect of equiaxed grains sedimentation and liquid thermosolutal flow. It is also found that the liquid solute transport in the F-EMS zone becomes the main factor with higher current intensity rather than the solidification rate, and therefore, the final billet center segregation decreases first and then turns to rise with the current intensity. The optimal current intensities of M-EMS and F-EMS proposed for SWRT82B billet continuous casting are 200 and 400 A, respectively.

  20. Solidification phenomena in metal matrix nanocomposites

    de Cicco, Michael Peter


    Nanoparticles in metal matrix nanocomposites (MMNCs) were shown to act as catalysts for nucleation of solidification of the matrix alloy, as well as to alter the intermetallic phase formation. These phenomena were studied in zinc, aluminum, and magnesium alloys. In all alloys studied, a refinement of the microstructure was seen with the addition of the nanoparticles. Various types of nanoparticles were used and had varying degrees of refinement. In a zinc alloy, AC43A, SiC, TiC, and Al2O3 gamma nanoparticles were all found to refine the alloy. Thermal analysis of bulk samples showed the onset of solidification at reduced undercoolings, indicating nucleation catalysis. Nucleation of the primary phase was also observed by employing the droplet emulsion technique (DET). DET results showed that the secondary phase nucleation was also catalyzed by the nanoparticles. Exploiting the nucleation catalysis of the nanoparticles and the associated grain refinement, a semi-solid casting (SSC) process was demonstrated in AC43A + SiC nanocomposites. This novel process successfully incorporated the strength enhancement of MMNCs and the casting quality benefits of SSC. This process required no additional processing steps or material handling typical of existing SSC processes. The nucleation catalysis of the nanoparticles was sufficient to create semi-solid slurries appropriate for SSC. Nanoparticle induced nucleation catalysis was also examined in a common aluminum alloy, A356, using the DET. All nanoparticles catalyzed nucleation of the primary Al phase. However, undercoolings varied depending on the nanoparticle identity and average diameter. The variation in undercoolings generally agreed with a modified lattice disregistry theory and the free growth theory. For nanoparticles with a small lattice spacing mismatch with the Al phase, undercoolings approached the size dependent free growth limit. Binary alloys of magnesium and zinc showed significant strength and ductility

  1. Morphology of solidification front in eutectic

    M. Trepczyńska - Łent


    Full Text Available In this paper the analysis of morphology of solidification front in eutectic made. It was present influence of composition, solidification velocity, concentration micro-field and capillarity effects on the morphology of the solid/liquid interface. It was introduced phase-field model.

  2. Numerical modelling of rapid solidification

    Pryds, Nini; Hattel, Jesper Henri


    A mathematical model of the melt spinning process has been developed based on the control-volume finite-difference method. The model avoids some of the limitations of the previous models, for example including the effect of the wheel in the heat how calculations and the temperature dependence...... of the thermophysical parameters of the material. The nucleation temperature was calculated based on the heterogeneous nucleation theory. The effect of various parameters, such as the heat transfer coefficient, the nucleation temperature and the heating and type of the wheel on the rapid solidification behaviour...

  3. Directional Solidification of Eutectic Ceramics

    Sayir, Ali


    Two major problems associated with structural ceramics are lack of damage tolerance and insufficient strength and creep resistance at very high temperatures of interest for aerospace application. This work demonstrated that the directionally solidified eutectics can have unique poly-phase microstructures and mechanical properties superior to either constituent alone. The constraining effect of unique eutectic microstructures result in higher resistance to slow crack growth and creep. Prospect of achieving superior properties through controlled solidification are presented and this technology can also be beneficial to produce new class of materials.

  4. Solidification characteristics of Fe-Ni peritectic alloy thin strips under a near-rapid solidification condition

    Chang-jiang Song


    Full Text Available This paper is an experimental investigation of the structure evolution and the solute distribution of 2 mm thick strips of Fe-(2.6, 4.2, 4.7, 7.9wt.%Ni peritectic alloy under a near-rapid solidification condition, which were in the regions of δ-ferrite single-phase, hypo-peritectic, hyper-peritectic and γ-austenite single-phase, respectively. The highest area ratio of equiaxed grain zone in the hyper-peritectic of Fe-4.7wt.%Ni alloy strip was observed, while other strips were mainly columnar grains. The lowest micro-segregation was obtained in the Fe-7.9wt.%Ni alloy strip, while micro-segregation in the Fe-4.7wt.%Ni alloy was the highest. As opposed to the micro-segregation, the macro-segregation of all the Fe-Ni strips was suppressed due to the rapid solidification rate. Finally, the structure formation mechanism of Fe-Ni alloy strips was analyzed.


    程绪铎; 严晓婕; 黄之斌


    阐述了双直溜槽与双螺旋溜槽连接式装粮器的结构设计原理和原则.绘出了双直溜槽与双螺旋溜槽连接式装粮器结构示意图,依据摩擦理论和功能原理,由给定的粮食入口速度、出口速度、粮食流量,粮食与溜管的摩擦系数,设计出直溜槽、螺旋溜槽与水平面倾角α,直溜槽、螺旋溜槽的长度S1、S2,直溜槽、螺旋溜槽半圆截面半径γ.%Principle on grain loading device of connection mode of double straight chutes and double spiral chutes are stated.Diagrammatic sketch of the grain loading device of connection mode of double straight chutes and double spiral chutes are drawn.According to frictional theory and principle of work and power,under given condition on entrance velocity of grain,outlet velocity of grain,rate of flow of grain and coefficient of friction of the chutes and grain,dip angle of the straight chute and the spiral chute for horizontal plane,length of the straight chute,length of the spiral chute s2 and radius of semi-circular section of the straight chute and the spiral chute γ are designed.

  6. Simulation of the aluminum alloy A356 solidification cast in cylindrical permanent molds


    A mathematical model based on the control volume method with fixed mesh was selected in order to simulate the solidification of cylindrical castings poured in permanent steel mold. The latent heat was incorporated using the effective specific heat. The application of the model allowed us to obtain the solidification front and the temperature fields at any time from the pouring. The mold was made of the SAE 1010 steel. Two mold temperatures were evaluated: 25°C and 300°C. The mathematical mode...




    Full Text Available Welding processes induce a state of residual stress into materials and jobs. This poses a series of problems, in terms of dimensional stability, corrosion cracking, reduced fatigue life and structural integrity . Thermal cycle produced near weld line generates residual stress and inhomogeneous plastic deformation in weldments. Understanding of grain nucleation and grain growth becomes necessary that are influenced under welding conditions. After completion of nucleation, the solidification process will continue with nucleus growth .With vibratory weld conditioning, the enhancement of weld metal microstructure can be achieved. The mechanical properties, level of residual stresses, and deformation can also be affected . Structural changes of the welds prepared under vibratory conditions affects the mechanical properties of the welds. The vibration duringwelding benefits energy absorbed in impact toughness test of weld metal and improves fracture behavior. This paper presents the microstructure, solidification behaviour and residual stress relaxation under vibratory welding condition.

  8. Continuous melting and directional solidification of silicon ingot with an electromagnetic cold crucible

    Huang Feng


    Full Text Available In order to avoid contamination from the crucible and to modify the structures, a new solidification method based on cold crucible technology was used to prepare silicon ingots. A silicon ingot with square cross section was directionally solidified with a cold crucible. The mechanism of the cold crucible directional solidification of silicon ingot was revealed. Due to the induction heat that was released in the surface layer and the incomplete contact between the crucible and the melt, the lateral heat loss was reduced and the silicon ingot was directionally solidified. The structures, dislocation defects and the grain growth orientation of the ingot were determined. The results show that neither intergranular nor intragranular precipitates are found in the ingot, except for the top part that was the last to solidify. The average dislocation density is about 1 to 2 × 106 cm-2. The grains are preferentially orientated.

  9. Solidification of gold nanoparticles in carbon nanotubes.

    Arcidiacono, S; Walther, J H; Poulikakos, D; Passerone, D; Koumoutsakos, P


    The structure and the solidification of gold nanoparticles in a carbon nanotube are investigated using molecular dynamics simulations. The simulations indicate that the predicted solidification temperature of the enclosed particle is lower than its bulk counterpart, but higher than that observed for clusters placed in vacuum. A comparison with a phenomenological model indicates that, in the considered range of tube radii (R(CNT)) of 0.5 < R(CNT) < 1.6 nm, the solidification temperature depends mainly on the length of the particle with a minor dependence on R(CNT).

  10. Theoretical - Experimental Analysis of Cellular and Primary Dendritic Spacings during Unidirectional Solidification of Sn-Pb Alloys

    Otávio F.L. da Rocha


    Full Text Available Structural parameters as grain size, dendritic and cellular spacings, segregated products, porosity and other phases are strongly influenced by the thermal behavior of the metal/mold system during solidification, imposing a close correlation between this and the resulting microstructure. Several unidirectional solidification studies with the objective of characterizing cellular and dendritic spacings have been developed in large scale involving solidification in steady-state heat flow. The main objective of this work is to determine the thermal solidification parameters during the cellular/dendritic transition as well as to compare theoretical models that predict cellular and primary dendritic spacings with experimental results for solidification situations in unsteady-state heat flow. Experiments were carried out in a water cooled unidirectional solidification apparatus and dilute alloys of the Sn-Pb system were used (Sn 1.5wt%Pb, Sn 2.5wt%Pb and Sn 5wt%Pb. The upper limit of the Hunt-Lu cellular growth model closely matched the experimental spacings. The lower limit calculated with the Hunt-Lu dendritic model best generated the experimental results. The cellular/dendritic transition was observed to occur for the Sn 2.5wt%Pb alloy over a range of analytical cooling rates from 0.28 K/s to 1.8 K/s.

  11. Rapid solidification of immiscible alloys

    Bosco, Enrica; Rizzi, Paola; Baricco, Marcello E-mail:


    Immiscible alloys have been rapidly solidified for the preparation of granular materials with giant magnetoresistance properties. Au-based (Au-Co and Au-Fe) and Cu-based (Cu-Co and Cu-Fe) systems have been investigated. Single supersaturated solid solution has been obtained for Au-Fe, whereas three FCC solid solutions with different Co content have been found for Au-Co. For Cu-Co and Cu-Fe a limit of solubility in Cu has been observed. Ni additions to Cu-Fe strongly enhance solid solubility. A thermodynamic analysis has been used to describe the competition between partition-less solidification and phase separation in undercooled liquid.

  12. Chemically bonded phosphate ceramics for radioactive and mixed waste solidification and stabilization

    Wagh, A.S.; Cunnane, J.C.; Singh, D.; Reed, D.T.; Armstrong, S.; Subhan, W.; Chawla, N.


    Results of an initial investigation of low temperature setting chemically bonded magnesium ammonium phosphate (MAP) ceramics as waste form materials, for solidification and stabilization of radioactive and mixed waste, are reported. The suitability of MAP for solidifying and encapsulating waste materials was tested by encapsulating zeolites at loadings up to [approximately]50 wt%. The resulting composites exhibited very good compressive strength characteristics. Microstructure studies show that zeolite grains remain unreacted in the matrix. Potential uses for solidifying and stab wastes are discussed.

  13. Chemically bonded phosphate ceramics for radioactive and mixed waste solidification and stabilization

    Wagh, A.S.; Cunnane, J.C.; Singh, D.; Reed, D.T.; Armstrong, S.; Subhan, W.; Chawla, N.


    Results of an initial investigation of low temperature setting chemically bonded magnesium ammonium phosphate (MAP) ceramics as waste form materials, for solidification and stabilization of radioactive and mixed waste, are reported. The suitability of MAP for solidifying and encapsulating waste materials was tested by encapsulating zeolites at loadings up to {approximately}50 wt%. The resulting composites exhibited very good compressive strength characteristics. Microstructure studies show that zeolite grains remain unreacted in the matrix. Potential uses for solidifying and stab wastes are discussed.

  14. Interrupted and Isothermal Solidification Studies of Low and Medium Carbon Steels

    Pottore, N. S.; Garcia, C. I.; Deardo, A. J.


    Low and medium carbon steels experience multiple phase transformations during solidification and subsequent cooling. The sequence, extent, and nature of the different transformations have a significant bearing on the microstructural evolution that occurs in the steel. The change in microstructure with temperature is very important, since it may influence the hot ductility of the steel during casting and/or rolling and the subsequent response of the material to thermoprocessing. The aim of this investigation was to gain a better understanding of the development of the as-cast structure in low and medium carbon steels. Of particular interest is the origin of the large austenite grains frequently associated with poor hot ductility. Interrupted and isothermal solidification experiments were therefore conducted to study the nonequilibrium and near-equilibrium structures which form at different stages of the freezing process. The results of the investigation established delta-ferrite as the primary solidifying phase in low carbon steels. Austenite forms as the secondary phase by nucleation at the solidification (delta-ferrite) boundaries. While excessive austenite grain coarsening is suppressed by the coexistence of the second phases delta-ferrite or liquid, this suppression occurs over only a limited temperature range, just below the peritectic temperature. Subsequent cooling leads to very large austenite grains, ranging up to 5 mm in diameter, in steels of low carbon content.

  15. Evolution of solidification texture during additive manufacturing

    Wei, H L; Mazumder, J; DebRoy, T


    Striking differences in the solidification textures of a nickel based alloy owing to changes in laser scanning pattern during additive manufacturing are examined based on theory and experimental data...

  16. A Citizen's Guide to Solidification and Stabilization

    This guide describes how solidification and stabilization refer to a group of cleanup methods that prevent or slow the release of harmful chemicals from wastes, such as contaminated soil, sediment, and sludge.

  17. Solidification process in melt spun Nd-Fe-B type magnets

    Li, Changping [Iowa State Univ., Ames, IA (United States)


    A generalized solidification model has been developed based on a systematic investigation on the microstructure of melt spun Nd-Fe-B alloys. Melt spinning was conducted on initial stoichiometric and TiC added Nd2Fe14B (2-14-1) compositions to produce under, optimally and over quenched microstructures. Microstructural characterization was carried out by TEM, SEM, Optical microscopy, XRD, DTA, VSM and DC SQUID techniques. By taking the dendritic breakup during recalescence into consideration, this generalized model has successfully explained the solidification process of the melt spun Nd-Fe-B alloys. Challenging the conventional homogeneous nucleation models, the new model explains the fine and uniform equiaxed 2-14-1 microstructure in optimally quenched ribbons as a result of the breakup of the 2-14-1 dendrites which nucleate heterogeneously from the wheel surface and grow dendritically across the ribbon thickness due to the recalescence. Besides this dendritic breakup feature, the under quenched microstructure is further featured with another growth front starting with the primary solidification of Fe phase near the free side, which results in a coarsely grained microstructure with Fe dendritic inclusions and overall variation in microstructure across the ribbon thickness. In addition, because a epitaxy exists between the Fe phase and the 2-14-1, the so-formed coarse 2-14-1 grains may be textured. C-axis texturing was observed in under quenched ribbons. As a constraint to solidification models in this system, the cause and characteristics of this phenomenon has been studied in detail to test the authors proposed model, and agreement has been found. An extension has also been made to understand the solidification process when TiC is added, which suggests that Ti and C slow down the growth front of both Fe and 2-14-1 phase.

  18. Analysis of Solidification Parameters and Macrostructure of IN-713C Castings after Complex Modification

    Binczyk F.


    Full Text Available The paper presents a research results concerning impact of volume modification (ceramic filter containning cobalt aluminate and hafnium powder and simultaneous surface and volume modification on solidification and stereological parameters of macrostructure of castings made from post-production scrap of nickel superalloy IN-713C. Research included investigation of the influence of chemical composition on the temperature Tliq i Tsol and evaluation of following macrostructure parameters: the number of grains per mm2, average grain area and shape coefficient. Results indicate high influence of carbon content on Tliq. Macrostructure of sample castings indicate positive effect of surface and volume modification, however impact of surface modification is more pronounced.

  19. Analysis of Solidification Parameters and Macrostructure of IN-713C Castings after Complex Modification

    F. Binczyk


    Full Text Available The paper presents a research results concerning impact of volume modification (ceramic filter containning cobalt aluminate and hafnium powder and simultaneous surface and volume modification on solidification and stereological parameters of macrostructure of castings made from post-production scrap of nickel superalloy IN-713C. Research included investigation of the influence of chemical composition on the temperature Tliq i Tsol and evaluation of following macrostructure parameters: the number of grains per mm2, average grain area and shape coefficient. Results indicate high influence of carbon content on Tliq. Macrostructure of sample castings indicate positive effect of surface and volume modification, however impact of surface modification is more pronounced.

  20. Modeling of columnar and equiaxed solidification of binary mixtures; Modelisation de la solidification colonnaire et equiaxe de melanges binaires

    Roux, P


    This work deals with the modelling of dendritic solidification in binary mixtures. Large scale phenomena are represented by volume averaging of the local conservation equations. This method allows to rigorously derive the partial differential equations of averaged fields and the closure problems associated to the deviations. Such problems can be resolved numerically on periodic cells, representative of dendritic structures, in order to give a precise evaluation of macroscopic transfer coefficients (Drag coefficients, exchange coefficients, diffusion-dispersion tensors...). The method had already been applied for a model of columnar dendritic mushy zone and it is extended to the case of equiaxed dendritic solidification, where solid grains can move. The two-phase flow is modelled with an Eulerian-Eulerian approach and the novelty is to account for the dispersion of solid velocity through the kinetic agitation of the particles. A coupling of the two models is proposed thanks to an original adaptation of the columnar model, allowing for undercooling calculation: a solid-liquid interfacial area density is introduced and calculated. At last, direct numerical simulations of crystal growth are proposed with a diffuse interface method for a representation of local phenomena. (author)

  1. Development of a High Chromium Ni-Base Filler Metal Resistant to Ductility Dip Cracking and Solidification Cracking

    Hope, Adam T.

    Hf-bearing compositions had gamma/Ni7Hf2 as the final eutectic to solidify. This study found that the extra Cr in the current generation alloys promotes the gamma/Laves phase eutectic, which expands the solidification temperature range and promotes solidification cracking. Both Ta-bearing and Hf-bearing eutectics were found to solidify at higher temperatures than Nb-bearing eutectics, leading to narrower solidification temperature ranges. Weldability testing on the optimized Ta-bearing compositions revealed good resistance to both DDC and solidification cracking. Unexpectedly, the optimized Hf-bearing compositions were quite susceptible to solidification cracking. This led to an investigation on the possible wetting effect of eutectics on solidification cracking susceptibly, and a theory on how wetting affects the solidification crack susceptibility and the volume fraction of eutectic needed for crack healing has been proposed. Alloys with eutectics that easily wet the grain boundaries have increased solidification crack susceptibility at low volume fraction eutectics, but as the fraction eutectic is increased, experience crack healing at relatively lower fraction eutectics than alloys with eutectics that don't wet as easily. Hf rich eutectics were found to wet grain boundaries significantly more than Nb rich eutectics. Additions of Mo were also found to increase the wetting of eutectics in Nb-bearing alloys.

  2. Detection of inner core solidification from observations of antipodal PKIIKP

    Cormier, Vernon F.


    PKIIKP waves, reflected from the underside of the inner core boundary, are very sensitive to the S velocity in the uppermost 80 km of the inner core at antipodal distances, undergoing a phase change and a factor of 4 amplification as the distance approaches 180°. Modeled PKIIKP waveforms are consistent with a near-zero shear modulus in the uppermost inner core in a 20-40 km thick patch beneath the eastern equatorial hemisphere. This bright spot of PKIIKP reflection correlates with a thin zone of low P velocity inferred from the complexity of PKIKP waveforms sampling this patch. Estimates of grain sizes from seismic attenuation, the absence of backscattered PKiKP coda in this region, and a prediction for enhanced heat flow through this patch suggest that it is a region of solidification rather than melting.

  3. Prediction of the solidification structure of casting and heterogeneous nucleation

    K. Ohsasa; H. Shirosawa; T. Narita


    The frequency of heterogeneous nucleation during the solidification of Al-Si binary alloy was estimated by comparing ex-perimentally obtained macrostructures of castings with numerically simulated ones. A molten alloy was unidirectionally solidifiedfrom a water-cooled copper chill in an adiabatic mold. The location of colunmar to equiaxed transition (CET) in the solidified alloyingot was measured. A numerical simulation for grain structure formation based on the Monte Carlo method was carried out, and thefrequency of heterogeneous nucleation in the alloy was evaluated by producing similar structure with the experimental one. The fre-quency of heterogeneous nucleation was expressed as a probabilistic function with an exponential form of undercooling that deter-mines the probability of nucleation event in the simulation. The value of the exponent is regarded as the nucleation parameter. Thenucleation parameter of Al-Si binary alloy varied with initial Sicontent.

  4. Solidification of Magnesium (AM50A) / vol%. SiCp composite

    Zhang, X.; Hu, H.


    Magnesium matrix composite is one of the advanced lightweight materials with high potential to be used in automotive and aircraft industries due to its low density and high specific mechanical properties. The magnesium composites can be fabricated by adding the reinforcements of fibers or/and particles. In the previous literature, extensive studies have been performed on the development of matrix grain structure of aluminum-based metal matrix composites. However, there is limited information available on the development of grain structure during the solidification of particulate-reinforced magnesium. In this work, a 5 vol.% SiCp particulate-reinforced magnesium (AM50A) matrix composite (AM50A/SiCp) was prepared by stir casting. The solidification behavior of the cast AM50A/SiCp composite was investigated by computer-based thermal analysis. Optical and scanning electron microscopies (SEM) were employed to examine the occurrence of nucleation and grain refinement involved. The results indicate that the addition of SiCp particulates leads to a finer grain structure in the composite compared with the matrix alloy. The refinement of grain structure should be attributed to both the heterogeneous nucleation and the restricted primary crystal growth.

  5. Solid Propellant Grain Structural Integrity Analysis


    The structural properties of solid propellant rocket grains were studied to determine the propellant resistance to stresses. Grain geometry, thermal properties, mechanical properties, and failure modes are discussed along with design criteria and recommended practices.

  6. Simulation of unconstrained solidification of A356 aluminum alloy on distribution of micro/macro shrinkage

    Hossein Bayani


    Full Text Available In the condition of Newtonian heat transfer, A356 aluminum alloy is solidified with randomly distributed equiaxed dendrites. Ability of interdendritic liquid flow is described by permeability parameter using Darcy's law and this parameter is used to predict the micro-shrinkages. In this study the interdendritic liquid flow during nucleation and grain growth are simulated in a 1 mm × 1 mm domain. Temperature gradient is zero in the initial condition of the unconstrained solidification. The numerical simulation procedure includes two stages; first, numerical evolution of the shape, number, size, and distribution of dendrites during solidification using a novel Cellular Automation Finite Volume (CA-FV method, and second, numerical determination of the micro-permeability by a Computational Fluid Dynamics (CFD technique. Subsequently, the effect of Reynolds number, cooling rate and solidification rate on a critical permeability range was investigated in order to predict the micro/macro shrinkage distribution. Results showed that it is possible to propose a mathematical model to relate the Reynolds number and liquid flow rate, in the creeping flow range, on the micro-permeability during unconstrained solidification.

  7. Eutectic Solidification in Al-13.0%Si Alloys with Combined Addition of Strontium and Boron

    Hengcheng Liao; Ke Ding; Juanjuan Bi; Min Zhang; Huipin Wang; Lei Zhao


    The influence of addition of boron (B) on eutectic solidification in a near-eutectic AI-13.0%Si alloy modified with strontium (Sr) was investigated using thermal analysis and macro/microstructure observation. Addition of B in the Sr-modified alloy leads to a considerable increase in nucleation temperature (Tn, the minimum temperature prior to recalescence (TM) and growth temperature (TG). In the Sr-modified alloy, nucleation of eutectic might originate at the heterogeneous sites on the mold wall or in the melt near the wall, and eutectic solidification proceeds gradually towards the center, controlled by undercooling of melt. However, with addition of B in the Sr-modified alloy, undercooling required for eutectic nucleation became small, and hence eutectic solidification might occur almost simultaneously within whole casting, controlled by amount of heterogeneous sites. With excessive addition of B in the Sr-modified alloy, nucleation of eutectic grains was explosive within the whole casting and the power of Sr on eutectic solidification was completely poisoned.

  8. Effect on the grain size of single-mode microwave sintered NiCuZn ferrite and zinc titanate dielectric resonator ceramics.

    Sirugudu, Roopas Kiran; Vemuri, Rama Krishna Murthy; Venkatachalam, Subramanian; Gopalakrishnan, Anisha; Budaraju, Srinivasa Murty


    Microwave sintering of materials significantly depends on dielectric, magnetic and conductive Losses. Samples with high dielectric and magnetic loss such as ferrites could be sintered easily. But low dielectric loss material such as dielectric resonators (paraelectrics) finds difficulty in generation of heat during microwave interaction. Microwave sintering of materials of these two classes helps in understanding the variation in dielectric and magnetic characteristics with respect to the change in grain size. High-energy ball milled Ni0.6Cu0.2Zn0.2Fe1.98O4-delta and ZnTiO3 are sintered in conventional and microwave methods and characterized for respective dielectric and magnetic characteristics. The grain size variation with higher copper content is also observed with conventional and microwave sintering. The grain size in microwave sintered Ni0.6Cu0.2Zn0.2Fe1.98O4-delta is found to be much small and uniform in comparison with conventional sintered sample. However, the grain size of microwave sintered sample is almost equal to that of conventional sintered sample of Ni0.3Cu0.5Zn0.2Fe1.98O4-delta. In contrast to these high dielectric and magnetic loss ferrites, the paraelectric materials are observed to sinter in presence of microwaves. Although microwave sintered zinc titanate sample showed finer and uniform grains with respect to conventional samples, the dielectric characteristics of microwave sintered sample are found to be less than that of conventional sample. Low dielectric constant is attributed to the low density. Smaller grain size is found to be responsible for low quality factor and the presence of small percentage of TiO2 is observed to achieve the temperature stable resonant frequency.


    李兰芳; 凌建


    At the same warehouse types and grain quality, the control effects have been investigated and com-pared by three fumigation modes, such as phosphine recirculation fumigation under film, natural deliques-cence on the surface of grain bulk and natural deliquescence under film. The fumigation doses decreased 1/ 3 by natural deliquescence under film than before, the optimum scheme of fumigation has also been select-ed.%相同的仓型、粮质条件,采用磷化铝膜下环流、粮面自然潮解、粮面膜下自然潮解(一次投该仓用药总量的2/3)三种熏蒸方法,比较其防治效果,优选出最佳熏蒸方案.

  10. Study of Dislocations in the Minicrystallized Regions in Multicrystalline Silicon Grown by the Directional Solidification Method

    Nan Chen


    Full Text Available Directionally solidified multicrystalline silicon (mc-Si-based solar cells have dominated the global photovoltaic market in recent years. The photovoltaic performance of mc-Si solar cells is strongly influenced by their crystalline defects. The occurrence of minicrystallization results in much smaller grain size and, therefore, a larger number of grain boundaries in mc-Si ingots. Dislocations in the minicrystallized regions have been rarely investigated in the literature. In this work, optical microscopy was used to investigate dislocations in the mincrystallized regions in mc-Si ingots grown by the directional solidification method. The distribution of dislocations was found to be highly inhomogeneous from one grain to another in the mincrystallized regions. High inhomogeneity of dislocation distribution was also observed in individual grains. Serious shunting behavior was observed in the mc-Si solar cells containing minicrystallized regions, which strongly deteriorates their photovoltaic properties. The shunting was found to be highly localized to the minicrystallized regions.

  11. Mechanisms of Solidification Structure Improvement of Ultra Pure 17 wt% Cr Ferritic Stainless Steel by Ti, Nb Addition

    Yating Shan; Xinghong Luo; Xiaoqiang Hu; Shi Liu


    The grain structures and the precipitates in the solidification microstructure of the ultra pure 17 wt% Cr ferritic stainless steels with different Ti and/or Nb micro-alloying were investigated both experimentally and theoretically. It was found by the grain structure observation that the addition of Ti or Nb to the steel reduced the grain size (D) and elongation factor (E), and improved the equiaxed grain proportion (P) and globularity factor (ε). Among the four steels studied, the minimum grain size and maximum equiaxed grain proportion were obtained by jointly adding both Ti and Nb to the steel. The SEM observation indicated that several kinds of precipitations, such as TiN, MC (rich in Nb), Laves phase (Fe2Nb) and so on, formed in the corresponding steels. In addition, the results calculated using the Thermo-Calc software illustrated that TiN precipitates in the liquid at proper Ti and N contents. Meanwhile, the solidification interval (△T) was enlarged by the addition of Ti or Nb, and the effectiveness of Nb was stronger than Ti. Based on the experimental and calculation results, the mechanisms of grain refinement and increment in equiaxed grain proportion were discussed.

  12. Experimental and Numerical Simulations of the Solidification Process in Continuous Casting of Slab

    Liang Bai


    Full Text Available Thermal simulation equipment (TSE was recently developed to simulate the solidification process in the industrial continuous casting of slab. The grain growth, solid-liquid interface movement, and columnar-to-equiaxed transition (CET in the continuous casting process can be reproduced using this equipment. The current study is focused on the effects of different cooling rates and superheat conditions on the grain growth in the solidification process of chromium-saving ferritic stainless steel (B425. The temperature distribution and microstructure evolution are simulated by a Cellular Automaton-Finite Element (CAFE model. The experimental results demonstrate that the temperature gradient and the grain growth rate of the sample can be effectively controlled by the equipment. It is observed from optical micrographs of the microstructure that the average equiaxed grain ratio increases when the superheat temperature decreases. The average equiaxed grain ratio is approximately 26% and 42% under superheat conditions of 40 °C and 30 °C, respectively, and no apparent columnar grain generation in the samples occurs under superheat conditions of 10 °C and 20 °C, as the result of a large thermal resistance at the copper-sample interface and low superheat inside the sample. A lower cooling rate results in a higher equiaxed crystal ratio in the sample. As the cooling rate decreases, the equiaxed crystal ratio becomes 14%, 23%, and 42%. Comparing the simulation results with the experimental observations, a reasonable qualitative agreement is achieved for the chilled layer thickness, grain morphology, and CET in the sample. Thus, the CAFE model in the current study can accurately predict the grain growth under different superheating and cooling rate conditions.

  13. 不同通风方式对储粮降温保水的影响%Coding water impact of different ventilation mode on grain storage

    宫庆; 殷树清; 王进卫; 隋清波


    通过比较不同的机械通风方式对小麦粮堆温度和水分的影响,确定经济有效的通风方式。%heap of wheat grain temperature and moisture through the comparison of different mechanical ventilation to determine the cost-effective ventilation.

  14. Rapid solidification of undercooled Al-Cu-Si eutectic alloys

    RUAN Ying; WEI BingBo


    Under the conventional solidification condition,a liquid aluminium alloy can be hardly undercooled because of oxidation.In this work,rapid solidification of an undercooled liquid Al,80.4Cu,13.6Si,6 ternary eutectic alloy was realized by the glass fluxing method combined with recycled superheating.The re-lationship between superheating and undercooling was investigated at a certain cooling rate of the alloy melt.The maximum undercooling is 147 K (0.18 TE).The undercooled ternary eutectic is composed of α(Al) solid solution,(Si) semiconductor and β(CuAl,2) intermetallic compound.In the (Al+Si+θ) ternary eutectic,(Si) faceted phase grows independently,while (Al) and θ non-faceted phases grow coopera-tively in the lamellar mode.When undercooling is small,only (Al) solid solution forms as the leading phase.Once undercooling exceeds 73 K,(Si) phase nucleates firstly and grows as the primary phase.The alloy microstructure consists of primary (Al) dendrite,(Al+9) pseudobinary eutectic and (Al+Si+θ) ternary eutectic at small undercooling,while at large undercooling primary (Si) block,(Al+θ) pseudo-binary eutectic and (Al+Si+θ) ternary eutectic coexist.As undercooling increases,the volume fraction of primary (Al) dendrite decreases and that of primary (Si) block increases.

  15. Grain rotation mediated by grain boundary dislocations in nanocrystalline platinum

    Wang, Lihua; Teng, Jiao; Liu, Pan; Hirata, Akihiko; Ma, En; Zhang, Ze; Chen, Mingwei; Han, Xiaodong


    Grain rotation is a well-known phenomenon during high (homologous) temperature deformation and recrystallization of polycrystalline materials. In recent years, grain rotation has also been proposed as a plasticity mechanism at low temperatures (for example, room temperature for metals), especially for nanocrystalline grains with diameter d less than ~15 nm. Here, in tensile-loaded Pt thin films under a high-resolution transmission electron microscope, we show that the plasticity mechanism transitions from cross-grain dislocation glide in larger grains (d>6 nm) to a mode of coordinated rotation of multiple grains for grains with d<6 nm. The mechanism underlying the grain rotation is dislocation climb at the grain boundary, rather than grain boundary sliding or diffusional creep. Our atomic-scale images demonstrate directly that the evolution of the misorientation angle between neighbouring grains can be quantitatively accounted for by the change of the Frank–Bilby dislocation content in the grain boundary. PMID:25030380

  16. PREFACE: MCWASP XIII: International Conference on Modeling of Casting, Welding and Advanced Solidification Processes

    Ludwig, Andreas


    ) Thermodynamics and Solidification Paths, and (x) Prediction of Defects. As microstructure prediction is one of the key disciplines of solidification modeling, sessions such as (x) Meso/Macroscale Modeling of Structure and Segregation, (xi) Formation of Macrosegregation, and (xii) Structure Formation at Microscale were added. Finally some new modeling ideas not being presented in the aforementioned sessions were presented in a small additional session named (xiii) Numerical Methods. In addition to the new findings obtained by using advanced in-situ observation techniques, significant progress has been made on modeling the formation of microstructures, both at micro and meso/macroscale. Here, three-dimensional simulations of complex situations, e.g. polyphase solidification or grain growth in the presence of melt convection can now be performed quite effectively. However, the community is still challenged when a combined treatment of different phenomena is necessary. Efforts on the numerical description of solid skeleton deformation in combination with (interdendritic) melt flow have just begun. Furthermore, the combination of models for microstructure prediction at the microscale with process models at the macroscale (including melt convection and equiaxed grain motion) is still unsatisfactory. This is also true for combining process models with complex thermodynamics (e.g. for alloys consisting of many solute elements). The dependency of the results on the used numerical scheme, or the fact that the numerical grid might not be fine enough, especially in 3D calculations, are also topics which need our future attention. In conclusion, it can be stated that although the community has gained celebrated success over the last decades, we are still challenged by the complexity of the physical phenomena occurring during the solidification of melts. Leoben, June 2012 Andreas Ludwig Conference Chairman Department of Metallurgy University of Leoben Franz-Josef-Strasse 18 8700 Leoben

  17. Finite element modelling of solidification phenomena

    K N Seetharamu; R Paragasam; Ghulam A Quadir; Z A Zainal; B Sathya Prasad; T Sundararajan


    The process of solidification process is complex in nature and the simulation of such process is required in industry before it is actually undertaken. Finite element method is used to simulate the heat transfer process accompanying the solidification process. The metal and the mould along with the air gap formation is accounted in the heat transfer simulation. Distortion of the casting is caused due to non-uniform shrinkage associated with the process. Residual stresses are induced in the final castings. Simulation of the shrinkage and the thermal stresses are also carried out using finite element methods. The material behaviour is considered as visco-plastic. The simulations are compared with available experimental data and the comparison is found to be good. Special considerations regarding the simulation of solidification process are also brought out.

  18. Non newtonian annular alloy solidification in mould

    Moraga, Nelson O.; Garrido, Carlos P. [Universidad de La Serena, Departamento de Ingenieria Mecanica, La Serena (Chile); Castillo, Ernesto F. [Universidad de Santiago de Chile, Departamento de Ingenieria Mecanica, Santiago (Chile)


    The annular solidification of an aluminium-silicon alloy in a graphite mould with a geometry consisting of horizontal concentric cylinders is studied numerically. The analysis incorporates the behavior of non-Newtonian, pseudoplastic (n=0.2), Newtonian (n=1), and dilatant (n=1.5) fluids. The fluid mechanics and heat transfer coupled with a transient model of convection diffusion are solved using the finite volume method and the SIMPLE algorithm. Solidification is described in terms of a liquid fraction of a phase change that varies linearly with temperature. The final results make it possible to infer that the fluid dynamics and heat transfer of solidification in an annular geometry are affected by the non-Newtonian nature of the fluid, speeding up the process when the fluid is pseudoplastic. (orig.)

  19. Segregation effects and phase developments during solidification of alloy 625

    Højerslev, Christian; Tiedje, Niels Skat; Hald, John


    The solidification behaviour of pure Alloy 625, and Alloy 625 enriched respectively in iron and carbon, was investigated in situ by hot-stage light optical microscopy. Using this technique planar front solidification for distances of several hundred microns was facilitated. After solidification...

  20. Solidification of ternary systems with a nonlinear phase diagram

    Alexandrov, D. V.; Dubovoi, G. Yu.; Malygin, A. P.; Nizovtseva, I. G.; Toropova, L. V.


    The directional solidification of a ternary system with an extended phase transition region is theoretically studied. A mathematical model is developed to describe quasi-stationary solidification, and its analytical solution is constructed with allowance for a nonlinear liquidus line equation. A deviation of the liquidus equation from a linear function is shown to result in a substantial change in the solidification parameters.

  1. A Model for Evaluation of Grain Sizes of Aluminum Alloys with Grain Refinement Additions


    Based on the assumption that the nucleation substrates are activated by constitutional undercooling generated by an adjacent grain growth and solute distribution during the initial solidification, a model for calculation of the grain size of aluminum alloys with the grain refinement is developed, where the nucleation is dominated by two parameters, I.e. Growth restriction factor Q and the undercooling parameter P. The growth restriction factor Q is proportional to the initial rate of constitutional undercooling development and can be used directly as a criterion of the grain refinement in the alloys with strong potential nucleation particles. The undercooling parameter P can be regarded as the maximum of constitutional undercooling △TC. For weak potential nucleation particles, the use of RGS would be more accurate. The experimental data of the grain refinement of pure aluminum and AISi7 alloys are coincident predicted results with the model.

  2. Solidification microstructures and phase transformations in Al-Ti-Si-Mn deoxidized steel weld metals

    Kluken, A. O.; Grong, Ø.; Rørvik, G.


    The present investigation is concerned with basic studies of solidification mechanisms in Al-Ti-Si-Mn deoxidized steel weld metals. Assessment of the weld metal solidification micro-structures was done on the basis of optical microscopy in combination with secondary ion mass spectrometry (SIMS), while both scanning electron microscopy (SEM) and transmission electron microscopy (TEM) were used for characterization of indigenous oxide inclusions. It is shown that nonmetallic inclusions play a critical role in the development of the weld metal columnar grain structure by acting as inert substrates for nucleation of delta ferrite ahead of the advancing interface. The nucleation potency of the oxides increases in the order SiO2-MnO, Al2O3-Ti2O3-SiO2-MnO, A12O3, reflecting a corresponding increase in the inclusion/liquid interfacial energy. Moreover, a shift in the peritectic reaction (which facilitates growth of the austenite grains across the phosphorus-rich boundaries of the primary delta ferrite phase) has been observed in the presence of A12O3 inclusions. Indications are that the resulting decrease in the local phosphorus concentrations at the austenite grain boundaries will strongly alter the kinetics of the subsequent solid-state transformation reactions by promoting growth of grain boundary ferrite sideplates at the expense of intragranularly nucleated acicular ferrite.

  3. Characterization of Solidification and Solid State Transformation in Duplex Cast Steel: Thermo-Calc Investigation

    Z. Stradomski


    Full Text Available The paper presents a characteristic of solidification process and changes occurring in the solid state in a duplex cast steel. Theoretical chemical composition of individual phases, its changes during solidification and cooling after solidification and also changes in volume fractions of phases versus temperature have been determined. Theoretical results of Thermo-Calc analysis have been correlated with the microstructure of as-cast cast steel as well as with analysis of chemical composition of individual phases, carried out on a scanning microscope equipped with an EDS attachment. It has been shown that at the carbon content of 0.1% the enrichment of residual liquid phase with carbon results in a peritectic reaction, changing the ferritic solidification model typical for cast steels with low carbon content. In the case of solidification grain boundary areas enrichment with carbon, chromium and molybdenum there is a possibility of carbides precipitation already in the liquid state, what increases propensity for hot cracking and reduces the quality of castings produced. A correlation between theoretical composition of ferrite, austenite and M23C6 carbides, determined based on Thermo-Calc software, and their actual composition determined based on local analyses of chemical composition carried out on a scanning microscope has been shown. The volume fractions of ferrite, austenite and carbides determined using Thermo-Calc software show a strong correlation with actual fractions of those phases in the examined alloy’s structure. The chemical composition of ferrite, austenite and carbides determined using Thermo-Calc software does not show any more such strong correlation with the actual chemical composition of those phases determined based on local analyses of chemical composition carried out using a scanning microscope.

  4. Analysis of solidification cracks in welds of Al-Mg-Si A6351 type alloy welded by high frequency pulsed TIG process. 1st report. Evaluation of solidification crack susceptibility by means of Houldcroft test

    Pereira, M.; Machida, S. [The Univ. of Tokyo, Tokyo (Japan); Taniguchi, C.; Brandi, S. [Univ. of Sao Paulo, Sao Paulo, SP (Brazil)


    The main objective of this work is to study the susceptibility to solidification crack by means of Houldcroft test on Al-Mg-Si alloy A6351 welded by TIG process using a D.C. straight polarity and pulsed current with high frequency with varied parameters. The parameters are welding speed, current, arc pulse, frequency, and heat input per unit weld length. The effect of grain structures on the susceptibility of solidification crack is evaluated as well as the welding pool geometry in which these structures has developed. The `quasi-stationary` state is studied for the specimen geometry used, and the process efficiencies are estimated using welding pool width method. The trend of increase of crack length with the welding speed observed in no pulsed arc conditions is significantly changed with the introduction of the pulsed arc. Therefore, the pulsed frequency and the welding speed seem to be competing parameters in effect on the development of solidification crack. This work shows that the generalized tendency of solidification crack susceptibility with regard to the obtained grain structures as presented in previous works is not a general trend. 40 refs., 13 figs., 3 tabs.

  5. Conditions Of Directional Solidification Affect Superalloy

    Schmidt, D. D.; Alter, W. S.; Hamilton, W. D.; Parr, R. A.


    Report describes experiments to determine effects of gradient of temperature and rate of solidification on microstructure and fatigue properties of nickel-based superalloy MAR-M246(Hf). Enhancement of properties extends lifespans of objects, including turbo-pump blades of Space Shuttle Main Engines. Results indicate significant improvements in fatigue properties derived through manipulation of parameters of directional solidification. Particularly MAR-M246(Hf) for turbine blades contains small, well-dispersed blocky carbide and microstructure with small distances between dendrite arms, and without eutectic phase.

  6. Solidification on fly ash, Yugoslav experiences

    Knezevic, D. [Mining Institute, Belgrade (Yugoslavia); Popov, S.; Salatic, D. [Faculty of Mining and Geology, Belgrade (Yugoslavia)


    A study was performed on ashes produced in the combustion process of coal from the Kosovo coal basin, in order to determine the potential and conditions of ash self-solidification. Investigations showed that the ash properties allows for the transformation into a solid mass through a controlled mixing with water. The optimal concentration of ash is 50 percent and the hydro-mixture is behaving as a Bingham plastic fluid. Solidification is obtained in a relatively short period (within 3 to 5 days) without additives. The resulting solidified mass is very consistent and stable

  7. Observations of a monotectic solidification interface morphology

    Kaukler, W. F.; Frazier, D. O.


    For detailed studies of the region around a solidification interface on a microscopic scale, a very thin (essentially two-dimensional) test cell may be translated across two temperature-controlled heating/cooling blocks and viewed with a microscope. Such a device is sometimes referred to as a temperature gradient microscope stage (TGS). Of particular interest in this study is the behavior of a monotectic type solution during solidification. Succinonitrile based model systems for metallic monotectic alloys, when solidified on a TGS, form an unusual 'worm-like' micromorphology. These interfaces are observable in situ under high optical magnification during growth.


    H.L. Zhang; E.G. Wang; G.L. Jia; J.C. He


    The effects of linear electromagnetic stirring (EMS) on the solidification steacture of billet were investigated by experiments, and the electromagnetic fields and flow fields during the stirring process were analyzed by numerical simulation. The results show that the billet of almost 100% equiaxed grains can be obtained by applying linear EMS at the maximum intensity of 1414A.Hz1/2, while the maximum electromagnetic force and the maximum velocity in the molten steel are 6386N-m-3 and 0.22m.s-1,respectively. It is presented that the pulsating electromagnetic force perpendicular to the movement of the molten steel, is an important factor of increasing the equiaxed zone ratio in the solidification structure, which further prevents the appearance of white band and internal defects.

  9. 3-D analysis of grain selection process

    Arao, Tomoka; Esaka, Hisao; Shinozuka, Kei


    It is known that the grain selection plays an important role in the manufacturing process for turbine blades. There are some analytical or numerical models to treat the grain selection. However, the detailed mechanism of grain selection in 3-D is still uncertain. Therefore, an experimental research work using Al-Cu alloy has been carried out in order to understand the grain selection in 3-D.A mold made by Al2O3 was heated to 600 °C ( = liquids temperature of the alloy) and was set on a water-colded copper chill plate. Molten Al-20 wt%Cu alloy was cast into the mold and unidirectional solidified ingot was prepared. The size of ingot was approximately phi25×65H mm. To obtain the thermal history, 4 thermocouples were placed in the mold. It is confirmed that the alloy solidified unidirectionally from bottom to top. Solidified structure on a longitudinal cross section was observed and unidirectional solidification up to 40 mm was ensured. EBSD analysis has been performed on horizontal cross section at an interval of ca.200 μm. These observations were carried out 7-5 mm from the bottom surface. Crystallographic orientation of primary Al phase and size of solidified grains were characterized. A large solidified grain, the crystallographic orientation of which is approximately along heat flow direction, is observed near the lowest cross section. The area of grain decreased as solidification proceeded. On the other hand, it is found that the area of grain increased.

  10. Multiscale modelling and simulation of single crystal superalloy turbine blade casting during directional solidification process

    Xu Qingyan


    Full Text Available As the key parts of an aero-engine, single crystal (SX superalloy turbine blades have been the focus of much attention. However, casting defects often occur during the manufacturing process of the SX turbine blades. Modeling and simulation technology can help to optimize the manufacturing process of SX blades. Multiscale coupled models were proposed and used to simulate the physical phenomena occurring during the directional solidification (DS process. Coupled with heat transfer (macroscale and grain growth (meso-scale, 3D dendritic grain growth was calculated to show the competitive grain growth at micro-scale. SX grain selection behavior was studied by the simulation and experiments. The results show that the geometrical structure and technical parameters had strong influences on the grain selection effectiveness. Based on the coupled models, heat transfer, grain growth and microstructure evolution of a complex hollow SX blade were simulated. Both the simulated and experimental results show that the stray grain occurred at the platform of the SX blade when a constant withdrawal rate was used in manufacturing process. In order to avoid the formation of the stray crystal, the multi-scale coupled models and the withdrawal rate optimized technique were applied to the same SX turbine blade. The modeling results indicated that the optimized variable withdrawal rate can achieve SX blade castings with no stray grains, which was also proved by the experiments.

  11. Direct observation of spatially isothermal equiaxed solidification of an Al-Cu alloy in microgravity on board the MASER 13 sounding rocket

    Murphy, A. G.; Mathiesen, R. H.; Houltz, Y.; Li, J.; Lockowandt, C.; Henriksson, K.; Melville, N.; Browne, D. J.


    For the first time, isothermal equiaxed solidification of a metallic alloy has been observed in situ in space, providing unique benchmark experimental data. The experiment was completed on board the MASER 13 sounding rocket, launched in December 2015, using a newly developed isothermal solidification furnace. A grain-refined Al-20 wt%Cu sample was fully melted and solidified during 360 s of microgravity and the solidification sequence was recorded using time-resolved X-radiography. Equiaxed nucleation, dendritic growth, solutal impingement, and eutectic transformation were thus observed in a gravity-free environment. Equiaxed nucleation was promoted through application of a controlled cooling rate of -0.05 K/s producing a 1D grain density of 6.5 mm-1, uniformly distributed throughout the field of view (FOV). Primary growth slowed to a visually imperceptible level at an estimated undercooling of 7 K, after which the cooling rate was increased to -1.0 K/s for the remainder of solidification and eutectic transformation, ensuring the sample was fully solidified inside the microgravity time window. The eutectic transformation commenced at the centre of the FOV proceeding radially outwards covering the entire FOV in 3 s Microgravity-based solidification is compared to an identical pre-flight ground-based experiment using the same sample and experiment timeline. The ground experiment was designed to minimise gravity effects, by choice of a horizontal orientation for the sample, so that any differences would be subtle. The first equiaxed nucleation occurred at an apparent undercooling of 0.6 K less than the equivalent event during microgravity. During primary equiaxed solidification, as expected, no buoyant grain motion was observed during microgravity, compared to modest grain rotation and reorientation observed during terrestrial-based solidification. However, when the cooling rate was increased from -0.05 K/s to -1.0 K/s during the latter stages of solidification, in

  12. Columnar- Equiaxed Transition in Solidification processing: The ESA-MAP CETSOL project

    Billia, Bernard; Gandin, Charles-André; Zimmermann, Gerhard; Browne, David; Dupouy, Marie-Danielle


    Many castings are the result of a competition between the growth of columnar and equiaxed grains. Indeed, microstructures are at the center of materials science and engineering, and solidification is the most important processing route for structural materials, especially metals and alloys. Presently, microstructure models remain mostly based on diffusive transport mechanisms so that there is a need of critical benchmark data to test fundamental theories of microstructure formation, which often necessitates to have recourse to solidification experiments in the reduced-gravity environment of space. Accordingly, the CETSOL (Columnar-Equiaxed Transition in SOLidification processing)-MAP project of ESA is gathering together European groups with complementary skills to carry out experiments and model the processes, in particular in view of the utilization of reduced-gravity environment that will be afforded by the International Space Station (ISS) to get benchmark data. The ultimate objective of the CETSOL research program is to significantly contribute to the improvement of integrated modeling of grain structure in industrially important castings. To reach this goal, the approach is devised to deepen the quantitative understanding of the basic physical principles that, from the microscopic to the macroscopic scales, govern microstructure formation in solidification processing under diffusive conditions and with fluid flow in the melt. Pending questions are attacked by well-defined model experiments on technical alloys and/or on model transparent systems, physical modeling at microstructure and mesoscopic scales (e.g. large columnar front or equiaxed crystals) and numerical simulation at all scales, up to the macroscopic scales of casting with integrated numerical models.

  13. A model for grain growth based on the novel description of dendrite shape

    O. Wodo


    Full Text Available We use novel description of dendritic shape in the micro solid phase growth model. The model describes evolution of both primary solid solution dendrite and eutectic that forms between arms and grains in the last stage of solidification. Obtained results show that our approach can be used in grain growth model to determine more reliable eutectic distribution. In the paper no kinetics connected with the eutectic transformation is taken into account. However, this does not affect the eutectic distribution because at the beginning of eutectic reaction all liquid phase was assumed to fully transform into eutectic. Results for solid phase growth model based on this description are presented. The obtained results of eutectic distribution are especially important in the hypoeutectic alloy solidification case, where the eutectic grains grow between formed solid solution grains. Thus, the distribution of solid solution grain becomes crucial due to its influence on the delay in solid fraction increase of eutectic grains.

  14. Solidification of oils and organic liquids

    Clark, D.E.; Colombo, P.; Neilson, R.M. Jr.


    The suitability of selected solidification media for application in the disposal of low-level oil and other organic liquid wastes has been investigated. In the past, these low-level wastes (LLWs) have commonly been immobilized by sorption onto solid absorbents such as vermiculite or diatomaceous earth. Evolving regulations regarding the disposal of these materials encourage solidification. Solidification media which were studied include Portland type I cement; vermiculite plus Portland type I cement; Nuclear Technology Corporation's Nutek 380-cement process; emulsifier, Portland type I cement-sodium silicate; Delaware Custom Materiel's cement process; and the US Gypsum Company's Envirostone process. Waste forms have been evaluated as to their ability to reliably produce free standing monolithic solids which are homogeneous (macroscopically), contain < 1% free standing liquids by volume and pass a water immersion test. Solidified waste form specimens were also subjected to vibratory shock testing and flame testing. Simulated oil wastes can be solidified to acceptable solid specimens having volumetric waste loadings of less than 40 volume-%. However, simulated organic liquid wastes could not be solidified into acceptable waste forms above a volumetric loading factor of about 10 volume-% using the solidification agents studied.

  15. Solidification studies of automotive heat exchanger materials

    Carlberg, T.; Jaradeh, M.; Kamgou Kamaga, H.


    Modifications of the aluminum alloy AA 3003 have been studied to improve and tailorits properties for applications in automotive heat exchangers. Laboratory techniques have been applied to simulate industrial direct-chill casting, and some basic solidification studies have been conducted. The results are coupled to structures observed in industrial-size ingots and discussed in terms of structure-property relations.

  16. Detached Growth of Germanium by Directional Solidification

    Palosz, W.; Volz, M. P.; Cobb, S.; Motakef, S.; Szofran, F. R.


    The conditions of detached solidification under controlled pressure differential across the meniscus were investigated. Uncoated and graphite- or BN-coated silica and pBN crucibles were used. Detached and partly detached growth was achieved in pBN and BN-coated crucibles, respectively. The results of the experiments are discussed based on the theory of Duffar et al.

  17. Microstructure Development during Solidification of Aluminium Alloys

    Ruvalcaba Jimenez, D.G.


    This Thesis demonstrates studies on microstructure development during the solidification of aluminium alloys. New insights of structure development are presented here. Experimental techniques such as quenching and in-situ High-brilliance X-ray microscopy were utilized to study the microstructure evo

  18. {alpha} grain refining and metallurgical study of alloyed uranium, Sicral F1, used for fuel elements; Affinage du grain {alpha} et etude metallurgique de l'alliage d'uranium sicral F1 pour elements combustibles

    Magnier, P. [Commissariat a l' Energie Atomique, Saclay (France). Centre d' Etudes Nucleaires


    This study was made to know more about grain refining in low alloyed uranium of composition not very different from SICRAL F 1. Alpha grain refining of fuel elements made of these alloys was studied after casting and quenching by the methods used for mass production. The author describes the effect: - of the metallurgical history before quenching: - casting - purity - rate of solidification - of quenching parameters: - annealing temperature before quenching - annealing time - quenching rate - of the composition of the alloy. For the graphite gas fuel elements of various dimensions, he suggests some modifications to give a better adaptation of fabrication to size. He describes the grain refining made during quenching and the {beta} -> {alpha} and {gamma} -> {alpha} transformation types. He proposes the use of a U-Fe-Si especially useful from the point of view of grain refining. (author) [French] Le but de l'etude est de determiner les facteurs metallurgiques favorables a l'affinage du grain {alpha} des alliages d'uranium a tres faibles teneurs en elements d'addition voisins du SICRAL F 1 au cours du cycle de fabrication et de trempe industrielle des elements combustibles nucleaires prepares avec ces alliages. L'auteur met en evidence l'influence: - de l'histoire metallurgique avant trempe: - coulee - teneur en impuretes - vitesse de solidification - des parametres de la trempe: - temperature de trempe - temps et maintien a cette temperature - vitesse de trempe - des variations de composition de l'alliage. Il envisage les modifications a apporter au cycle de fabrication du SICRAL F 1 de facon a l'adapter aux differentes geometries des elements combustibles des reacteurs de la filiere graphite-gaz. L'auteur presente a cette occasion les mecanismes de l'affinage du grain {alpha} par trempe dans les alliages d'uranium et les modes de transformation {beta} -> {alpha} et {gamma} -> {alpha} au cours de la trempe

  19. Pulsatile instability in rapid directional solidification - Strongly-nonlinear analysis

    Merchant, G. J.; Braun, R. J.; Brattkus, K.; Davis, S. H.


    In the rapid directional solidification of a dilute binary alloy, analysis reveals that, in addition to the cellular mode of Mullins and Sekerka (1964), there is an oscillatory instability. For the model analyzed by Merchant and Davis (1990), the preferred wavenumber is zero; the mode is one of pulsation. Two strongly nonlinear analyses are performed that describe this pulsatile mode. In the first case, nonequilibrium effects that alter solute rejection at the interface are taken asymptotically small. A nonlinear oscillator equation governs the position of the solid-liquid interface at leading order, and amplitude and phase evolution equations are derived for the uniformly pulsating interface. The analysis provides a uniform description of both subcritical and supercritical bifurcation and the transition between the two. In the second case, nonequilibrium effects that alter solute rejection are taken asymptotically large, and a different nonlinear oscillator equation governs the location of the interface to leading order. A similar analysis allows for the derivation of an amplitude evolution equation for the uniformly pulsating interface. In this case, the bifurcation is always supercritical. The results are used to make predictions about the characteristics of solute bands that would be frozen into the solid.

  20. In situ X-ray observations of gas porosity interactions with dendritic microstructures during solidification of Al-based alloys

    Murphy, A. G.; Browne, D. J.; Houltz, Y.; Mathiesen, R. H.


    In situ X-radiography solidification experiments were performed on Al-based alloys, using both synchrotron and laboratory-based X-ray sources, in conjunction with a gradient furnace and a newly developed isothermal furnace, respectively. The effect of gas porosity nucleation and growth within the semi-solid mush during both columnar and equiaxed solidification was thereby observed. In all experimental cases examined, gas porosity was observed to nucleate and grow within the field-of-view (FOV) causing various levels of distortion to the semi-solid mush, and thereafter disappearing from the sample leaving no permanent voids within the solidified microstructure. During columnar growth, a single bubble caused severe remelting and destruction of primary trunks leading to secondary fragmentation and evidence of blocking of the columnar front. Equiaxed solidification was performed under microgravity-like conditions with restricted grain motion in the FOV. The degree to which the nucleated gas bubbles affected the surrounding grain structure increased with increasing solid fraction. However, bubble sphericity remained unaffected by apparent solid fraction or grain coherency.

  1. Experimental Verification of Solidification Stress Theory

    Solbrig, C W; Morrison, M C; SImpson, M F; Bateman, K J


    A research program is being conducted to develop a crack-free ceramic waste form (CWF) to be used for long term encasement of fission products and actinides resulting from processing spent nuclear fuel. Cracking usually occurs in the cooldown phase of the glass or ceramic formations. A crack-free formation should have more resistance to leaching than one with many cracks. In the research leading up to producing a CWF, a model was developed that proposes a permanent stress develops when the melt solidifies and that this stress can cause failure as the CWF nears room temperature. This paper reports on how the formation, CWF2, confirms the existence of this stress. The solidification stress is in addition to and of opposite sign of the thermal stress. Its derivation is reported on in Ref. 1. Cracking of the CWF would occur at low temperatures if solidification stress exists but at high temperatures if it doesn’t. If solidification stress occurs, then the cooldown rate during solidification should be reduced. If not, it should be reduced when the thermal stresses are highest. Recording cracking sounds confirm the existence of this solidification stress since cracking occurred during the low temperature phase of the cooldown. As a side purpose of this paper, a cooldown rate is proposed that should eliminate cracking in the next experiment, CWF3. CWF2 is a prototype vertical ceramic waste cylinder formed over a period of 10 days by heating a mixture of 75% zeolite, 25% glass frit in an argon atmosphere furnace through melting to 925 C and then cooling through solidification to room temperature. It is approximately 1 m high, 0.5 m in diameter, weighs about 400 kg, and is formed in a stainless steel can 0.5 cm thick. This cylinder developed many cracks on cooldown. At least 15 loud cracks were recorded over a period of 4 days at the end of cooldown when the temperatures were below 400 C. The CWF2 surface and centerline temperatures at mid height were measured which

  2. Transport Phenomena During Equiaxed Solidification of Alloys

    Beckermann, C.; deGroh, H. C., III


    Recent progress in modeling of transport phenomena during dendritic alloy solidification is reviewed. Starting from the basic theorems of volume averaging, a general multiphase modeling framework is outlined. This framework allows for the incorporation of a variety of microscale phenomena in the macroscopic transport equations. For the case of diffusion dominated solidification, a simplified set of model equations is examined in detail and validated through comparisons with numerous experimental data for both columnar and equiaxed dendritic growth. This provides a critical assessment of the various model assumptions. Models that include melt flow and solid phase transport are also discussed, although their validation is still at an early stage. Several numerical results are presented that illustrate some of the profound effects of convective transport on the final compositional and structural characteristics of a solidified part. Important issues that deserve continuing attention are identified.

  3. Solidification Behavior of Laser Melting Layer of Nd15Fe77 B8Sintered Magnets and Its Microstructures Evolution

    Pan Jing; Liu Xincai


    To research the solidification behavior and microstructures of a laser remelting/solidification layer on anisotropic Nd15Fe77B8 sintered magnets with their magnetization direction parallel to X, Y, Z-axis respectively, their surfaces (parallel to XOY plane) were scanned by 5 kW Roffin-Sinar 850 type of CO2 laser along Y axis. The rapid solidification of the molten alloy in the layer results in three distinct zones. The transition zone close to the unmolten portion of a magnet (substrate), consists of the columnar Nd2Fe14B phase (matrix), the 10.0%~15.1% dendrite primary iron phase dispersing in the matrix, and the Nd-rich phase along Nd2Fe14B grain boundaries. The columnar crystal zone in the middle of the layer consists of the long columnar Nd2Fe14B grains and their grain boundary Nd-rich phase. And the dendrite crystal zone near the free surface of the layer consists of dendrite Nd2Fe14B grains and their grain boundary Nd-rich phase. When the laser scanning velocity is lower, the growing direction of the microstructures in the layer tends to the laser scanning direction step by step. When the velocity is not lower than 25 mm · s-1, the laser remelting/solidification layer thins and the columnar crystal zone comprises almost the whole layer. Under this condition, on the substrate with its magnetization direction along X or Y-axis respectively, the columnar Nd2Fe14B grains in the layer grow in the direction of Z-axis (that is their long-axis along Z-axis), their alignment of the easy magnetization axis [001] is parallel to the magnetization direction of the substrate correspondingly; but on the substrate with its magnetization direction along Z-axis, the columnar Nd2Fe14B grains in the transition zone grow at an angle of 30°~50° between Z-axis and their long-axis. And the columnar Nd2Fe14B grains in the columnar crystal zone gradually tend to the Z-axis,and their easy magnetization axis [001] arrange in the range of 0°~360° of the plane perpendicular to

  4. Convective stability in the Rayleigh-Benard and directional solidification problems - High-frequency gravity modulation

    Wheeler, A. A.; Mcfadden, G. B.; Murray, B. T.; Coriell, S. R.


    The effect of vertical, sinusoidal, time-dependent gravitational acceleration on the onset of solutal convection during directional solidification is analyzed in the limit of large modulation frequency. When the unmodulated state is unstable, the modulation amplitude required to stabilize the system is determined by the method of averaging. When the unmodulated state is stable, resonant modes of instability occur at large modulation amplitude. These are analyzed using matched asymptotic expansions to elucidate the boundary-layer structure for both the Rayleigh-Benard and directional solidification configurations. Based on these analyses, a thorough examination of the dependence of the stability criteria on the unmodulated Rayleigh number, Schmidt number, and distribution coefficient, is carried out.

  5. Solidification characteristics of Pb-Sb hypereutectic alloy within ultrasonic field

    ZHAI Wei; HONG ZhenYu; XIE WenJun; WEI BingBo


    The solidification of Pb-16 %Sb hypereutectic alloy is investigated within ultrasonic field with a frequency of 15 kHz. It is found that the ultrasonic field promotes crystal nucleation and terminates the further bulk undercooling of the alloy melt. Theoretical analysis shows that the cavitation effect and the forced bulk vibration are the main factors that reduce the undercooling level. With the increase of ultrasound intensity, the primary (Sb) phase experiences a growth mode transition from faceted to non-faceted branched growth, and the macrosegregation of primary (Sb) phase is gradually suppressed. In addition, the microstructures of Pb-Sb eutectic exhibit a conspicuous coarsening with increasing ultrasound intensity, and a structural transition of "lamellar eutectic-anomalous eutectic"occurs when ultrasound intensity rises up to 1.6 W/cm2. The ultrasonic field also changes the solute distribution adjacent to the solidification front, which lowers the Pb contents in primary (Sb) phase.

  6. Complex banded structures in directional solidification processes.

    Korzhenevskii, A L; Rozas, R E; Horbach, J


    A combination of theory and numerical simulation is used to investigate impurity superstructures that form in rapid directional solidification (RDS) processes in the presence of a temperature gradient and a pulling velocity with an oscillatory component. Based on a capillary wave model, we show that the RDS processes are associated with a rich morphology of banded structures, including frequency locking and the transition to chaos.

  7. Molecular dynamics modelling of solidification in metals

    Boercker, D.B.; Belak, J.; Glosli, J. [Lawrence Livermore National Lab., CA (United States)


    Molecular dynamics modeling is used to study the solidification of metals at high pressure and temperature. Constant pressure MD is applied to a simulation cell initially filled with both solid and molten metal. The solid/liquid interface is tracked as a function of time, and the data are used to estimate growth rates of crystallites at high pressure and temperature in Ta and Mg.

  8. Study on undercooling of metal droplet in rapid solidification

    GAO; Yulai; GUAN; Wanbing; ZHAI; Qijie; XU; Kuangdi


    A mathematical model for the undercooling of the metal droplet during the rapid solidification is established, by which the factors that influence the undercooling of the metal droplet during the rapid solidification are analyzed, and the parameter ζ=σSL3/ (TLΔH 2 ) is defined as the impact factor of the undercooling for the droplet solidification. Different undercoolings of droplets induced by various rapid solidification conditions are mainly ascribed to the change of the impact factor. Moreover, it is shown that the larger of ζ, the higher the relative undercooling can be gained. Meanwhile, the parameters such as solid-liquid interfacial energy σSL and latent heat of solidification ΔH also vary with the rapid solidification conditions of droplets.

  9. Influence of Alloying Treatment and Rapid Solidification on the Degradation Behavior and Mechanical Properties of Mg

    Jian Chen


    Full Text Available Magnesium (Mg has drawn increasing attention as a tissue engineering material. However, there have been very few studies of laser-melted Mg-Zn alloys. In this study, four binary Mg-xZn (x = 2, 4, 6 and 8 wt. % alloys were fabricated by laser melting. The influence of zinc (Zn content and technique on the degradation behavior and mechanical properties of Mg were discussed. Results revealed that Mg-xZn alloys consisted of an α-Mg matrix and MgZn phases, which dispersed at the grain boundaries. In addition, the MgZn phase increased with the increase in Zn content. The laser-melted alloy had fine homogenous grains, with an average grain size of approximately 15 μm. Grain growth was effectively inhibited due to the precipitation of the MgZn phase and rapid solidification. Grain refinement consequently slowed down the degradation rate, with Zn content increasing to 6 wt. %. However, a further increase of Zn content accelerated the degradation rate due to the galvanic couple effect between α-Mg and MgZn. Moreover, the mechanical properties were improved due to the grain refinement and reinforcement of the MgZn phase.

  10. Shape of growth cells in directional solidification.

    Pocheau, A; Georgelin, M


    The purpose of this study is to characterize experimentally the whole shape of the growth cells displayed in directional solidification and its evolution with respect to control parameters. A library of cells is first built up from observation of directional solidification of a succinonitrile alloy in a large range of pulling velocity, cell spacing, and thermal gradient. Cell boundaries are then extracted from these images and fitted by trial functions on their whole profile, from cell tip to cell grooves. A coherent evolution of the fit parameters with the control parameters is evidenced. It enables us to characterize the whole cell shape by a single function involving only two parameters which vary smoothly in the control parameter space. This, in particular, evidences a continuous evolution of the cell geometry at the cell to dendrite transition which denies the existence of a change of branch of solutions at the occurrence of sidebranching. More generally, this global determination of cell shape complemented with a previous determination of the position of cells in the thermal field (the cell tip undercooling) provides a complete characterization of growth solutions and of their evolutions in this system. It thus brings about a relevant framework for testing and improving theoretical and numerical understanding of cell shapes and cell stability in directional solidification.

  11. Effect of the melt superheat on equiaxed solidification of Al-20 wt% Cu alloy investigated by in situ synchrotron radiography

    Luo, Shifeng; Yang, Guangyu; Xiao, Lei; Huang, Wanxia; Yuan, Qingxi; Jie, Wanqi


    Effect of the melt superheat on equiaxed solidification of Al-20 wt% Cu alloy was investigated by in-situ synchrotron radiography at Beijing Synchrotron Radiation Facility. For comparison, the corresponding DSC analysis was also conducted. It was found that the grain size decreased with increasing the melt superheat. The relationship between the final mean grain size and the melt superheat can be expressed as: d = 4919.3 × ΔT-0.33 . During solidification, the mean grain size increased sharply in the first 70 s, then reached the final grain size gradually. Furthermore, with increasing the melt superheat, the mean nucleation rate increased, which can be attributed to the fact that increasing the melt superheat led to an increase in nucleation undercooling, and the growth rate and the duration of free growth stage decreased. As the melt superheat increased from 100 °C to 160 °C, the mean nucleation rate increased by 78.2% while the mean growth rate only decreased by 19.3%, which indicated that the high mean nucleation rate and the consequent low mean growth rate may be the real reasons for grain refinement. The increased nucleation density caused earlier growth deceleration due to solutal impingement effects.

  12. Oscillatory cellular patterns in three-dimensional directional solidification.

    Tourret, D; Debierre, J-M; Song, Y; Mota, F L; Bergeon, N; Guérin, R; Trivedi, R; Billia, B; Karma, A


    We present a phase-field study of oscillatory breathing modes observed during the solidification of three-dimensional cellular arrays in microgravity. Directional solidification experiments conducted onboard the International Space Station have allowed us to observe spatially extended homogeneous arrays of cells and dendrites while minimizing the amount of gravity-induced convection in the liquid. In situ observations of transparent alloys have revealed the existence, over a narrow range of control parameters, of oscillations in cellular arrays with a period ranging from about 25 to 125 min. Cellular patterns are spatially disordered, and the oscillations of individual cells are spatiotemporally uncorrelated at long distance. However, in regions displaying short-range spatial ordering, groups of cells can synchronize into oscillatory breathing modes. Quantitative phase-field simulations show that the oscillatory behavior of cells in this regime is linked to a stability limit of the spacing in hexagonal cellular array structures. For relatively high cellular front undercooling (i.e., low growth velocity or high thermal gradient), a gap appears in the otherwise continuous range of stable array spacings. Close to this gap, a sustained oscillatory regime appears with a period that compares quantitatively well with experiment. For control parameters where this gap exists, oscillations typically occur for spacings at the edge of the gap. However, after a change of growth conditions, oscillations can also occur for nearby values of control parameters where this gap just closes and a continuous range of spacings exists. In addition, sustained oscillations at to the opening of this stable gap exhibit a slow periodic modulation of the phase-shift among cells with a slower period of several hours. While long-range coherence of breathing modes can be achieved in simulations for a perfect spatial arrangement of cells as initial condition, global disorder is observed in both

  13. Analysis of solidification and melting of Pcm with energy generation

    Jiji, Latif M. [Department of Mechanical Engineering, The City College of the City University of New York, New York, NY 10031 (United States); Gaye, Salif [Ecole Superieure Polytechnique, Enseignant a l' ESP BP A10, Universite Cheikh Anta Diop, Thies (Senegal)


    One-dimensional solidification and melting of a slab with uniform volumetric energy generation is examined analytically. A sudden change in surface temperature triggers phase transformation and interface motion. Analytic solutions are obtained using a quasi-steady approximation. Unlike solidification, the melting case is characterized by a pure liquid phase and a mixture of solid and liquid at the fusion temperature. The solution is governed by a single energy generation parameter. Temperature profiles, interface location and steady state conditions are presented for solidification and melting. Results are applied to two examples: solidification of a nuclear material and melting of ice. [Author].

  14. A Numerical Study of Directional Solidification and Melting in Microgravity

    Chen, P. Y. P.; Timchenko, V.; Leonardi E.; deVahlDavis, G.; deGroh, H. C., III


    A computational model is presented for the study of the solidification and melting of a pure substance and of a binary alloy. The enthalpy method has been used, and incorporated into a commercial CFD code. Three examples of the use of the model are described: the three-dimensional solidification of a pure substance (succinonitrile), the results of which are compared with experiment; an example of the solidification of a bismuth-tin alloy; and a simulation of a solidification and melting experiment done in space known as the MEPHISTO program.

  15. Effects of the location of a cast in the furnace on flatness of the solidification front in directional solidification

    Lian, Yuanyuan; Li, Dichen; Zhang, Kai


    Many defects of single crystals are caused by the nonplanar solidification front. The transverse temperature gradient at melt-crystal interface results in nonplanar solidification fronts. The location of a cast in the directional solidification furnace affects heat dissipation and thus influences the transverse temperature gradient. This paper presents a criterion and a searching algorithm to find the optimal location of the cast for flattening the solidification front. A numerical simulation was employed for the verification of our method. Additionally, the effects of the size of the cooling device of the furnace on the optimal location, the transverse temperature gradient and the solidification time were discussed. The transverse temperature gradient is reduced about 50% without increasing much solidification time when setting the cast with a varying thickness mould at the optimal location. In addition, the optimal location is mainly influenced by the radius of the cooling ring.

  16. Effect of composition, cooling rate, and solidification velocity on the microstructural development of molybdenum-bearing stainless steels

    Perricone, Matthew J.

    A series of Mo-bearing stainless steel compositions ranging from 0 to 10 wt% Mo were analyzed over a range of laser welding conditions to evaluate the effect of composition, cooling rate, and solidification velocity on microstructural development. Of particular engineering interest are alloys expected to solidify as primary delta-ferrite and transform in the solid state to gamma-austenite. Such compositions are essentially immune to solidification cracking and can potentially eliminate microsegregation (due to primary ferrite solidification) while still having high toughness and no magnetic signature at room temperature (transformation to austenite). A total of 64 Fe-Ni-Cr-Mo compositions were chosen based on multi-component phase stability diagrams calculated using the CALPHAD method. Alloys were created using the arc button melting process and laser welds were prepared on each alloy at constant power and travel speeds ranging from 4.2 mm/s to 42 mm/s. The cooling rates of these processes were estimated to range from 10 °C/s for are buttons to 105 °C/s for the fastest laser welds. Microstructural analysis was completed to determine primary solidification mode and the nature of solid state transformation behavior. Good agreement was observed between experimental observations and predictions from thermodynamic calculations. No shift in solidification mode was observed from primary delta-ferrite to primary gamma-austenite in the range of welding conditions studied. Metastable microstructural features were observed in many laser weld fusion zones, as well as a massive transformation from delta-ferrite to gamma-austenite in many of the alloys exhibiting primary delta-ferrite solidification. Evidence of epitaxial massive growth without nucleation was also found in primary delta-ferrite alloys with intercellular gamma-austenite already present from a solidification reaction. The resulting single phase gamma-austenite in both cases exhibited a homogenous distribution of

  17. Online process control for directional solidification by ultrasonic pulse echo technique.

    Drevermann, A; Pickmann, C; Tiefers, R; Zimmermann, G


    A method of controlling the actual growth velocity during directional solidification based on ultrasound has been developed. For this purpose a pulse echo technique is used to measure the actual solidification rate online. This quantity is used to control the furnace velocity. Solidification experiments with metallic alloys and constant furnace velocity often result in non-steady actual solidification rates. Experiments carried out with online process control demonstrate that a really steady-state solidification with a constant solidification rate is achieved.

  18. Multiphysics and multiscale modelling of ductile cast iron solidification

    D. Gurgul


    Full Text Available The presented model of ductile cast iron solidification is a typical sample of multiphysics and multiscale engineering system. This model takes into consideration the different time and spatial scales of accounted phenomenon of microstructure formation: heat diffusion, components mass diffusion in the liquid and solid phases, thermodynamic of phase transformation under the condition of inhomogeneous chemical composition of growing and vanishing phases, phase interface kinetics and grains nucleation.The results of two-dimensional modelling of the microstructure formation in the ductile cast iron (so called - Ductile Iron - DI are pre-sented. The cellular automaton model (CA was used for the simulation. Six states of CA cells were adopted to three phases above men-tioned (liquid, austenite and graphite and to three two-phase interfaces. For the modelling of concentration and temperature fields the numerical solution was used. The parabolic nonlinear differential equa-tions with a source term were solved by using the finite difference method and explicit scheme. The overlapping lattices with the same spatial step were used for the concentration field modelling and for the CA. The time scale of the temperature field for this lattice is about 104 times shorter. Due to above reasons the another lattice was used with a multiple spatial step and the same time step.

  19. Directional Solidification of Bi-Sn on USMP-4

    Abbaschian, Reza; deGroh, H., III; Leonardi, E.; Timchenko, V.; deVahlDavis, G.


    The experiments used MEPHISTO hardware to study the solidification and melting behavior of bismuth alloyed with 1 at% tin. Three samples, each approximately 900 mm long and 6mm in diameter, were used. A portion of each sample also included a 2 mm diameter growth capillary, to assist in the formation of a single grain. One sample provided the Seebeck voltage generated during melting and freezing processes. Another provided temperature data and Peltier pulsed demarcation of the interface shape for post flight analysis. The third sample provided resistance and growth velocity measurements, as well as additional thermal data. The third sample was also quenched at the end of the mission to preserve the composition of the liquid near the interface for post flight determination. A total of 450mm of directionally solidified samples were preserved for post mission structural and compositional characterization. Substantial differences were observed in the Seebeck signal between the ground-based experiments and the space-based experiments. The temperature gradient in the liquid for the ground-based experiments was significantly lower than the temperature gradient in the liquid for the space-based experiments.

  20. Solidification crack susceptibility of aluminum alloy weld metals


    The susceptibilities of the three aluminum alloys to solidification crack were studied with trans-varestraint tests and tensile tests at elevated temperature. Their metallurgical characteristics, morphologies of the fractured surface and dynamic cracking behaviors at elevated temperature were analyzed with a series of micro-analysis methods. The results show that dynamic cracking models can be classified into three types. The first model has the healing effect which is called type A. The second is the one with deformation and breaking down of metal bridge, called type B. The last one is with the separation of liquid film along grain boundary, called type C.Moreover, the strain rate has different effects on crack susceptibility of aluminum alloys with different cracking models. ZL101 and 5083 alloys belong to type A and type C cracking model respectively, in which strain rate has greater effect on eutectic healing and plastic deformation of metal bridge. 6082 alloy is type B cracking model in which the strain rate has little effect on the deformation ability of the liquid film.

  1. Prediction of solidification and phase transformation in weld metals for welding of high performance stainless steels; Kotaishoku kotainetsu stainless koyo yosetsu kinzoku no gyoko hentai no yosoku gijutsu

    Koseki, T.; Inoue, H.; Morimoto, H.; Okita, S. [Nippon Steel Corp., Tokyo (Japan)


    Prediction technology is introduced on the solidification and transformation of weld metals used for high performance stainless steel. A model has been developed which uses Thermo Calc, a multiple balanced calculation program, as a means to analyze the solidification of multi-component alloys including the polyphase solidification such as eutectic and peritectic. Verification has been in progress concerning the adequacy of this model and the adaptability as a practical steel. The following are the prediction technologies for solidification and transformation which have been derived from experiments and applied to welding techniques: the effects of nitrogen on the solidification mode and residual {gamma}quantity of a welding metal that is required for controlling the welding/solidification of high nitrogen content {gamma}system stainless steel; the structural control of weld metal for high corrosion resistance high Mo stainless steel, in which high Ni and high Mo contents are indispensable for attaining the optimum structure; the structural control of weld metal for two-phase stainless steel containing Mo and N, in which it is essential to secure a high nitrogen content and a {delta}/{gamma}phase balance in a weld metal; and the precipitation prediction of intermetallic compound in a high alloy weld metal for a high alloy stainless steel, for which an explanation is there by Cieslak et al. based on the phase stability theory. 22 refs., 16 figs.

  2. Contracts for Grain Biosecurity and Grain Quality

    Abougamos, Hoda; White, Benedict; Sadler,Rohan


    The export of grain from Western Australia depends upon a grain supply network that takes grain from farm to port through Cooperative Bulk Handling receival and storage sites. The ability of the network to deliver pest free grain to the port and onto ship depends upon the quality of grain delivered by farmers and the efficacy of phosphine based fumigation in controlling stored grain pests. Phosphine fumigation is critical to the grain supply network because it is the cheapest effective fumiga...

  3. Heat Transfer Model of Directional Solidification by LMC Process for Superalloy Casting Based on Finite Element Method

    Cao, Liu; Liao, Dunming; Lu, Yuzhang; Chen, Tao


    With the rapid development of the aviation industry, the turbine blade, a critical component of the aeronautical engine, has come to be widely produced by liquid-metal cooling (LMC) process. A temperature- and time-dependent heat transfer coefficient was used to represent the heat convection between the shell and the cooling liquid, and an improved Monte Carlo ray-tracing approach was adopted to handle the boundary of radiation heat transfer. Unstructured mesh was used to fit the irregular shell boundary, and the heat transfer model of directional solidification by LMC process based on finite element method (FEM) was established. The concept of local matrix was here proposed to guarantee computational efficiency. The pouring experiments of directional solidification by LMC process were carried out, then simulation and experimental results were compared here. The accuracy of the heat transfer model was validated by the cooling curves and grain morphology, and the maximum relative error between simulation and experimental cooling curve was 2 pct. The withdrawal rate showed an important influence on the shape of solidification interface, and stray grain is liable to be generated on the bottom of platform at an excessive withdrawal rate.

  4. Numerical Simulation of Steady State Conduction Heat Transfer During the Solidification of Aluminum Casting in Green Sand Mould

    Victor ANJO


    Full Text Available The solidification of molten metal during the casting process involves heat transfer from the molten metal to the mould, then to the atmosphere. The mechanical properties and grain size of metals are determined by the heat transfer process during solidification. The aim of this study is to numerically stimulate the steady conduction heat transfer during the solidification of aluminum in green sand mould using finite difference analysis 2D. The properties of materials used are industrial AI 50/60 AFS green sand mould, pure aluminum and MATLAB 7.0.1. for the numerical simulation. The method includes; the finite difference analysis of the heat conduction equation in steady (Laplace’s and transient states and using MATLAB to numerically stimulate the thermal flow and cooling curve. The results obtained are: the steady state thermal flow in 2D and transient state cooling curve of casting. The results obtain were consider relevant in the control of the grain size and mechanical properties of the casting.

  5. Microstructural evolution of directionally solidified DZ125 superalloy castings with different solidification methods

    Ge Bingming


    Full Text Available The properties of Ni-base superalloy castings are closely related to the uniformity of their as-cast microstructure, and different solidification methods have serious effect on microstructural uniformity. In this paper, the influences of high rate solidification (HRS process (with or without superheating and liquid metal cooling (LMC process on the microstructure of DZ125 superalloy were investigated. Blade-shape castings were solidified at rates of 40 μm·s-1 to 110 μm·s-1 using HRS process and a comparative experiment was carried out at a rate of 70 μm·s-1 by LMC process. The optical microscope (OM, scanning electron microscope (SEM were used to observe the microstructure and the grain size was analyzed using electron back scattered diffraction (EBSD technique. Results show that for the castings by either HRS or LMC process, the primary dendrite arm spacing and size of γ' precipitates decrease with increasing the withdrawal rate; the dendrites and γ' precipitates at the upper section of the blade are coarser than those in the middle, especially for the HRS castings without high superheating technique. When the withdrawal rate is 70 μm·s-1, the castings by HRS with high superheating technique have the smallest PDAS with fine γ' precipitates; while the size distribution of γ' precipitates is more homogenous in LMC castings, and the number of larger grains in LMC castings is smaller than that in the HRS castings. Moreover, high superheating technique yields smaller grains in the castings. Both the LMC method and HRS with high superheating technique can be used to prepare castings with reduced maximum grain size.

  6. Processing of alnico permanent magnets by advanced directional solidification methods

    Zou, Min; Johnson, Francis; Zhang, Wanming; Zhao, Qi; Rutkowski, Stephen F.; Zhou, Lin; Kramer, Matthew J.


    Advanced directional solidification methods have been used to produce large (>15 cm length) castings of Alnico permanent magnets with highly oriented columnar microstructures. In combination with subsequent thermomagnetic and draw thermal treatment, this method was used to enable the high coercivity, high-Titanium Alnico composition of 39% Co, 29.5% Fe, 14% Ni, 7.5% Ti, 7% Al, 3% Cu (wt%) to have an intrinsic coercivity (Hci) of 2.0 kOe, a remanence (Br) of 10.2 kG, and an energy product (BH)max of 10.9 MGOe. These properties compare favorably to typical properties for the commercial Alnico 9. Directional solidification of higher Ti compositions yielded anisotropic columnar grained microstructures if high heat extraction rates through the mold surface of at least 200 kW/m2 were attained. This was achieved through the use of a thin walled (5 mm thick) high thermal conductivity SiC shell mold extracted from a molten Sn bath at a withdrawal rate of at least 200 mm/h. However, higher Ti compositions did not result in further increases in magnet performance. Images of the microstructures collected by scanning electron microscopy (SEM) reveal a majority α phase with inclusions of secondary αγ phase. Transmission electron microscopy (TEM) reveals that the α phase has a spinodally decomposed microstructure of FeCo-rich needles in a NiAl-rich matrix. In the 7.5% Ti composition the diameter distribution of the FeCo needles was bimodal with the majority having diameters of approximately 50 nm with a small fraction having diameters of approximately 10 nm. The needles formed a mosaic pattern and were elongated along one crystal direction (parallel to the field used during magnetic annealing). Cu precipitates were observed between the needles. Regions of abnormal spinodal morphology appeared to correlate with secondary phase precipitates. The presence of these abnormalities did not prevent the material from displaying superior magnetic properties in the 7.5% Ti composition

  7. Modelling the grain orientation of austenitic stainless steel multipass welds to improve ultrasonic assessment of structural integrity

    Moysan, J.; Apfel, A.; Corneloup, G.; Chassignole, B


    Knowledge of the grain orientation quantifies the material anisotropy which helps to ensure the good ultrasonic testing of welded assemblies and the assessment of their mechanical integrity. The model described here concerns the weld solidification of 316L stainless steel. The solidification of multipass welds made with a shielded electrode raises many unsolved modelling questions as it involves heat and fluid flow modelling in addition to solute redistribution models. To overcome these difficulties we have developed the MINA model to predict the resulting grain orientations without using a complete solidification model. This model relies upon a phenomenological description of grain orientations from macrograph analysis. One important advance of this model is to include data reporting in the welding notebook that ensures the generality of the model. This model allows us to accurately simulate the ultrasonic testing of welded components and to propose a new tool to associate welding design with the ultrasonic assessment of structural integrity.

  8. Pattern and phase selection of peritectic reaction during directional solidification

    HUANG; Weidong; (黄卫东); LIN; Xin; (林鑫); WANG; Meng; (王猛); SHEN; Shujuan; (沈淑娟); SU; Yunpeng; (苏云鹏); LIU; Zhenxia; (刘振侠)


    Based on the growth competition between different pattern and phases, the pattern and phase selection during peritectic solidification is analysed by applying the maximum interface temperature criterion to the interface response functions calculated from a numerical model for single phase solidification. The theoretical results agree very well with the experimental results published in literature.

  9. A Computer Aided System for Simulating Weld Metal Solidification Crack


    A computer-aided system for simulating weld solidification crack has been developed by which a welding engineer can carry out the welding solidification crack simulation on the basis of a commercial finite element analysis software package. Its main functions include calculating the heat generations of the moving arc, mesh generation, calculating stress-strain distributions with element rebirth technique.

  10. Grain Spectroscopy

    Allamandola, L. J.


    Our fundamental knowledge of interstellar grain composition has grown substantially during the past two decades thanks to significant advances in two areas: astronomical infrared spectroscopy and laboratory astrophysics. The opening of the mid-infrared, the spectral range from 4000-400 cm(sup -1) (2.5-25 microns), to spectroscopic study has been critical to this progress because spectroscopy in this region reveals more about a materials molecular composition and structure than any other physical property. Infrared spectra which are diagnostic of interstellar grain composition fall into two categories: absorption spectra of the dense and diffuse interstellar media, and emission spectra from UV-Vis rich dusty regions. The former will be presented in some detail, with the latter only very briefly mentioned. This paper summarized what we have learned from these spectra and presents 'doorway' references into the literature. Detailed reviews of many aspects of interstellar dust are given.

  11. 不同种植模式玉米子粒灌浆进程研究%A Study of Fil ing Process of Corn Grain with Different Planting Modes

    王霞; 吴欣


    Using Simon No.5 corn cultivars as the materials, corn grain filling process with different planting modes were de-termined and compared under the same sowing time conditions. The results showed that the final dry weight of the grains of the singly-planted corn was greater than that of the corn interplanted with wheat. The date of start of the grain filling of the singly-planted corn was earlier than that of the corn interplanted with wheat. The average filling rate of the corn interplanted with wheat was greater than that of the singly-planted corn. The maximum filling rate of the singly-planted corn was greater than that of the corn interplanted with wheat, but the occurrence time of the corn interplanted with wheat was earlier than that of the singly-planted corn. The filling rate of the singly-planted corn in late mid August was higher and the filling rate of the corn interplanted with wheat was higher in early mid August.%以西蒙5号玉米品种为材料,在播期相同的条件下,对不同种植模式的玉米子粒灌浆进程进行了测定比较。结果表明:玉米子粒最终的百粒干重为单种玉米>麦套玉米;玉米子粒开始灌浆的日期为单种玉米早于麦套玉米;平均灌浆速率为麦套玉米>单种玉米;最大灌浆速率为单种玉米>麦套玉米,但出现的时间麦套玉米早于单种玉米;8月中旬后期单种玉米灌浆速率高;8月中旬前麦套玉米的灌浆速率高。

  12. [Solidification of volatile oil with graphene oxide].

    Yan, Hong-Mei; Jia, Xiao-Bin; Zhang, Zhen-Hai; Sun, E; Xu, Yi-Hao


    To evaluate the properties of solidifying volatile oil with graphene oxide, clove oil and zedoary turmeric oil were solidified by graphene oxide. The amount of graphene oxide was optimized with the eugenol yield and curcumol yield as criteria. Curing powder was characterized by differential scanning calorimetry (DSC) and scanning electron microscopy (SEM). The effects of graphene oxide on dissolution in vitro and thermal stability of active components were studied. The optimum solidification ratio of graphene oxide to volatile oil was 1:1. Dissolution rate of active components had rare influence while their thermal stability improved after volatile oil was solidified. Solidifying herbal volatile oil with graphene oxide deserves further study.

  13. Seaweed to dendrite transition in directional solidification.

    Provatas, Nikolas; Wang, Quanyong; Haataja, Mikko; Grant, Martin


    We simulate directional solidification using a phase-field model solved with adaptive mesh refinement. For small surface tension anisotropy directed at 45 degrees relative to the pulling direction we observe a crossover from a seaweed to a dendritic morphology as the thermal gradient is lowered, consistent with recent experimental findings. We show that the morphology of crystal structures can be unambiguously characterized through the local interface velocity distribution. We derive semiempirically an estimate for the crossover from seaweed to dendrite as a function of thermal gradient and pulling speed.

  14. Low Melt Height Solidification of Superalloys

    Montakhab, Mehdi; Bacak, Mert; Balikci, Ercan


    Effect of a reduced melt height in the directional solidification of a superalloy has been investigated by two methods: vertical Bridgman (VB) and vertical Bridgman with a submerged baffle (VBSB). The latter is a relatively new technique and provides a reduced melt height ahead of the solidifying interface. A low melt height leads to a larger primary dendrite arm spacing but a lower mushy length, melt-back transition length, and porosity. The VBSB technique yields up to 38 pct reduction in the porosity. This may improve a component's mechanical strength especially in a creep-fatigue type dynamic loading.

  15. Novel Directional Solidification of Hypermonotectic Alloys

    Grugel, R. N.; Fedoseyev, A. I.; Rose, M. Franklin (Technical Monitor)


    There are many metal alloy systems that separate into two different liquids upon cooling from a higher temperature. Uniform microstructural development during solidification of these immiscible liquids on Earth is hampered by inherent density differences between the phases. Microgravity processing minimizes settling but segregation still occurs due to gravity independent wetting and coalescence phenomena. Experiments with the transparent organic, metal analogue, succinonitrile-glycerol system were conducted in conjunction with applied ultrasonic energy. The processing parameters associated with this technique have been evaluated in view of optimizing dispersion uniformity. Characterization of the experimental results in terms of an initial modeling effort will also be presented.

  16. Alternating tip splitting in directional solidification.

    Utter, B; Ragnarsson, R; Bodenschatz, E


    We report experimental results on the tip splitting dynamics of seaweed growth in directional solidification of succinonitrile alloys. Despite the random appearance of the growth, a tip splitting morphology was observed in which the tip alternately splits to the left and to the right. The tip splitting frequency f was found to be related to the growth velocity V as a power law f~V1.5. This finding is consistent with the predictions of a tip splitting model that is also presented. Small anisotropies are shown to lead to different kinds of seaweed morphologies.

  17. ORNL liquid low-level waste solidification

    Schultz, R.M.; Monk, T.H.; du Mont, S.P.; Helms, R.E.; Keigan, M.V.; Morris, M.I.


    The solidification of LLLW at ORNL has developed two basic strategies, a near-term or backup flowsheet is planned to alleviate the immediate capacity problem for storage of concentrated LLLW and a long-term or reference flowsheet is planned to incorporate filtration of the settleable TRU and cesium and strontium decontamination of the LLLW. Presently a feasibility study is evaluating the process alternatives for segregating LLLW from remote-handled transuranic (RH-TRU) sludges, decontamination of the LLLW for beta-gamma radionuclides such as cesium and strontium, and the handling and storage of the RH-TRU sludges and decontamination media. 14 refs.

  18. Aluminum alloy weldability. Identification of weld solidification cracking mechanisms through novel experimental technique and model development

    Coniglio, Nicolas


    The objective of the present thesis is to make advancements in understanding solidification crack formation in aluminum welds, by investigating in particular the aluminum 6060/4043 system. Alloy 6060 is typical of a family of Al-Mg-Si extrusion alloys, which are considered weldable only when using an appropriate filler alloy such as 4043 (Al-5Si). The effect of 4043 filler dilution (i.e. weld metal silicon content) on cracking sensitivity and solidification path of Alloy 6060 welds are investigated. Afterwards, cracking models are developed to propose mechanisms for solidification crack initiation and growth. Cracking Sensitivity. Building upon the concept that silicon improves weldability and that weldability can be defined by a critical strain rate, strain rate-composition combinations required for solidification crack formation in the Al- 6060/4043 system were determined using the newly developed Controlled Tensile Weldability (CTW) test utilizing local strain extensometer measurements. Results, presented in a critical strain rate - dilution map, show a crack - no crack boundary which reveals that higher local strain rates require higher 4043 filler dilution to avoid solidification cracking when arc welding Alloy 6060. Using the established crack - no crack boundary as a line of reference, additional parameters were examined and their influence on cracking characterized. These parameter influences have included studies of weld travel speed, weld pool contaminants (Fe, O, and H), and grain refiner additions (TiAl{sub 3} + Boron). Each parameter has been independently varied and its effect on cracking susceptibility quantified in terms of strain rate - composition combinations. Solidification Path. Solidification path of the Al-6060/4043 system was characterized using thermal analysis and phase identification. Increasing 4043 filler dilution from 0 to 16% in Alloy 6060 arc welds resulted in little effect on thermal arrests and microstructure, no effect on

  19. Melt Flow Control in the Directional Solidification of Binary Alloys

    Zabaras, Nicholas


    Our main project objectives are to develop computational techniques based on inverse problem theory that can be used to design directional solidification processes that lead to desired temperature gradient and growth conditions at the freezing front at various levels of gravity. It is known that control of these conditions plays a significant role in the selection of the form and scale of the obtained solidification microstructures. Emphasis is given on the control of the effects of various melt flow mechanisms on the local to the solidification front conditions. The thermal boundary conditions (furnace design) as well as the magnitude and direction of an externally applied magnetic field are the main design variables. We will highlight computational design models for sharp front solidification models and briefly discuss work in progress toward the development of design techniques for multi-phase volume-averaging based solidification models.

  20. Nanoparticle-induced unusual melting and solidification behaviours of metals

    Ma, Chao; Chen, Lianyi; Cao, Chezheng; Li, Xiaochun


    Effective control of melting and solidification behaviours of materials is significant for numerous applications. It has been a long-standing challenge to increase the melted zone (MZ) depth while shrinking the heat-affected zone (HAZ) size during local melting and solidification of materials. In this paper, nanoparticle-induced unusual melting and solidification behaviours of metals are reported that effectively solve this long-time dilemma. By introduction of Al2O3 nanoparticles, the MZ depth of Ni is increased by 68%, while the corresponding HAZ size is decreased by 67% in laser melting at a pulse energy of 0.18 mJ. The addition of SiC nanoparticles shows similar results. The discovery of the unusual melting and solidification of materials that contain nanoparticles will not only have impacts on existing melting and solidification manufacturing processes, such as laser welding and additive manufacturing, but also on other applications such as pharmaceutical processing and energy storage.

  1. Tailoring the grain structure of IN718 during selective electron beam melting

    Körner Carolin


    Full Text Available Selective electron beam melting (SEBM is an additive manufacturing method where complex parts are built from metal powders in layers of about 50 μm. SEBM works under vacuum conditions which results in a perfect protection of the metal alloy. The electron beam is used for heating (about 900 ∘C building temperature and selective melting. The high beam velocities allow innovative scanning strategies in order to adapt the local solidification conditions which determine the epitaxial solidification process of IN718. We show how scanning strategies can be used either to produce a columnar grain structure with a high texture in building direction or a complete texture-free fine grained structure. Numerical simulations of the selective melting process are applied to reveal the fundamental mechanisms responsible for the completely different grain structures. In addition the influence of the different grain structures on the mechanical properties of IN718 is briefly discussed.

  2. Grain Nucleation Parameters for Aluminum Alloys: Experimental Determination and Model Validation

    Ahmadein, M.; Pustal, B.; Berger, R.; Subašić, E.; Bührig-Polaczek, A.


    A statistical grain nucleation model was implemented as a part of a multiphase flow and solidification simulation code for metallic alloys. Three characteristic parameters control the solution accuracy of the nucleation model: the total grain density, the mean undercooling, and the standard deviation of the undercooling. These parameters were obtained experimentally for grain-refined (GR) A356, GR AlCu4, and unrefined (UR) AlCu4 aluminum alloys. An apparatus was constructed and equipped with a cooling system to provide different cooling rates throughout the cast sample. The local grain density related to each cooling rate and undercooling was determined. The model parameters were obtained via statistical tools and were used to perform a simulation for the solidification of the cast sample. Calculated results were compared to experimental results, and the model exhibited good agreement with the experiments.

  3. Microstructure characteristics and solidification behavior of wrought aluminum alloy 2024 rheo-diecast with self-inoculation method

    Li Yanlei


    Full Text Available One important problem in casting wrought aluminum alloys is the high tendency to the formation of hot tears in the solidification process. By using semi-solid metal (SSM processing, the hot tearing tendency of alloys can be minimized during casting. In the present research, the semi-solid slurry of wrought aluminum alloy 2024 was firstly prepared with a novel self-inoculation method (SIM, and then the microstructure characteristics of the semi-solid slurry and the rheo-diecastings cast with the semi-solid slurry were investigated. The results indicate that finer and more uniform globular primary α-Al particles can be obtained when the semi-solid slurry are isothermally held for a short period within the semi-solid temperature range, and the primary α-Al particles without entrapped liquid are uniformly fine, globular grains in the rheo-diecastings. The holding temperature and time affect the solid fraction, particle size, and shape factor. After the semi-solid slurry is held at 625 ℃ for 3 min and 5 min, the optimal values for the average equivalent diameter are 70.80 μm and 74.15 μm, and for the shape factor are 1.32 and 1.42, respectively. The solidification process of the rheo-diecastings is composed of the following two distinct stages: primary solidification process and secondary solidification process. The secondary solidification process consists further of the following three stages: (1 direct growth of secondary primary (α2 phase from the surface of the primary α-Al phase particles without re-nucleation, (2 independent nucleation and growth of α3 phase from the residual liquid, and (3 eutectic reaction at the end.

  4. Phase Transformations During Solidification of a Laser-Beam-Welded TiAl Alloy—An In Situ Synchrotron Study

    Liu, Jie; Staron, Peter; Riekehr, Stefan; Stark, Andreas; Schell, Norbert; Huber, Norbert; Schreyer, Andreas; Müller, Martin; Kashaev, Nikolai


    An in situ highly time-resolved, high-energy X-ray diffraction investigation was carried out to observe the phase transformations of a TiAl alloy during laser beam welding. The diffraction patterns are recorded every 0.1 seconds by a fast area two-dimensional detector and plotted according to time, yielding the solidification pathway, the solid phase volume fraction, and the lattice parameter variation of different phases during the solidification and cooling process. Moreover, it is the first study that can demonstrate that the α phase without any Burgers orientation relationship, the so-called non-Burgers α, precipitates appear earlier than the Burgers α. The non-Burgers α grains are found to nucleate on the primary borides.

  5. Analysis of the solidification and microstructure of two aluminium alloys reinforced with TiB{sub 2} particles

    Egizabal, Pedro; Garcia de Cortazar, Maider [Fundacion Inasmet E-20009 Donostia-San Sebastian (Spain); Torregaray, Amaia [University of Basque Country UPV/EHU E-48012, Bilbo-Bilbao (Spain); Veillere, Amelie; Silvain, Jean-Francois [CNRS, Universite de Bordeaux, ICMCB 87 Avenue du Docteur Albert Schweitzer, 33608 Pessac (France); Douin, Joel [CEMES-CNRS 29 Rue Jeanne Marvig, BP 94347, 31055 Toulouse Cedex 4 (France)


    Two aluminium alloys with 6 wt% TiB{sub 2} particles are studied for applications where increased wear resistance and mechanical strength at high temperature are required. The incorporation of hard ceramic particles has a strong influence on the microstructure and properties of the alloys. TiB{sub 2} particles play an important role in the nucleation of the different phases of the alloys during solidification, and in the reduction of grain size and porosity. The solidification patterns of Al-Si{sub 7}Mg{sub 0.3} + TiB{sub 2} (6 wt%) and Al-Cu{sub 5}MgTi+TiB{sub 2} (6 wt%) materials are compared to their corresponding non-reinforced alloys, and the microstructures are analyzed. (Copyright copyright 2011 WILEY-VCH Verlag GmbH and Co. KGaA, Weinheim)

  6. Correlation of recalescence with grain refinement of magnesium alloys


    The grain refinement of Mg-Al based alloys with carbon inoculation was investigated by a computer-aided cooling curve analysis(CA-CCA)system.The results show that carbon inoculation decreases the main parameters of the recalescence regime during the initial stage of solidification.These parameters include the recalescence undercooling(△θrec),duration of recalescence (trec),and liquid peak parameter(LPP)which is firstly introduced into magnesium alloys.The resultant grain size decreases with increasing nucleation temperature(θn)and decreasing values of △θrec,trec and LPE


    G.F. Liang; C.Q. Wan; J.C. Wu; G.M. Zhu; Y. Yu; Y. Fang


    It was presented the in situ observation of growth behavior and morphology of delta-ferrite as a function of solidification rate in an AISI304 stainless steel. The specimens have been solidified and observed using confocal scanning laser microscopy ( CSLM). The δ-phase always appears like cells on the sample surface when critical supercooling occurs, during which the L→δtransformation starts. The solid-liquid (S-L) interface is found to be finger shaped and has no faceted shape. Γ phase appears among δ grains due to partitioning of Ni into the melt during solidification, when solidification rate is higher. The mergence of observed δ cells is possible for the steel sample cooled at 7.5℃/min. The formation of dendrites can be observed on the free surface of the steel sample cooled at 150℃/min. The size of solidified delta grains decreases from 120 to 20-80μm, and the volume fraction of solidified austenite increases with increase in solidification rate from 7.5 to 150℃/min. The relation between the tip radius of δ cell and its growth rate is deduced, and the results agree with the experimental values.

  8. The melting and solidification of nanowires

    Florio, B. J.; Myers, T. G.


    A mathematical model is developed to describe the melting of nanowires. The first section of the paper deals with a standard theoretical situation, where the wire melts due to a fixed boundary temperature. This analysis allows us to compare with existing results for the phase change of nanospheres. The equivalent solidification problem is also examined. This shows that solidification is a faster process than melting; this is because the energy transfer occurs primarily through the solid rather than the liquid which is a poorer conductor of heat. This effect competes with the energy required to create new solid surface which acts to slow down the process, but overall conduction dominates. In the second section, we consider a more physically realistic boundary condition, where the phase change occurs due to a heat flux from surrounding material. This removes the singularity in initial melt velocity predicted in previous models of nanoparticle melting. It is shown that even with the highest possible flux the melting time is significantly slower than with a fixed boundary temperature condition.

  9. The Advanced Automated Directional Solidification Furnace

    Gillies, D. C.; Reeves, F. A.; Jeter, L. B.; Sledd, J. D.; Cole, J. M.; Lehoczky, S. L.


    The Advanced Automated Directional Solidification Furnace (AADSF) is a five zone tubular furnace designed for Bridgman-Stockbarger, other techniques of crystal growth involving multiple temperature zones such as vapor transport experiments and other materials science experiments. The five zones are primarily designed to produce uniform hot and cold temperature regions separated by an adiabatic region constructed of a heat extraction plate and an insert to reduce radiation from the hot to the cold zone. The hot and cold zone temperatures are designed to reach 1600 C and 1100 C, respectively. AADSF operates on a Multi-Purpose Experiment Support Structure (MPESS) within the cargo bay of the Space Shuttle on the United States Microgravity Payload (USMP) missions. Two successful flights, both employing the directional solidification or Bridgman Stockbarger technique for crystal growth have been made, and crystals of HgCdTe and PbSnTe grown in microgravity have been produced on USMP-2 and USMP-3, respectively. The addition of a Sample Exchange Mechanism (SEM) will enable three different samples to be processed on future flights including the USMP-4 mission.

  10. Carburizer Effect on Cast Iron Solidification

    Janerka, Krzysztof; Kondracki, Marcin; Jezierski, Jan; Szajnar, Jan; Stawarz, Marcin


    This paper presents the effect of carburizing materials on cast iron solidification and crystallization. The studies consisted of cast iron preparation from steel scrap and different carburizers. For a comparison, pig iron was exclusively used in a solid charge. Crystallization analysis revealed the influence of the carburizer material on the crystallization curves as well as differences in the solidification paths of cast iron prepared with the use of different charge materials. The carburizers' influence on undercooling during the eutectic crystallization process was analyzed. The lowest undercooling rate was recorded for the melt with pig iron, then for synthetic graphite, natural graphite, anthracite, and petroleum coke (the highest undercooling rate). So a hypothesis was formulated that eutectic cells are created most effectively with the presence of carbon from pig iron (the highest nucleation potential), and then for the graphite materials (crystallographic similarity with the carbon precipitation in the cast iron). The most difficult eutectic crystallization is for anthracite and petroleum coke (higher undercooling is necessary). This knowledge can be crucial when the foundry plant is going to change the solid charge composition replacing the pig iron by steel scrap and the recarburization process.

  11. Solidification microstructure of centrifugally cast Inconel 625

    Silvia Barella


    Full Text Available Centrifugal casting is a foundry process allowing the production of near net-shaped axially symmetrical components. The present study focuses on the microstructural characterization of centrifugally cast alloys featuring different chemical compositions for the construction of spheres applied in valves made of alloy IN625 for operation at high pressure. Control of the solidification microstructure is needed to assure the reliability of the castings. Actually, a Ni-base superalloy such as this one should have an outstanding combination of mechanical properties, high temperature stability and corrosion resistance. Alloys such as IN625 are characterised by a large amount of alloying elements and a wide solidification range, so they can be affected by micro-porosity defects, related to the shrinkage difference between the matrix and the secondary reinforcing phases (Nb-rich carbides and Laves phase. In this study, the microstructure characterization was performed as a function of the applied heat treatments and it was coupled with a calorimetric analysis in order to understand the mechanism ruling the formation of micro-porosities that can assure alloy soundness. The obtained results show that the presence of micro-porosities is governed by morphology and by the size of the secondary phases, and the presence of the observed secondary phases is detrimental to corrosion resistance.

  12. Spasmodic growth during the rapid solidification of undercooled Ag-Cu eutectic melts

    Clopet, C. R.; Cochrane, R. F.; Mullis, A. M.


    A melt fluxing technique has been used to undercool Ag-Cu eutectic alloy by 10-70 K and the subsequent recalescence has been studied using high speed imaging. Spasmodic growth of the solidification front was observed, in which the growth front would make a series of quasi-periodic jumps separated by extended periods during which time growth appeared to arrest. Evidence of this previously unreported mode of growth is presented. The high speed images and microstructural evidence support the theory that anomalous eutectics form by the growth and subsequent remelting of eutectic dendrites.

  13. Spatiotemporal dynamics of oscillatory cellular patterns in three-dimensional directional solidification.

    Bergeon, N; Tourret, D; Chen, L; Debierre, J-M; Guérin, R; Ramirez, A; Billia, B; Karma, A; Trivedi, R


    We report results of directional solidification experiments conducted on board the International Space Station and quantitative phase-field modeling of those experiments. The experiments image for the first time in situ the spatially extended dynamics of three-dimensional cellular array patterns formed under microgravity conditions where fluid flow is suppressed. Experiments and phase-field simulations reveal the existence of oscillatory breathing modes with time periods of several 10's of minutes. Oscillating cells are usually noncoherent due to array disorder, with the exception of small areas where the array structure is regular and stable.

  14. Numerical Simulation of Transport Phenomena in Solidification of Multicomponent Ingot Using a Continuum Model


    A continuum model proposed for dendrite solidification of multicomponent alloys, with any partial solid back diffusion, was used to numerically simulate the macroscopic solidification transport phenomena and macrosegregations in an upwards directionally solidified plain carbon steel ingot. The computational results of each macroscopic field of the physical variables involved in the solidification process at a middle solidification stage were presented.

  15. Solidification science in cast MMCs: The influence of merton flemings

    Rohatgi, Pradeep; Asthana, Rajiv


    The solidification science of cast metalmatrix composites (MMC) evolved as a subset of the broad field of solidification of monolithic alloys pioneered by Merton Flemings and his students. As a result of advances in solidification, the cast MMC field has evolved from its early incarnation—employing empirical research to engineer novel materials using versatile and cost-effective casting techniques—to using solidification-science-based approaches to tailor advanced materials for application-specific needs. The current and emerging applications of cast MMCs in a variety of automotive, aerospace, electronic packaging, and consumer-good industries exemplify the maturity of the field and the materials. Innovations in composite-forming techniques and efforts at wider industrial acceptance of MMCs will undoubtedly continue. However, the scientific principles underlying the solidification microstructure evolution that governs the composite properties have become well established, to a great extent, due to Flemings’ early, pioneering work on monolithic alloys and some of his more recent studies on solidification of reinforced metals. This paper reviews some aspects of solidification of discontinuously reinforced cast metals that owe their current understanding to Flemings’ contributions, in particular, the scientific understanding of macro- and microsegregation, fluidity and rheology of multiphase slurries, and stircasting, semi-solid casting, and preform infiltration. Current research to develop and test prototype components made from cast composites, including Al-flyash, Cu-graphite, Al-graphite, Al-alumina, and SiC-Al, is also presented, along with directions for future research.

  16. Effect of Carbon and Phosphorous on the Solidification Microstructure in a Cr-Ni-Mn-N Austenitic Hydrogen-resistant Steel

    Jun TAN; Luming MA; Shouxin LI; Lijian RONG; Jincai YUAN; Yiyi LI


    The influence of carbon and phosphorus on the solidification microstructure of a Cr-Ni-Mn-N austenitic steel was studied. The button specimens were prepared by vacuum induction melting and magnetic convection. The experimental results show that the increase of C or P concentration in the steel can change the solidification modes of Cr-Ni-Mn-N austenitic steels and has a significant effect on the morphology of the dendrites. The content of δ-ferrite in the microstructure reduces with increasing the concentration of C or P in the steel, there is a gradient of the content of δ-ferrite formed from surface through the center of the specimens.

  17. Structures Self-Assembled Through Directional Solidification

    Dynys, Frederick W.; Sayir, Ali


    Nanotechnology has created a demand for new fabrication methods with an emphasis on simple, low-cost techniques. Directional solidification of eutectics (DSE) is an unconventional approach in comparison to low-temperature biomimetic approaches. A technical challenge for DSE is producing microstructural architectures on the nanometer scale. In both processes, the driving force is the minimization of Gibb's free energy. Selfassembly by biomimetic approaches depends on weak interaction forces between organic molecules to define the architectural structure. The architectural structure for solidification depends on strong chemical bonding between atoms. Constituents partition into atomic-level arrangements at the liquid-solid interface to form polyphase structures, and this atomic-level arrangement at the liquid-solid interface is controlled by atomic diffusion and total undercooling due to composition (diffusion), kinetics, and curvature of the boundary phases. Judicious selection of the materials system and control of the total undercooling are the keys to producing structures on the nanometer scale. The silicon-titanium silicide (Si-TiSi2) eutectic forms a rod structure under isothermal cooling conditions. At the NASA Glenn Research Center, directional solidification was employed along with a thermal gradient to promote uniform rods oriented with the thermal gradient. The preceding photomicrograph shows the typical transverse microstructure of a solidified Si-TiSi2 eutectic composition. The dark and light gray regions are Si and TiSi2, respectively. Preferred rod orientation along the thermal gradient was poor. The ordered TiSi2 rods have a narrow distribution in diameter of 2 to 3 m, as shown. The rod diameter showed a weak dependence on process conditions. Anisotropic etch behavior between different phases provides the opportunity to fabricate structures with high aspect ratios. The photomicrographs show the resulting microstructure after a wet chemical etch and a

  18. Purification by high vacuum fusion and progressive solidification of uranium from electrolytic origin; Purification par fusion sous vide eleve et solidification progressive d'uranium d'origine electrolytique

    Poeydomenge, P. [Commissariat a l' Energie Atomique, Saclay (France). Centre d' Etudes Nucleaires


    ;dissociative growth' of the grain observed, so-called secondary recrystallisation. in appendix, the method for measuring the electrical resistance by induction (with direct current)is studied from the fundamental and experimental point of view. The author applied it to the particular case of uranium for measuring the low-temperature resistance of the bars from the same which solidified first to the least pure ended the ingot. (author) [French] Dans le cadre de recherches generales sur la purification de l'uranium par fusion de zone, on a entrepris de determiner le degre de purification que l'on pourrait atteindre par une simple solidification progressive a vitesse et direction soigneusement controlees d'un uranium de purete nucleaire courante. Cet uranium de purete intermediaire fournirait un materiau de depart approprie au mode de purification ultime qu'est la fusion a zone verticale, dite ''flottante''. Dans ce but, des lingots d'uranium d'origine electrolytique ont ete refondus sous vide (2 a 5 x 10{sup -6} mm) dans une longue nacelle en UO{sub 2} apres une monte lente en temperature pour eliminer le maximum de gaz et d'impuretes volatiles. Ce degazage et cette volatilisation d'impuretes sont completes par maintien prolonge a haute temperature du bais liquide. Celui-ci est ensuite solidifie d'une extremite a l'autre de la nacelle par deplacement a vitesse lente et constante du front de solidification de facon a obtenir une repartition des impuretes selon les lois etablies par PFANN. Differentes methodes experimentales ont permis de montrer que le metal solidifie en premier lieu est nettement plus pur que celui de la partie solidifie a l'extremite opposee du lingot. Le degre de purification du metal en tete du lingot a ete apprecie, soit quantitativement par mesure du rapport des resistivites electriques a la temperature ambiante et a celle de l'azote liquide, soit qualitativement par l

  19. Localized microstructures induced by fluid flow in directional solidification.

    Jamgotchian, H; Bergeon, N; Benielli, D; Voge, P; Billia, B; Guérin, R


    The dynamical process of microstructure localization by multiscale interaction between instabilities is uncovered in directional solidification of transparent alloy. As predicted by Chen and Davis, morphological instability of the interface is observed at inward flow-stagnation regions of the cellular convective field. Depending on the driving force of fluid flow, focus-type and honeycomb-type localized patterns form in the initial transient of solidification, that then evolves with time. In the case of solute-driven flow, the analysis of the onset of thermosolutal convection in initial transient of solidification enables a complete understanding of the dynamics and of the localization of morphological instability.

  20. Capillary-wave description of rapid directional solidification.

    Korzhenevskii, Alexander L; Bausch, Richard; Schmitz, Rudi


    A recently introduced capillary-wave description of binary-alloy solidification is generalized to include the procedure of directional solidification. For a class of model systems a universal dispersion relation of the unstable eigenmodes of a planar steady-state solidification front is derived, which readjusts previously known stability considerations. We moreover establish a differential equation for oscillatory motions of a planar interface that offers a limit-cycle scenario for the formation of solute bands and, taking into account the Mullins-Sekerka instability, of banded structures.

  1. Inverse thermal analysis method to study solidification in cast iron

    Dioszegi, Atilla; Hattel, Jesper


    Solidification modelling of cast metals is widely used to predict final properties in cast components. Accurate models necessitate good knowledge of the solidification behaviour. The present study includes a re-examination of the Fourier thermal analysis method. This involves an inverse numerical...... solution of a 1-dimensional heat transfer problem connected to solidification of cast alloys. In the analysis, the relation between the thermal state and the fraction solid of the metal is evaluated by a numerical method. This method contains an iteration algorithm controlled by an under relaxation term...... inverse thermal analysis was tested on both experimental and simulated data....

  2. Modelling of soft impingement during solidification

    K T Kashyap; S Yamdagni


    It has been well established that spheroidal grain morphology in the microstructure forms during stir casting (rheocasting) and grain refinement of magnesium alloys by zirconium addition. This curious microstructure has been of interest both commercially from enhanced mechanical properties and also scientific interest in explaining the mechanism of spheroidal grain formation. Vogel and Doherty proposed a model describing the fracturing of dendrite arms during stir casting to produce a high density of nuclei which they presume to give rise to spheroidal grains. They proposed that there is soft impingement of diffusion fields of neighbouring nuclei, which reduces the concentration gradient ahead of the planar solid and liquid interface, which in turn negates shape instability. In this paper, the Vogel and Doherty model is pursued by quantitative modeling of soft impingement problem and related to shape instability by constitutional supercooling theory. This analysis correctly predicts the spheroidal grain formation during stir casting or rheocasting. This model can also be used to explain the grain refinement of magnesium alloys by zirconium addition wherein spheroidal grains are formed.

  3. Simulation of continuous cast steel product solidification

    Ardelean, E.


    Full Text Available Primary cooling – inside the tundish – has a great impact over the thickness of the solidified steel crust. If on exiting the tundish the crust is too thin, it can punch and break, as a result of the ferrostatic pressure exerted from the inside by the liquid steel as well as because of the weight of the molten steel. The parameters that influence the amount of dissipated heat depend on the cooling water flow of the tundish, on the pressure and temperature of the cooling water but also on the overheating of the continuously cast steel. The secondary cooling takes place at the exit of the semi-finished product from the tundish, when the solidification is supposed to take place all along the cross section of the strand. In order to achieve it, in addition to a correctly managed primary cooling, it is necessary to obtain the proper correlation of the factors that influence the secondary cooling as well: the water flow rate long the three zones of the installation and its pressure in the secondary circuit. All these have in view a proper solidification length; an intense cooling can generate cracks due to the thermal stress, while a too slow cooling can generate a partial solidification of the strand up to the cropping machine area. The paper presents a mathematical simulation of the continuously cast steel solidification.

    El enfriamiento primario del cristalizador tiene una gran importancia sobre el espesor de la costra de acero solidificado. Si al salir del cristalizador, esta costra es demasiado sutil, bajo la acción de la presión ferro estática ejercitada por el acero líquido del interior y gracias el peso propio del hilo, ésta, puede perforar resultando su rompimiento. Los parámetros que influenyen sobre la cantidad de calor cedida dependen del agua de enfriamiento del catalizador, de la presión y de la temperatura de agua de enfriamiento, pero también del sobrecalentamiento del acero fundido continuamente. A la salida del

  4. Convection and morphological stability during directional solidification

    Coriell, Sam R.; Chernov, A. A.; Murray, Bruce T.; Mcfadden, G. B.


    For growth of a vicinal face at constant velocity, the effect of anisotropic interface kinetics on morphological stability is calculated for a binary alloy. The dependence of the interface kinetic coefficient on crystallographic orientation is based on the motion and density of steps. Anisotropic kinetics give rise to traveling waves along the crystal-melt interface, and can lead to a significant enhancement of morphological stability. The stability enhancement increases as the orientation approaches a singular orientation and as the solidification velocity increases. Shear flows interact with the traveling waves and, depending on the direction of the flow, may either stabilize or destabilize the interface. Specific calculations are carried out for germanium-silicon alloys.

  5. Directional Solidification Assisted by Liquid Metal Cooling

    Jian ZHANG; Langhong LOU


    An overview of the development and current status of the directional solidification process assisted by liquid metal cooling (LMC) has been presented in this paper. The driving force of the rapid development of the LMC process has been analyzed by considering the demands of (1) newer technologies that can provide higher thermal gradients for alleviated segregation in advanced alloy systems, and (2) better production yield of the large directionally solidified superalloy components. The brief history of the industrialization of the LMC process has been reviewed, followed by the discussion on the LMC parameters including selection of the cooling media, using of the dynamic baffle, and the influence of withdrawal rates and so on. The microstructure and mechanical properties of the traditional superalloys processed by LMC, as well as the new alloys particularly developed for LMC process were then described. Finally, future aspects concerning the LMC process have been summarized.

  6. The cement solidification systems at LANL

    Veazey, G.W.


    There are two major cement solidification systems at Los Alamos National Laboratory. Both are focused primarily around treating waste from the evaporator at TA-55, the Plutonium Processing Facility. The evaporator receives the liquid waste stream from TA-55's nitric acid-based, aqueous-processing operations and concentrates the majority of the radionuclides in the evaporator bottoms solution. This is sent to the TA-55 cementation system. The evaporator distillate is sent to the TA-50 facility, where the radionuclides are precipitated and then cemented. Both systems treat TRU-level waste, and so are operated according to the criteria for WIPP-destined waste, but they differ in both cement type and mixing method. The TA-55 systems uses Envirostone, a gypsum-based cement and in-drum prop mixing; the TA-50 systems uses Portland cement and drum tumbling for mixing.

  7. The effect of natural and forced melt convection on dendritic solidification in Ga-In alloys

    Shevchenko, N.; Roshchupkina, O.; Sokolova, O.; Eckert, S.


    The directional solidification of Ga-25 wt%In alloys within a Hele-Shaw cell was visualized by means of X-ray radioscopy. The experimental investigations are especially focused on the impact of melt convection on the dendritic growth. Natural convection occurs during a bottom up solidification because lighter solute is rejected at the solid-liquid interface leading to an unstable density stratification. Forced convection was produced by a rotating wheel with two parallel disks containing at their inner sides a set of permanent NdFeB magnets with alternating polarization. The direction of forced melt flow is almost horizontal at the solidification front whereas local flow velocities in the range between 0.1 and 1.0 mm/s were achieved by controlling the rotation speed of the magnetic wheel. Melt flow induces various effects on the grain morphology primarily caused by the convective transport of solute. Our observations show a facilitation of the growth of primary trunks or lateral branches, suppression of side branching, dendrite remelting and fragmentation. The manifestation of all phenomena depends on the dendrite orientation, local direction and intensity of the flow. The forced flow eliminates the solutal plumes and damps the local fluctuations of solute concentration. It provokes a preferential growth of the secondary arms at the upstream side of the primary dendrite arms, whereas the high solute concentration at the downstream side of the dendrites can inhibit the formation of secondary branches completely. Moreover, the flow changes the inclination angle of the dendrites and the angle between primary trunks and secondary arms.

  8. Mechanism of pulse magneto-oscillation grain refinement on pure Al

    Pei Ning


    Full Text Available Pulse magneto-oscillation (PMO was developed as a novel technique to refine the solidification structure of pure aluminium. Its grain refining mechanism was proposed. The PMO refinement mechanism is that the nucleus falls off from the mould wall and drifts into the melt under the action of PMO. The solidification structure of Al melt depends on the linear electric current density, and also the discharge and oscillation frequencies. The radial pressure of PMO sound wave is the major factor that contributes to the migration of nucleus into the melt.

  9. Experimental Determination of the Primary Solidification Phase dependency on the solidification velocity for 17 different austenitic stainless steel compositions

    Laursen, Birthe Nørgaard; Olsen, Flemming Ove; Yardy, John;


    to the austenite phase.Most stainless steels are weldable by conventional welding techniques. However, during laser weldng the solidification velocities can be very much higher than by conventional welding techniques. By increasing the solidification velocity to a critical value known as the transition velocity......, the primary solidification phase is found to change from ferrite to austenite.A novel laser remelting technique has been modified to enable the transition velocity for laser welded austenitic stainless steels to be deermined experimentally and on the basis of results from 17 different alloy compositions...... an equation for the calculation of the transition velocity from alloy composition is proposed....

  10. Fundamentals of Alloy Solidification Applied to Industrial Processes


    Solidification processes and phenomena, segregation, porosity, gravity effects, fluid flow, undercooling, as well as processing of materials in the microgravity environment of space, now available on space shuttle flights were discussed.

  11. Progress of Solidification Researches and the Applications in Materials Processing


    The research achievements of solidification theories and technologies in the last decades are reviewed with the stresses on some new development in the recent years. Some new interesting areas emerged in the last years are also pointed out.

  12. Effect Of Natural Convection On Directional Solidification Of Pure Metal

    Skrzypczak T.


    Full Text Available The paper is focused on the modeling of the directional solidification process of pure metal. During the process the solidification front is sharp in the shape of the surface separating liquid from solid in three dimensional space or a curve in 2D. The position and shape of the solid-liquid interface change according to time. The local velocity of the interface depends on the values of heat fluxes on the solid and liquid sides. Sharp interface solidification belongs to the phase transition problems which occur due to temperature changes, pressure, etc. Transition from one state to another is discontinuous from the mathematical point of view. Such process can be identified during water freezing, evaporation, melting and solidification of metals and alloys, etc.

  13. Topics about steel technologies. 2. ; Semi-solidification process. Tekko gijutsu topics. 2. ; Hangyoko kako process

    Kawakami, M.


    This paper describes features, the current status and examples of studies on the metal semi-solidification process. This process provides fine and uniform grain structures without coarse dendrite, internal defects, and segregation. The process uses a low processing pressure that makes uniform processing easier, and can make new composite materials and alloys with new components because of high viscosity in slurry. The thixomolding that combines a semi-melting process with the semi-solidification process is expected of the early realization of its use because it is easier in controlling metal crystal shapes, processing temperatures, and viscosity during processing than in the rheocasting. Research and development efforts in other countries are addressed to developing cryogenic casting processes for mass-produced steel materials aimed at reducing segregation, and studying a process to supply semi-solidified metal slurries to different manufacturing processes to fabricate difficult-to-process materials and functional materials into a near net shape. Studies include identification of relationship between cooling rates and stirring rates affecting crystal shapes, understanding of formability and transformation behavior of semi-solidified metals, and introduction of viscosity inferring equations. 3 figs., 1 tab.

  14. Initiation and growth kinetics of solidification cracking during welding of steel

    Aucott, L.; Huang, D.; Dong, H. B.; Wen, S. W.; Marsden, J. A.; Rack, A.; Cocks, A. C. F.


    Solidification cracking is a key phenomenon associated with defect formation during welding. To elucidate the failure mechanisms, solidification cracking during arc welding of steel are investigated in situ with high-speed, high-energy synchrotron X-ray radiography. Damage initiates at relatively low true strain of about 3.1% in the form of micro-cavities at the weld subsurface where peak volumetric strain and triaxiality are localised. The initial micro-cavities, with sizes from 10 × 10−6 m to 27 × 10−6 m, are mostly formed in isolation as revealed by synchrotron X-ray micro-tomography. The growth of micro-cavities is driven by increasing strain induced to the solidifying steel. Cavities grow through coalescence of micro-cavities to form micro-cracks first and then through the propagation of micro-cracks. Cracks propagate from the core of the weld towards the free surface along the solidifying grain boundaries at a speed of 2–3 × 10−3 m s−1. PMID:28074852

  15. Numerical Simulation and Optimization of Directional Solidification Process of Single Crystal Superalloy Casting

    Hang Zhang


    Full Text Available The rapid development of numerical modeling techniques has led to more accurate results in modeling metal solidification processes. In this study, the cellular automaton-finite difference (CA-FD method was used to simulate the directional solidification (DS process of single crystal (SX superalloy blade samples. Experiments were carried out to validate the simulation results. Meanwhile, an intelligent model based on fuzzy control theory was built to optimize the complicate DS process. Several key parameters, such as mushy zone width and temperature difference at the cast-mold interface, were recognized as the input variables. The input variables were functioned with the multivariable fuzzy rule to get the output adjustment of withdrawal rate (v (a key technological parameter. The multivariable fuzzy rule was built, based on the structure feature of casting, such as the relationship between section area, and the delay time of the temperature change response by changing v, and the professional experience of the operator as well. Then, the fuzzy controlling model coupled with CA-FD method could be used to optimize v in real-time during the manufacturing process. The optimized process was proven to be more flexible and adaptive for a steady and stray-grain free DS process.

  16. Directional solidification processing of eutectic alloys in the Ni Al V system

    Milenkovic, S.; Coelho, A. A.; Caram, R.


    Intermetallic matrix composites (IMCs) offer attractive properties, such as high toughness of the metal coupled with low density, high modulus and high strength of the intermetallics. Among a large number of the intermetallics, a particular interest has been shown in the NiAl intermetallic compound, since it exhibits several advantages over the currently used nickel-based superalloys. Recently, there has been a renewed interest in directional solidification of the eutectic alloys as a concept of reinforcing intermetallics with in situ refractory metals. The present study is related to the study of the eutectic alloys in the ternary NiAl-V system. The eutectic composition and temperature were accurately determined. It was concluded that the solidification behaviour of the Ni-Al-V eutectic is strongly dependent on the growth conditions, namely growth rate and orientation, and that it can be easily modified. Also, it was observed that the orientation of the grain, i.e., the direction of growth is the determining factor in the lamellar/rod transition as well as in the morphology of the degenerated structure.

  17. Initiation and growth kinetics of solidification cracking during welding of steel

    Aucott, L.; Huang, D.; Dong, H. B.; Wen, S. W.; Marsden, J. A.; Rack, A.; Cocks, A. C. F.


    Solidification cracking is a key phenomenon associated with defect formation during welding. To elucidate the failure mechanisms, solidification cracking during arc welding of steel are investigated in situ with high-speed, high-energy synchrotron X-ray radiography. Damage initiates at relatively low true strain of about 3.1% in the form of micro-cavities at the weld subsurface where peak volumetric strain and triaxiality are localised. The initial micro-cavities, with sizes from 10 × 10‑6 m to 27 × 10‑6 m, are mostly formed in isolation as revealed by synchrotron X-ray micro-tomography. The growth of micro-cavities is driven by increasing strain induced to the solidifying steel. Cavities grow through coalescence of micro-cavities to form micro-cracks first and then through the propagation of micro-cracks. Cracks propagate from the core of the weld towards the free surface along the solidifying grain boundaries at a speed of 2–3 × 10‑3 m s‑1.

  18. The effect of ultrasonic vibration on the solidification of light alloys

    Jian, Xiaogang


    This exposition presents a novel thermodynamical and microstructural modification to light alloys, such as aluminum alloys and magnesium alloys, by ultrasonic vibrations. An experimental apparatus which supplied a powerful 1500 Watts at 20 kHz of ultrasonic power was designed and built. Thermodynamic simulations were carried out using the Scheil model to determine the temperature versus solid fraction curve of the alloys. Thermal analysis shows that, with ultrasonic vibration, the steady growth temperature and the minimum supercooling temperature have been elevated; the recalescence time decreased significantly, which indicates a much slower growth rate of primary fcc aluminum grains. Upon ultrasonic vibration, in A356 alloy, fine globular primary aluminum grains were obtained at an unprecedented level of 20 to 40 mum; superfine globular grains less than 20 mum in size were obtained in the area near the ultrasonic radiator; the morphology of eutectic silicon in the alloy was modified from a coarse acicular plate-like form to a finely dispersed rosette-like form, with significantly reduced length, width, and aspect ratio; fine globular grains were also obtained in other aluminum alloys, including A354, 319, 6063, 6061, 2618 alloys; 670°C is the optimum casting temperature for grain refinement of 2618 alloy; not only did magnesium AM60B alloy experience a reduction in size of primary alpha-Mg grains from 760 mum to about 25˜48 mum in diameter, which is much better than other traditional grain refinement methods, but also the volume fraction of eutectic phases was reduced significantly. The mechanisms for ultrasonic influence on solidification have been studied. It was concluded that acoustically induced heterogeneous nucleation, rather than dendrite fragmentation, played a dominant role in the formation of a globular microstructure; high acoustic amplitude/intensity favors the formation of small, spherical primary aluminum grains; the casting temperature of 630

  19. Rapid Solidification of AB5 Hydrogen Storage Alloys

    Gulbrandsen-Dahl, Sverre


    This doctoral thesis is concerned with rapid solidification of AB5 materials suitable for electrochemical hydrogen storage. The primary objective of the work has been to characterise the microstructure and crystal structure of the produced AB5 materials as a function of the process parameters, e.g. the cooling rate during rapid solidification, the determination of which has been paid special attention to.The thesis is divided in to 6 parts, of which Part I is a literature review, starting wit...

  20. Eutectic-Free Superalloy Made By Directional Solidification

    Schmidt, Deborah Dianne


    By suitable control of thermal conditions in directional-solidification process, supperalloy structural and machine components (e.g., turbine blades) cast with microstructures enhancing resistance to fatigue. Specific version of process and thermal conditions chosen to reduce micro-segregation during solidification and to minimize or eliminate script carbide and eutectic-phase inclusions, which are brittle inclusions found to decrease resistance to fatigue.

  1. Variable-Temperature-Gradient Device for Solidification Research

    Kaukler, W. F.


    Device for research in solidification and crystal growth allows crystallization of melt observed as occurs. Temperature gradient across melt specimen increased or decreased rapidly while solidification front proceeds at constant speed across sample. Device moves sample at same speed, thereby holding position of liquid/solid interface stationary within field of optical microscope. Device, variabletemperature-gradient microscope stage, used to study crystal growth at constant rate while thermal driving force is varied.

  2. Modeling of Cell/Dendrite Transition During Directional Solidification of Ti-AI Alloy Using Cellular Automaton Method

    WANG Kuang-fei; LI Bang-sheng; MI Guo-fa; GUO Jing-jie; FU Heng-zhi


    Solute diffusion controlled solidification model was used to simulate the initial stage cellular to dendrite transition of Ti44AI alloys during directional solidification at different velocities. The simulation results show that during this process, a mixed structure composed of cells and dendrites was observed, where secondary dendrites are absent at facing surface with parallel closely spaced dendrites, which agrees with the previous experimental observa-tion. The dendrite spacings are larger than cellular spacings at a given rate, and the columnar grain spacing sharply increases to a maximum as solidification advance to coexistence zone. In addition, simulation also revealed that decreasing the numbers of the seed causes the trend of unstable dendrite transition to increase. Finally, the main influence factors affecting cell/dendrite transition were analyzed, which could be the change of growth rates resulting in slight fluctuations of liquid composition occurred at growth front. The simulation results are in reasonable agreement with the results of previous theoretical models and experimental observation at low cooling rates.

  3. Proceedings of the 2010 international solidification-stabilization technology forum

    Lake, C.B. [Dalhousie Univ., Halifax, NS (Canada). Dept. of Civil and Resource Engineering; Hills, C.D. [Greenwich Univ. (United Kingdom). Centre for Contaminated Land Remediation] (eds.)


    Solidification/stabilization (S/S) is remediation technology used to manage the risk associated with contaminated soils, wastes, and brownfield sites. Canada is now facing considerable challenges in ensuring that sites impacted by hydrocarbon contaminants are efficiently and effectively remediated. This forum was held to bring together leading researchers and practitioners in S/S remediation technology. Recent advances in research were presented, as well as new developments in the implementation of S/S technologies in the field, and methods of safely stabilizing and using potentially hazardous waste products. The conference was divided into the following 8 sessions: (1) stabilization/solidification of organics, (2) stabilization/solidification case studies, (3) stabilization/solidification of metals, (4) performance assessment, (5) mining applications, (6) new stabilization/solidification applications and approaches, (7) marine/coastal applications, and (8) stabilization/solidification amendments or alternatives. The forum featured 28 presentations, of which 6 have been catalogued separately for inclusion in this database. refs., figs.

  4. Experimental Determination of the Primary Solidification Phase dependency on the solidification velocity for 17 different austenitic stainless steel compositions

    Laursen, Birthe Nørgaard; Olsen, Flemming Ove; Yardy, John


    When studying laser welding of austenitic stainless steel, hot cracking is frequently observed. To prevent hot cracking in laser welded stainless steel it is advantageous to obtain primary solidification of the ferrite phase that subsequently, on cooling, transforms in the solid state...... to the austenite phase.Most stainless steels are weldable by conventional welding techniques. However, during laser weldng the solidification velocities can be very much higher than by conventional welding techniques. By increasing the solidification velocity to a critical value known as the transition velocity......, the primary solidification phase is found to change from ferrite to austenite.A novel laser remelting technique has been modified to enable the transition velocity for laser welded austenitic stainless steels to be deermined experimentally and on the basis of results from 17 different alloy compositions...

  5. Directional solidification of silicon in carbon crucibles by an oscillating crucible technique

    Daud, T.; Dumas, K.A.; Kim, K.M.; Schwuttke, G.H.; Smetana, P.


    Casting of silicon ingots is of importance to the terrestrial photovoltaic industry because of its potential low cost. However, the quality of silicon cast by present techniques is limited by the presence of dislocations and grain boundaries in unseeded growth and by cellular structures with dislocation networks in the case of the seeded growth. To address these concerns, a new method of directional solidification called the Oscillating Crucible Technique (OCT) is developed. During growth, a carbon crucible is oscillated to provide for effective stirring of the melt. This growth technique (seeded growth only), along with material characterization and solar-cell fabrication and testing, is described. Solar-cell efficiencies of up to 13% at 100 mW/cm/sup 2/ are obtained in the single crystalline areas. Minority-carrier diffusion lengths exceeding 100 are measured even in the polycrystalline areas of the wafers. Limitations of the present setup and possible future improvements are discussed.

  6. Dual-scale phase-field simulation of Mg-Al alloy solidification

    Monas, A.; Shchyglo, O.; Höche, D.; Tegeler, M.; Steinbach, I.


    Phase-field simulations of the nucleation and growth of primary α-Mg phase as well as secondary, β-phase of a Mg-Al alloy are presented. The nucleation model for α- and β-Mg phases is based on the “free growth model” by Greer et al.. After the α-Mg phase solidification we study a divorced eutectic growth of α- and β-Mg phases in a zoomed in melt channel between α-phase dendrites. The simulated cooling curves and final microstructures of α-grains are compared with experiments. In order to further enhance the resolution of the interdendritic region a high-performance computing approach has been used allowing significant simulation speed gain when using supercomputing facilities.

  7. The effects of solidification on sill propagation dynamics and morphology

    Chanceaux, L.; Menand, T.


    Sills are an integral part of the formation and development of larger plutons and magma reservoirs. Thus sills are essential for both the transport and the storage of magma in the Earth's crust. However, although cooling and solidification are central to magmatism, their effects on sills have been so far poorly studied. Here, the effects of solidification on sill propagation dynamics and morphology are studied by means of analogue laboratory experiments. Hot fluid vegetable oil (magma analogue), that solidifies during its propagation, is injected as a sill in a colder layered gelatine solid (elastic host rock analogue). The injection flux and temperature are maintained constant during an experiment and systematically varied between each experiment, in order to vary and quantify the amount of solidification between each experiments. The oil is injected directly at the interface between the two gelatine layers. When solidification effects are small (high injection temperatures and fluxes), the propagation is continuous and the sill has a regular and smooth surface. Inversely, when solidification effects are important (low injection temperatures and fluxes), sill propagation is discontinuous and occurs by steps of surface-area creation interspersed with periods of momentary arrest. The morphology of these sills displays folds, ropy structures on their surface, and lobes with imprints of the leading fronts that correspond to each step of area creation. These experiments show that for a given, constant injected volume, as solidification effects increase, the area of the sills decreases, their thickness increases, and the number of propagation steps increases. These results have various geological and geophysical implications. The morphology of sills, such as lobate structures (interpretation of 3D seismic studies in sedimentary basin) and ropy flow structures (field observations) can be related to solidification during emplacement. Moreover, a non-continuous morphology

  8. In Situ Synchrotron X-ray Study of Ultrasound Cavitation and Its Effect on Solidification Microstructures

    Mi, Jiawei; Tan, Dongyue; Lee, Tung Lik


    Considerable progress has been made in studying the mechanism and effectiveness of using ultrasound waves to manipulate the solidification microstructures of metallic alloys. However, uncertainties remain in both the underlying physics of how microstructures evolve under ultrasonic waves, and the best technological approach to control the final microstructures and properties. We used the ultrafast synchrotron X-ray phase contrast imaging facility housed at the Advanced Photon Source, Argonne National Laboratory, US to study in situ the highly transient and dynamic interactions between the liquid metal and ultrasonic waves/bubbles. The dynamics of ultrasonic bubbles in liquid metal and their interactions with the solidifying phases in a transparent alloy were captured in situ. The experiments were complemented by the simulations of the acoustic pressure field, the pulsing of the bubbles, and the associated forces acting onto the solidifying dendrites. The study provides more quantitative understanding on how ultrasonic waves/bubbles influence the growth of dendritic grains and promote the grain multiplication effect for grain refinement.

  9. Continuous and directional solidification technology of titanium alloys with cold crucible

    CHEN Rui-run; DING Hong-sheng; GUO Jing-jie; BI Wei-sheng; FU Heng-zhi


    The experiments of continuous and directional solidification of titanium alloys with cold crucible were carried out in a multifunctional electromagnetic cold crucible apparatus. Parameters and factors influencing the surface crack and macrostructure of titanium alloy ingots were studied. The mechanism of the parameters and factors influencing the surface crack and macrostructure of the ingots were interpreted. The results show that the surface cracks of the prepared ingots decrease with the increase of the input power from 50 to 60 kW or with the increase of the coil turns from 3 to 5 circles. The surface cracks increase with the increase of withdrawal velocity from 3 to 5 mm/min or the height of the primer from 2 to 3 cm, then decrease with the increase of withdrawal velocity from 5 to 8.7 mm/min or the height of the primer from 3 to 4 cm. Coil turns is the most important one in all parameters effect on the surface crack, the input power is more important, then the withdrawal velocity is important and the height of the primer is the least important. Withdrawal velocity is the most important factor affecting the macrostructure, and effects of other factors on macrostructure is slight. With the decrease of velocity from 8.7 to 0.5 mm/min, the quantity of grains reduces, the grain orientation degree becomes small, and the solidification fronts change from concave to plane to convex. The ingot can be directional solidified at velocity of 1 mm/min. The ingot with free surface crack and directional macrostructure is prepared under definite conditions.

  10. Effect of microgravity and magnetic field on the metallic and crystalline structure of magnetostrictive SmFe2 synthesized by unidirectional solidification.

    Okutani, Takeshi; Nagai, Hideaki; Mamiya, Mikito; Shibuya, Masachika; Castillo, Martin


    The Sm-2Fe molten alloy with 1:2 molar ratio was unidirectionally solidified in both microgravity and normal gravity in concurrence with a magnetic flux (0-0.12 T). The compound SmFe2 was produced by the unidirectional solidification in microgravity with a magnetic flux of 0T and exhibited a lamellar microstructure. The average lamellar thickness was 30 mum and each lamella possessed a crystallographic alignment along major axis aligned in the direction of cooling. Unidirectional solidification in microgravity with a magnetic field of 0.04 T produced crystalline SmFe2 and Fe phases. The microstructure of this product was lamellar with an average lamellar thickness of 17 mum and no crystalline alignment. Unidirectional solidification in microgravity with a magnetic flux ranging from 0.06 to 0.12 T and in normal gravity with a magnetic flux ranging from 0 to 0.12 T produced crystalline Sm2Fe17 and Fe. During unidirectional solidification in microgravity without a magnetic flux, few nucleation sites were formed and rapid crystal growth occurred, consequently forming large-grain SmFe2. The produced SmFe2 had a lamellar structure with a dominant crystallographic alignment in the direction of cooling. Convection in the molten state and where a magnetic flux was present caused homogeneous nucleation, forming Sm2Fe17 with a disordered structure and crystalline alignment coinciding with the formation of the dendritic Fe.

  11. The effects of nucleation and solidification mechanisms on the microstructure and thermomechanical response of tin silver copper solder joints

    Arfaei, Babak

    This work examines the nucleation mechanism of Sn in SnAgCu alloys and its effect on the microstructure of those solder joints. The nucleation rate of Sn in a SAC alloy was obtained by simultaneous calorimetric examination of the isothermal solidification of 88 flip chip Sn-Ag-Cu solder joints. Qualitative agreement with classic nucleation theory was observed, although it was concluded that the spherical cap model cannot be applied to explain the structure of nucleus. It was shown that the solidification temperature significantly affects the microstructure; samples that undercooled less than approximately 40oC revealed one or three large Sn grains, while interlaced twinning was observed in the samples that solidified at lower temperatures. In order to better understand the effect of microstructure on the thermomechanical properties of solder joints, a study of the dependence of room temperature shear fatigue lifetime on Sn grain number and orientation was conducted. This study examined the correlations of variations in fatigue life of solder balls with the microstructure of Sn-Ag-Cu solder. The mean fatigue lifetime was found to be significantly longer for samples with multiple Sn grains than for samples with single Sn grains. For single grain samples, correlations between Sn grain orientation (with respect to the loading direction) and lifetime were observed, providing insight on early failures in SnAgCu solder joints. Correlations between the lifetimes of single Sn grained, SAC205 solder joints with differences in Ag3Sn and Cu6Sn5 precipitate microstructures were investigated. It was found that Ag3Sn precipitates were highly segregated from Cu6Sn 5 precipitates on a length scale of approximately twenty microns. Furthermore, large (factor of two) variations of the Sn dendrite arm size were observed within given samples. Such variations in values of dendrite arm size within a single sample were much larger than observed variations of this parameter between

  12. Stabilization/solidification of TSCA incinerator ash

    Spence, R.D.; Trotter, D.R.; Francis, C.L.; Morgan, I.L.


    Stabilization/solidification is a well-known waste treatment technique that utilizes different additives and processes. The Phoenix Ash Technology of the Technical Innovation Development Engineering Company is such a technique that uses Cass C fly ash and mechanical pressure to make brick waste forms out of solid wastes, such as the bottom ash from the Toxic Substances Control Act incinerator at the Oak Ridge K-25 Site. One advantage of this technique is that no volume increase over the bulk volume of the bottom ash occurs. This technique should have the same high pH stabilization for Resource Conservation and Recovery Act metals as similar techniques. Also, consolidation of the bottom ash minimizes the potential problems of material dispersion and container corrosion. The bottom ash was spiked with {sup 99}{Tc} to test the effectiveness of the bricks as a physical barrier. The {sup 99}{Tc} leachability index measured for these bricks was 6.8, typical for the pertechnetate anion in cementitious waste forms, indicating that these bricks have accessible porosity as high as that of other cementitious waste forms, despite the mechanical compression, higher waste form density, and water resistant polymer coating.

  13. Crustal fingering: solidification on a moving interface

    Fu, Xiaojing; Jimenez-Martinez, Joaquin; Porter, Mark; Cueto-Felgueroso, Luis; Juanes, Ruben


    Viscous fingering-the hydrodynamic instability that takes place when a less viscous fluid displaces a more viscous fluid-is a well known phenomenon. Motivated by the formation of gas hydrates in seafloor sediments and during the ascent of gas bubbles through ocean water, here we study the interplay of immiscible viscous fingering with solidification of the evolving unstable interface. We present experimental observations of the dynamics of a bubble of Xenon in a water-filled and pressurized Hele-Shaw cell. The evolution is controlled by two processes: (1) the formation of a hydrate "crust" around the bubble, and (2) viscous fingering from bubble expansion. To reproduce the experimental observations, we propose a phase-field model that describes the nucleation and thickening of a porous solid shell on a moving gas-liquid interface. We design the free energy of the three-phase system (gas-liquid-hydrate) to rigorously account for interfacial effects, mutual solubility, and phase transformations (hydrate formation and disappearance). We introduce a pseudo-plasticity model with large variations in viscosity to describe the plate-like rheology of the hydrate shell. We present high-resolution numerical simulations of the model, which illustrate the emergence of complex "crustal fingering" patterns as a result of gas fingering dynamics modulated by hydrate growth at the interface.

  14. Onset of sidebranching in directional solidification.

    Echebarria, Blas; Karma, Alain; Gurevich, Sebastian


    We use a computationally efficient phase-field formulation [B. Echebarria, Phys. Rev. E 70, 061604 (2004)] to investigate the origin and dynamics of sidebranching in directional solidification for realistic parameters of a dilute alloy previously studied experimentally [M. Gorgelin and A. Pocheau, Phys. Rev. E 57, 3189 (1998)]. Sidebranching is found to result either from noise amplification or from deterministic oscillations that exist both in two dimensions and in a three-dimensional thin-sample geometry. The oscillatory branch of growth solutions bifurcates subcritically from the main steady-state branch of solutions and exists over a finite range of large array spacings. In contrast, noise-induced sidebranching is associated with a smooth transition where the sidebranching amplitude increases exponentially with spacing up to nonlinear saturation due to the overlap of diffusion fields from neighboring cells, as observed experimentally. In the latter case where sidebranching is noise-induced, we find that increasing the externally imposed thermal gradient reduces the onset velocity and wavelength of sidebranching, as also observed experimentally. We show that this counterintuitive effect is due to tip blunting with increasing thermal gradient that promotes noise amplification in the tip region.

  15. Interface Pattern Selection in Directional Solidification

    Trivedi, Rohit; Tewari, Surendra N.


    The central focus of this research is to establish key scientific concepts that govern the selection of cellular and dendritic patterns during the directional solidification of alloys. Ground-based studies have established that the conditions under which cellular and dendritic microstructures form are precisely where convection effects are dominant in bulk samples. Thus, experimental data can not be obtained terrestrially under pure diffusive regime. Furthermore, reliable theoretical models are not yet possible which can quantitatively incorporate fluid flow in the pattern selection criterion. Consequently, microgravity experiments on cellular and dendritic growth are designed to obtain benchmark data under diffusive growth conditions that can be quantitatively analyzed and compared with the rigorous theoretical model to establish the fundamental principles that govern the selection of specific microstructure and its length scales. In the cellular structure, different cells in an array are strongly coupled so that the cellular pattern evolution is controlled by complex interactions between thermal diffusion, solute diffusion and interface effects. These interactions give infinity of solutions, and the system selects only a narrow band of solutions. The aim of this investigation is to obtain benchmark data and develop a rigorous theoretical model that will allow us to quantitatively establish the physics of this selection process.

  16. A new coupled model for alloy solidification

    LI Daming; LI Ruo; ZHANG Pingwen


    A new coupled model in the binary alloy solidification has been developed. The model is based on the cellular automaton (CA)technique to calculate the evolution of the interface governed by temperature, solute diffusion and Gibbs-Thomson effect. The diffusion equation of temperature with the release of latent heat on the solid/liquid (S/L) interface is valid in the entire domain.The temperature diffusion without the release of latent heat and solute diffusion are solved in the entire domain. In the interface cells, the energy and solute conservation, thermodynamic and chemical potential equilibrium are adopted to calculate the temperature, solid concentration, liquid concentration and the increment of solid fraction. Compared with other models where the release of latent heat is solved in implicit or explicit form according to the solid/liquid (S/L) interface velocity, the energy diffusion and the release of latent heat in this model are solved at differentscales, I.e. The macro-scale and micro-scale. The variation ofsolid fraction in this model is solved using several algebraicrelations coming from the chemical potential equilibrium andthermodynamic equilibrium which can be cheaply solved insteadof the calculation of S/L interface velocity. With the assumptionof the solute conservation and energy conservation, the solidfraction can be directly obtained according to the thermodynamicdata. This model is natural to be applied to multiple (>2)spatial dimension case and multiple (>2) component alloy. Themorphologies of equiaxed dendrite are obtained in numericalexperiments.

  17. Preparation of the initial solid liquid interface and melt in directional solidification

    Nguyen Thi, H.; Drevet, B.; Debierre, J. M.; Camel, D.; Dabo, Y.; Billia, B.


    The preparation of the initial conditions (solid-liquid interface morphology and solute segregation in the liquid phase) on which growth is started is a very critical step in directional-solidification experiments. Dedicated experiments on Al-1.5 wt% Ni consisting in directional melting followed by thermal stabilisation with different lengths, show that precise control is in practice not straightforward. Indeed, in the mushy zone created by melting the original solid sample, temperature gradient zone melting (TGZM) causes migration of solute-rich liquid droplets and channels. A model is proposed to describe this process and validate the physical interpretation of the experiments through numerical simulation. Knowing the status of the preparation, the intriguing observations in the partially melted region of the Al-1.5 wt% Ni alloys solidified in the Advanced Gradient Heating Facility of European Space Agency during the LMS and STS-95 space missions can now be explained. Finally, the influence of initial interface morphology and melt segregation on directional-solidification transient is discussed, based on a comparison of Al-Ni alloys with hypoeutectic Al-Li alloys previously grown on Earth and in space. It follows that for experiments achieved on original rods with equiaxed microstructure, the efficiency of the preparatory melting and stabilisation phases can be evaluated from the solute macrosegregation profile in the region in between the non-melted solid and directional solidification. The major conclusion is that when the melt is mixed by fluid flow, the initial conditions are near to their asymptotic state at the end of TGZM whereas, when solute diffusion is the mode of transport into the bulk liquid, the condition of homogeneous melt becomes limiting and too much time-consuming to be fulfilled, which in particular holds for the 3D-experiments carried out in the reduced-gravity environment of space.

  18. Grain size effect on the thermal-induced martensitic transformation in polycrystalline Cu-based shape memory alloys

    la Roca, Paulo Matías; Isola, Lucio Manuel; Sobrero, Cesar Enrique; Vermaut, P.; Malarria, Jorge Alberto


    In Cu-based SMA alloys, the grain size (d) effect on the martensitic transformation temperature was investigated for a wide range of d. Specimens were prepared by different heat treatments in order to create a range of grain sizes, from about 500 nm (ribbons and tapes obtained by rapid solidification techniques) up to 6 mm diameter single-crystals (grown by the Bridgman method). Information obtained from the literature was also included in the set of analyzed experimental data. The reduction ...

  19. Grain Refinement of Freeform Fabricated Ti-6Al-4V Alloy Using Beam/Arc Modulation

    Mitzner, Scott; Liu, Stephen; Domack, Marcia S.; Hafley, Robert A.


    Grain refinement can significantly improve the mechanical properties of freeform-fabricated Ti-6Al-4V alloy, promoting increased strength and enhanced isotropy compared with coarser grained material. Large beta-grains can lead to a segregated microstructure, in regard to both alpha-phase morphology and alpha-lath orientation. Beam modulation, which has been used in conventional fusion welding to promote grain refinement, is explored in this study for use in additive manufacturing processes including electron beam freeform fabrication (EBF(sup 3)) and gas-tungsten arc (GTA) deposition to alter solidification behavior and produce a refined microstructure. The dynamic molten pool size induced by beam modulation causes rapid heat flow variance and results in a more competitive grain growth environment, reducing grain size. Consequently, improved isotropy and strength can be achieved with relatively small adjustments to deposition parameters.

  20. Grain structure evolution in Inconel 718 during selective electron beam melting

    Helmer, H.; Bauereiß, A., E-mail:; Singer, R.F.; Körner, C.


    Selective electron beam melting (SEBM) is an additive manufacturing method where complex parts are built from metal powders in layers of typically 50 µm. An electron beam is used for heating (about 900 °C building temperature) and selective melting of the material. The grain structure evolution is a result of the complex thermal and hydrodynamic conditions in the melt pool. We show how different scanning strategies can be used to produce either a columnar grain structure with a high texture in building direction or an equiaxed fine grained structure. Numerical simulations of the selective melting process are applied to study the fundamental mechanisms responsible for differing grain structures. It is shown, that the direction of the thermal gradient during solidification can be altered by scanning strategies to acquire either epitaxial growth or stray grains. We show that it is possible to locally alter the grain structure of a part, thus allowing tailoring of the mechanical properties.

  1. Fabrication of TiC-Reinforced Composites by Vacuum Arc Melting: TiC Mode of Reprecipitation in Different Molten Metals and Alloys

    Karantzalis, A. E.; Arni, Z.; Tsirka, K.; Evangelou, A.; Lekatou, A.; Dracopoulos, V.


    TiC crystals were developed and grown through a melt dissolution and reprecipitation mechanism, in different alloy matrices (pure Fe, 316L, Fe-22 at.%Al, Ni-25at.%Al, and pure Co) through the use of Vacuum Arc Melting (VAM) process. The TiC surfaces exhibit a characteristic faceted mode of growth which is explained in terms of classic nucleation and crystal growth theories and is related with the well-known Jackson factor of crystal growth. Different morphologies of the finally solidified TiC grains are observed (dendritic, radially grown, isolated blocky crystals, particle clusters), the establishment of which may be most likely related with solidification progress, cooling rate, and melt compositional considerations. An initial, rough and qualitative phase identification shows a variety of compounds, and the attempts to define specific phase crystallographic-orientational relationships led to rather random results.

  2. Effects of cooling rate on solidification behavior of dilute Al-Sc and Al-Sc-Zr solid solution

    金头男; 聂祚仁; 徐国富; 阮海琼; 杨军军; 付静波; 左铁镛


    Six alloys with different compositions of Al-0.1%Sc, Al-0.3%Sc, Al-0.3%Zr, Al-0.1% Sc-0. 1%Zr,Al-0.3%Sc-0.1%Zr and Al-0.3%Sc-0.3%Zr were prepared by casting in a wedge shaped copper mould. The hardness test, microstructure observation, and DSC thermal analysis were applied to fully investigate the solidification behavior of the wedge tip (whose cooling rate is 1 000 K/s) and the top surface (cooling rate 100 K/s) of each casting. The results show that the cast structures in the hypoeutectic region of Al-Sc alloys are slightly affected by cooling rates during the solidification. In the case of hypereutectic alloy of Al-0.3%Sc-0.3%Zr , the cast grains were remarkably refined under the condition of a 100 K/s cooling rate, however, under a 1 000 K/s cooling rate condition,solute atoms contribute nothing to the grain-refinement, due to the eutectic concentration becomes higher. The hardness can be improved to a greater degree by Sc single addition, compared to single Zr addition, but it can be improved even greater when Sc added together with Zr. It is sensitive to cooling rate, the higher the cooling rate, the greater the hardness. By combining the results of TEM examination and DSC analysis, it can be seen that a supersaturated Al solid solution forms during the solidification, and the solubility of Sc in Al solution can be improved by increasing the cooling rate.

  3. Combination of microscopic model and VoF-multiphase approach for numerical simulation of nodular cast iron solidification

    Subasic, E.; Huang, C.; Jakumeit, J.; Hediger, F.


    The ongoing increase in the size and capacity of state-of-the-art wind power plants is highlighting the need to reduce the weight of critical components, such as hubs, main shaft bearing housings, gear box housings and support bases. These components are manufactured as nodular iron castings (spheroid graphite iron, or SGI). A weight reduction of up to 20% is achievable by optimizing the geometry to minimize volume, thus enabling significant downsizing of wind power plants. One method for enhancing quality control in the production of thick-walled SGI castings, and thus reducing tolerances and, consequently, enabling castings of smaller volume is via a casting simulation of mould filling and solidification based on a combination of microscopic model and VoF-multiphase approach. Coupled fluid flow with heat transport and phase transformation kinetics during solidification is described by partial differential equations and solved using the finite volume method. The flow of multiple phases is described using a volume of fluid approach. Mass conservation equations are solved separately for both liquid and solid phases. At the micro-level, the diffusion-controlled growth model for grey iron eutectic grains by Wetterfall et al. is combined with a growth model for white iron eutectic grains. The micro-solidification model is coupled with macro-transport equations via source terms in the energy and continuity equations. As a first step the methodology was applied to a simple geometry to investigate the impact of mould-filling on the grey-to-white transition prediction in nodular cast iron.

  4. Interactions between grain boundary faceting, migration and grain rotation: Color group and molecular dynamics simulation approaches

    Huang, Yue

    Color group theory and molecular dynamics (MD) simulations were used to study the faceting and rotation of grains in nanocrystalline materials and their interactions. Color group arguments were used to determine symmetry-dictated extrema with respect to misorientation of the grains and with respect to grain boundary normal orientations. MD simulations were used to study the evolution of the system and to elucidate the interactions between grain rotation and faceting in nano-scale systems. The systems of study were fcc bicrystalline systems with two grains sharing their [110] directions. Two geometric parameters were studied: the misorientation between two grains with a common rotation axis in the [110] direction of both grains, and the grain boundary normal orientation of fcc (110) tilt grain boundaries. The symmetry-dictated extremum (SDE) with respect to misorientation around both grains' [110] direction is 90 degrees. The SDE with respect to GB normal orientations for (110) tilt GBs are located on top of the color and classical mirror planes of their dichromatic patterns. By using periodic boundary conditions and a cylindrical embedded grain structure in our simulations, grains are only free to vary the misorientation between grains around the common [110] direction, and the normal of the grain boundaries are always perpendicular to both grains [110] direction. All SDE studied in our simulation are observed to be local energy minimum states. We observed the systems reducing their excess energy through three main modes: forming facets at the boundaries, rotating between the two grains, and reduction of grain boundary area through grain shrinkage. Facets are formed in low-energy grain boundaries and oscillating rotation occurred when the initial misorientation was not a SDE. A new algorithm was developed to quantitatively measure the grain rotation. The ovsered rotations are not rigid-body rotations and have strong interaction with faceting. Systems with lower

  5. Optimisation of the microstructure of YBa{sub 2}Cu{sub 3}O{sub 7-{delta}} superconducting ceramics textured by horizontal solidification. Effects of a magnetic field applied vertically during the solidification process; Optimisation de la microstructure de ceramiques supraconductrices texturees YBa{sub 2}Cu{sub 3}O{sub 7-{delta}} par solidification horizontale. Effets de l`application d`un champ magnetique vertical au cours de la croissance

    Durand, L.


    We have shown that il was possible to disperse in a very homogeneous way, into the 123 matrix, 211 particles regular in size around 1{mu}m, by directional solidification of a mixture of 123 plus 211 sol-gel powders. The addition of 0.5 wt% of Pt lo this precursor mixture has permitted us to refine further the size of the 211 particles. Moreover, we have established that the finer the 123 powder and the faster the heating rate, the smaller the 211 particles. From another hand, we have found that the size and the microstructure of the solidified single domain was dependant upon numerous parameters. In particular, we have noted that if the cold pressed green body was not sintered before being melted, grains of solid CuO appeared into the liquid which next hardly recombined with it, giving rise to a comb like solidification front, witness of a local un-stability. Moreover, in these particular conditions, the 123 formed was found to be understoichiometric in Cu and the single domains severely limited in extension. Finally, we have observed that the application of a 4 T magnetic field during the solidification of a bar the longest axis of which was horizontal tended to align the c axis of the 123 grains parallel to the field. Incidentally, we have discovered that in the same conditions, the 211 particles trapped into the 123 matrix were also preferentially oriented. (author).

  6. Effect of centrifugal counter-gravity casting on solidification microstructure and mechanical properties of A357 aluminum alloy

    Li Xinlei


    Full Text Available To investigate the influence of Centrifugal Counter-gravity Casting (C3 process on the solidification microstructure and mechanical properties of the casting, A357 aluminum alloy samples were produced by different process conditions under C3. The results show that C3 has better feeding capacity compared with the vacuum suction casting; and that the mechanical vibration and the convection of melts formed at the centrifugal rotation stage suppress the growth of dendrites, subsequently resulting in the refinement of grains and the improvement of mechanical properties, density and hardness. A finer grain and higher strength can be obtained in the A357 alloy by increasing centrifugal radius and rotational speed. However, casting defects will appear near the rotational axis and the mechanical properties will decrease once the rotational speed exceeds 150 r·min-1.

  7. The role of ultrasonic cavitation in refining the microstructure of aluminum based nanocomposites during the solidification process.

    Xuan, Yang; Nastac, Laurentiu


    Recent studies showed that the microstructure and mechanical properties of aluminum based nanocomposites can be significantly improved when ultrasonic cavitation and solidification processing is used. This is because ultrasonic cavitation processing plays an important role not only in degassing and dispersion of the nanoparticles, but also in breaking up the dendritic grains and refining the as-cast microstructure. In the present study, A356 alloy and Al2O3 nanoparticles are used as the matrix alloy and the reinforcement, respectively. Nanoparticles were added into the molten A356 alloy and dispersed via ultrasonic cavitation processing. Ultrasonic cavitation was applied over various temperature ranges during molten alloy cooling and solidification to investigate the grain structure formation and the nanoparticle dispersion behavior. Optical Microscopy and Scanning Electron Microscopy were used to investigate in detail the differences in the microstructure characteristics and the nanoparticle distribution. Experimental results indicated that the ultrasonic cavitation processing and Al2O3 nanoparticles play an important role for microstructure refinement. In addition, it was shown in this study that the Al2O3 nanoparticles modified the eutectic phase. Copyright © 2017 Elsevier B.V. All rights reserved.

  8. Influence of solidification rate on the microstructure of(Nd,Dy)12.8(Fe,Co)80.7B6.5 cast strips

    LIU Hanqiang; WANG Biao; HAN Guangbing; GAO Ruwei


    The influence of solidification rate on the microstructure of (Nd,Dy)12.8(Fe,Co)80.7B6.5 cast strips was reported in this paper. The strips prepared at different wheel speeds were analyzed by X-ray diffraction (XRD). The microstructure of the strips was investigated by backscattered scanning microscope (BSM). The XRD results show that the strips are mainly composed of the main phase (T1) existing apparent alignment along [00L]. The thickness of T1 columnar grains is larger when the solidification rate is lower and the over-small isotropic microcrystalline appear on the cooling surface of the strips when the solidification rate is too high. The adequate wheel speed for obtaining the optimum microstructure of the strips is about V = 2.0 m/s. The strip prepared at V = 2.0 m/s possesses suitable thickness and the highest alignment degree of T1 columnar grains, uniformly distributed Nd-rich phase, and no existence of α-Fe phase. This kind of cast strip is an ideal starting material for preparing sintered magnets with high magnetic properties.

  9. Utilization of granular solidification during terrestrial locomotion of hatchling sea turtles.

    Mazouchova, Nicole; Gravish, Nick; Savu, Andrei; Goldman, Daniel I


    Biological terrestrial locomotion occurs on substrate materials with a range of rheological behaviour, which can affect limb-ground interaction, locomotor mode and performance. Surfaces like sand, a granular medium, can display solid or fluid-like behaviour in response to stress. Based on our previous experiments and models of a robot moving on granular media, we hypothesize that solidification properties of granular media allow organisms to achieve performance on sand comparable to that on hard ground. We test this hypothesis by performing a field study examining locomotor performance (average speed) of an animal that can both swim aquatically and move on land, the hatchling Loggerhead sea turtle (Caretta caretta). Hatchlings were challenged to traverse a trackway with two surface treatments: hard ground (sandpaper) and loosely packed sand. On hard ground, the claw use enables no-slip locomotion. Comparable performance on sand was achieved by creation of a solid region behind the flipper that prevents slipping. Yielding forces measured in laboratory drag experiments were sufficient to support the inertial forces at each step, consistent with our solidification hypothesis.

  10. Modeling of Ti-W Solidification Microstructures Under Additive Manufacturing Conditions

    Rolchigo, Matthew R.; Mendoza, Michael Y.; Samimi, Peyman; Brice, David A.; Martin, Brian; Collins, Peter C.; LeSar, Richard


    Additive manufacturing (AM) processes have many benefits for the fabrication of alloy parts, including the potential for greater microstructural control and targeted properties than traditional metallurgy processes. To accelerate utilization of this process to produce such parts, an effective computational modeling approach to identify the relationships between material and process parameters, microstructure, and part properties is essential. Development of such a model requires accounting for the many factors in play during this process, including laser absorption, material addition and melting, fluid flow, various modes of heat transport, and solidification. In this paper, we start with a more modest goal, to create a multiscale model for a specific AM process, Laser Engineered Net Shaping (LENS™), which couples a continuum-level description of a simplified beam melting problem (coupling heat absorption, heat transport, and fluid flow) with a Lattice Boltzmann-cellular automata (LB-CA) microscale model of combined fluid flow, solute transport, and solidification. We apply this model to a binary Ti-5.5 wt pct W alloy and compare calculated quantities, such as dendrite arm spacing, with experimental results reported in a companion paper.

  11. Impact of the Solidification Rate on the Chemical Composition of Frozen Cryolite Bath

    Sándor Poncsák


    Full Text Available Solidification of cryolite (Na3AlF6-based bath takes place at different rates along the sideledge, and around alumina rafts and new anodes. The solidification rate has a significant impact on the structure and the chemical composition that determine the thermal conductivity and thus the thickness of sideledge, or the duration of the existence of the temporary frozen bath layers in other cases. Unfortunately, samples that can be collected in industrial cells are formed under unknown, spatially and temporally varying conditions. For this reason, frozen bath samples were created under different heat flux conditions in a well-controlled laboratory environment using the so-called cold finger technique. The samples were analyzed by X-ray Diffractometer (XRD and Scanning Electron Microscope (SEM in Back Scattering (BS mode in order to obtain spatial distribution of chemical composition. Results were correlated with structural analysis. XRD confirmed our earlier hypothesis of recrystallization of cryolite to chiolite under medium heat flux regime. Lower α-alumina, and higher γ-alumina content in the samples obtained with very high heating rate suggest that fast cooling reduces α–γ conversion. In accordance with the expectation, SEM-BS revealed significant variation of the Na/Al ratio in the transient sample.

  12. Rapid solidification and dendrite growth of ternary Fe-Sn-Ge and Cu-Pb-Ge monotectic alloys


    The phase separation and dendrite growth characteristics of ternary Fe-43.9%Sn- 10%Ge and Cu-35.5%Pb-5%Ge monotectic alloys were studied systematically by the glass fluxing method under substantial undercooling conditions. The maximum undercoolings obtained in this work are 245 and 257 K, respectively, for these two alloys. All of the solidified samples exhibit serious macrosegregation, indicating that the homogenous alloy melt is separated into two liquid phases prior to rapid solidification. The solidification structures consist of four phases including α-Fe, (Sn), FeSn and FeSn2 in Fe-43.9%Sn-10%Ge ternary alloy, whereas only (Cu) and (Pb) solid solution phases in Cu-35.5%Pb-5%Ge alloy under different undercool- ings. In the process of rapid monotectic solidification, α-Fe and (Cu) phases grow in a dendritic mode, and the transition "dendrite→monotectic cell" happens when alloy undercoolings become sufficiently large. The dendrite growth velocities of α-Fe and (Cu) phases are found to increase with undercooling according to an exponential relation.

  13. Rapid solidification and dendrite growth of ternary Fe-Sn-Ge and Cu-Pb-Ge monotectic alloys

    ZHANG XueHua; RUAN Ying; WANG WeiLi; WEI BingBo


    The phase separation and dendrite growth characteristics of ternary Fe-43.9%Sn- 10%Ge and Cu-35.5%Pb-5%Ge monotectic alloys were studied systematically by the glass fluxing method under substantial undercooling conditions. The maximum undercoolings obtained in this work are 245 and 257 K, respectively, for these two alloys. All of the solidified samples exhibit serious macrosegregation, indicating that the homogenous alloy melt is separated into two liquid phases prior to rapid solidification. The solidification structures consist of four phases including α-Fe, (Sn), FeSn and FeSn2 in Fe-43.9%Sn-10%Ge ternary alloy, whereas only (Cu) and (Pb) solid solution phases in Cu-35.5%Pb-5%Ge alloy under different undercoolings. In the process of rapid monotectic solidification, α-Fe and (Cu) phases grow in a dendritic mode, and the transition "dendrite→monotectic cell" happens when alloy undercoolings become sufficiently large. The dendrite growth velocities of α-Fe and (Cu) phases are found to increase with undercooling according to an exponential relation.

  14. Shape sensitivity analysis in numerical modelling of solidification

    E. Majchrzak


    Full Text Available The methods of sensitivity analysis constitute a very effective tool on the stage of numerical modelling of casting solidification. It is possible, among others, to rebuilt the basic numerical solution on the solution concerning the others disturbed values of physical and geometrical parameters of the process. In this paper the problem of shape sensitivity analysis is discussed. The non-homogeneous casting-mould domain is considered and the perturbation of the solidification process due to the changes of geometrical dimensions is analyzed. From the mathematical point of view the sensitivity model is rather complex but its solution gives the interesting information concerning the mutual connections between the kinetics of casting solidification and its basic dimensions. In the final part of the paper the example of computations is shown. On the stage of numerical realization the finite difference method has been applied.

  15. Simulation of shrinkage cavity formation during solidification of binary alloy

    T. Skrzypczak


    Full Text Available Presented paper is focused on numerical modeling of binary alloy solidification process with connection to shrinkage cavity formation phenomenon. Appropriate matching of cooling parameters during solidification process of the cast with raiser is essential to obtain suitable properties of the manufactured part. Localization, structure and depth of the shrinkage cavity is connected to these parameters. The raiser is removed after process, so defect localization in the top part of the manufactured element is of great importance. Mathematical model of solidification process is presented in the paper. The main focus is put on the algorithm of shrinkage cavity creation process. On the basis of mathematical model the numerical approach using finite element method is proposed. On the base of mathematical and numerical model computer program is made. It is able to perform simulation of the shrinkage cavity formation in 2D region. Shape and localization of shrinkage cavity obtained from simulation is compared to defect which was created during experiment.

  16. Matemathical description of solidification cooling curves of pure metals

    Arno Müller


    Full Text Available The introduction of an "incubation time" to the Schwarz classical mathematical description of metals solidification, resulted in a new model called Modified Schwarz Model. By doing so it was possible to identify and quantify the "delay time" that separates the two heat waves traveling independently in a casting during the solidification: the Supercooled / Superheated Liquid and the Solid / Liquid. The thermal shock produced in the initial stage of the undercooling generation process, can be used as an important parameter in the forecasting of the solidification's behavior of pure metals and alloys, when changing mold's materials, pouring and ambient temperatures. The hypercooling proneness degree of metals and alloys, can also be calculated.

  17. Non-equilibrium solidification of undercooled droplets during atomization process

    Prashant Shukla; R K Mandal; S N Ojha


    Thermal history of droplets associated with gas atomization of melt has been investigated. A mathematical model, based on classical theory of heterogeneous nucleation and volume separation of nucleants among droplets size distribution, is described to predict undercooling of droplets. Newtonian heat flow condition coupled with velocity dependent heat transfer coefficient is used to obtain cooling rate before and after nucleation of droplets. The results indicate that temperature profile of droplets in the spray during recalescence, segregated and eutectic solidification regimes is dependent on their size and related undercooling. The interface temperature during solidification of undercooled droplets rapidly approaches the liquidus temperature of the alloy with a subsequent decrease in solid–liquid interface velocity. A comparison in cooling rates of atomized powder particles estimated from secondary dendrite arm spacing measurements are observed to be closer to those predicted from the model during segregated solidification regime of large size droplets.

  18. Stabilization/Solidification Remediation Method for Contaminated Soil: A Review

    Tajudin, S. A. A.; Azmi, M. A. M.; Nabila, A. T. A.


    Stabilization/Solidification (S/S) is typically a process that involves a mixing of waste with binders to reduce the volume of contaminant leachability by means of physical and chemical characteristics to convert waste in the environment that goes to landfill or others possibly channels. Stabilization is attempts to reduce the solubility or chemical reactivity of the waste by changing the physical and chemical properties. While, solidification attempt to convert the waste into easily handled solids with low hazardous level. These two processes are often discussed together since they have a similar purpose of improvement than containment of potential pollutants in treated wastes. The primary objective of this review is to investigate the materials used as a binder in Stabilization/Solidification (S/S) method as well as the ability of these binders to remediate the contaminated soils especially by heavy metals.

  19. Inverse thermal analysis method to study solidification in cast iron

    Dioszegi, Atilla; Hattel, Jesper


    Solidification modelling of cast metals is widely used to predict final properties in cast components. Accurate models necessitate good knowledge of the solidification behaviour. The present study includes a re-examination of the Fourier thermal analysis method. This involves an inverse numerical...... solution of a 1-dimensional heat transfer problem connected to solidification of cast alloys. In the analysis, the relation between the thermal state and the fraction solid of the metal is evaluated by a numerical method. This method contains an iteration algorithm controlled by an under relaxation term...... was developed in order to investigate the thermal behaviour of the solidifying metal. Three cylindrically shaped cast samples surrounded by different cooling materials were introduced in the same mould allowing a common metallurgical background for samples solidifying at different cooling rates. The proposed...

  20. In-Situ Analysis of Coarsening during Directional Solidification Experiments in High-Solute Aluminum Alloys

    Ruvalcaba, D.; Mathiesen, R.H.; Eskin, D.G.; Arnberg, L.; Katgerman, L.


    Coarsening within the mushy zone during continuous directional solidification experiments was studied on an Al-30 wt pct Cu alloy. High brilliance synchrotron X-radiation microscopy allowed images to be taken in-situ during solidification. Transient conditions were present during directional solidif

  1. Application of modern software packages to calculating the solidification of high-speed steels

    Morozov, S. I.


    The solidification of high-speed steels is calculated with the Pandat and JMatPro software packages. The results of calculating equilibrium and nonequilibrium solidification are presented and discussed. The nonequilibrium solidification is simulated using the Shelley-Gulliver model. The fraction of carbides changes as a function of the carbon content in the steels.

  2. Modelling of convection during solidification of metal and alloys

    A K Singh; R Pardeshi; B Basu


    The role of convection during solidification is studied with the help of a mathematical model. The effect of various mush models on convection and consequent macrosegregation is examined with the help of numerical simulations. The predicted macrosegregation profiles are compared with published experimental data. Subsequently, the importance of proper auxiliary relationship for thermo-solutal coupling in the mushy region is highlighted through some careful numerical simulations. Finally, the role of material parameters on double-diffusive convection is illustrated through comparative study of solidification of aqueous ammonium chloride, iron-carbon and lead-tin binary systems. Important results of these studies are presented and discussed.

  3. Modeling solidification structure evolution and microsegregation under pressure condition

    Qiang Li; Qiaoyi Guo; Rongde Li


    Solidification microstructure and microsegregation were simulated under a constant pressure condition using the cellular automaton method. First, a single dendrite evolution was simulated and compared under pressure condition and under normal condition,respectively. The solidification microstructure and microsegregation were then simulated. Through simulation, it may be concluded that if the growth direction of the dendrite is parallel to the pressure direction, dendrite growth will be hindered. On the other hand,pressure has no influence on the dendrite evolution. However, when two dendrites grow in close contact, solute enrichment occurs in the dendrites, which hinders the growth of the dendrites. In addition, the solute is preferentially enriched along the pressure direction.

  4. Heat Transfer and Its Effect on Solidification in Combined Mould

    QIU Sheng-tao; TAO Hong-biao; TANG Hong-wei; ZHANG Hui; ZHAO Pei


    The nucleation can be enhanced by decreasing the superheat of molten steel, thus reducing temperature gradient on the solidification front can retard the growth of columnar crystals and enlarge the equiaxed zone in continuous casting strand. The billets with equiaxed zone more than 90% were cast with a combined mould and the heatflux was measured. The heat transfer of the combined mould and traditional mould was compared. The results show that under same casting conditions, the temperature gradient on the solidification front in the combined mould is smaller than that in traditional mould at a distance within 0-150 mm from the meniscus.

  5. Solidification microstructure of directionally solidified superalloy under high temperature gradient


    The effect of solidification rate on the microstructure development of nickel-based superalloy under the temperature gradient of 500 K·cm-1 was studied. The results show that, with the increase of directional solidification rate from 50 to 800 μm·s-1, both the primary and the secondary dendrite arm spacings of the alloy decrease gradually, and the dendrite morphologies transform from coarse dendrite to superfine dendrite. The sizes of all precipitates in the superalloy decrease gradually. The morphology of ...

  6. Entropy production in coarse grained Vlasov equations

    Morawetz, K. [Grand Accelerateur National d' Ions Lourds (GANIL), LPC-ISMRA, 14 - Caen (France); Walke, R. [Rostock Univ., Fachbereich Physick (Germany)


    The Vlasov equation is analyzed for coarse grained distributions. This coarse graining resembles a finite width of test-particles as used in numerical implementations. It is shown that this coarse grained distribution obeys a kinetic equation similar to the Vlasov equation, but with additional terms. These terms give rise to entropy production indicating dissipative features. The reason is a nonlinear mode coupling due to the finite width of the test-particles. The interchange of coarse graining and dynamical evolution is discussed with the help of an exactly solvable model and practical consequences are worked out. By calculating analytically the stationary solution we can show that a sum of modified Boltzmann-like distributions is approached dependent on the initial distribution. This behavior is independent of degeneracy and only controlled by the width of test-particles. The condition for approaching a stationary solution is derived in that the coarse graining energy given by momentum coarse graining should be smaller than a quarter of the kinetic energy. Observable consequences of this coarse graining are: (i) In the thermodynamics the coarse graining leads to spatial correlations in observables. (ii) Too large radii of nucleus in self-consistent treatments are observed and an explicit correction term appears in the Thomas Fermi equation. (iii) The momentum coarse graining translates into a structure term in the response function and resembles to a certain extent vertex correction correlations or internal structure effects. (iv) The coarse graining which is numerically unavoidable leads to a modified centroid energy and higher damping width of collective modes. The numerical codes should be revised in that a refolding is proposed. (author)

  7. Potential Flow Interactions With Directional Solidification

    Buddhavarapu, Sudhir S.; Meiburg, Eckart


    The effect of convective melt motion on the growth of morphological instabilities in crystal growth has been the focus of many studies in the past decade. While most of the efforts have been directed towards investigating the linear stability aspects, relatively little attention has been devoted to experimental and numerical studies. In a pure morphological case, when there is no flow, morphological changes in the solid-liquid interface are governed by heat conduction and solute distribution. Under the influence of a convective motion, both heat and solute are redistributed, thereby affecting the intrinsic morphological phenomenon. The overall effect of the convective motion could be either stabilizing or destabilizing. Recent investigations have predicted stabilization by a flow parallel to the interface. In the case of non-parallel flows, e.g., stagnation point flow, Brattkus and Davis have found a new flow-induced morphological instability that occurs at long wavelengths and also consists of waves propagating against the flow. Other studies have addressed the nonlinear aspects (Konstantinos and Brown, Wollkind and Segel)). In contrast to the earlier studies, our present investigation focuses on the effects of the potential flow fields typically encountered in Hele-Shaw cells. Such a Hele-Shaw cell can simulate a gravity-free environment in the sense that buoyancy-driven convection is largely suppressed, and hence negligible. Our interest lies both in analyzing the linear stability of the solidification process in the presence of potential flow fields, as well as in performing high-accuracy nonlinear simulations. Linear stability analysis can be performed for the flow configuration mentioned above. It is observed that a parallel potential flow is stabilizing and gives rise to waves traveling downstream. We have built a highly accurate numerical scheme which is validated at small amplitudes by comparing with the analytically predicted results for the pure

  8. Effect of electromagnetic stirring on solidification structure of austenitic stainless steel in horizontal continuous casting

    ZHOU Shu-cai


    Full Text Available An investigation on the influence of low frequency rotary electromagnetic stirring on solidification structure of austenitic stainless steel in horizontal continuous casting was experimentally conducted and carried out on an industrial trial basis. The results show that application of appropriate electromagnetic stirring parameters can obviously improve the macrostructure of austenitic stainless steel, in which both columnar and equiaxed grains can be greatly refined and shrinkage porosity or cavity zone along centerline can be remarkably decreased due to eliminating intracrystalline and enlarging equiaxed grains zone. The industrial trials verify that the electromagnetic stirring intensity of austenitic stainless steel should be higher than that of plain carbon steel. Electromagnetic stirring has somewhat affected the macrostructure of austenitic stainless steel even if the magnetic flux density of the electromagnetic stirring reaches 90 mT (amplitude reaches 141 mT in average at frequency f=3-4Hz, which provides a reference for the optimization of design and process parameters when applying the rotary electromagnetic stirrer.

  9. Effect of electromagnetic stirring on solidification structure of austenitic stainless steel in horizontal continuous casting


    An investigation on the influence of low frequency rotary electromagnetic stirring on solidification structure of austenitic stainless steel in horizontal continuous casting was experimentally conducted and carried out on an industrial trial basis. The results show that application of appropriate electromagnetic stirring parameters can obviously improve the macrostructure of austenitic stainless steel, in which both columnar and equiaxed grains can be greatly refined and shrinkage porosity or cavity zone along centerline can be remarkably decreased due to eliminating intracrystalline and enlarging equiaxed grains zone. The industrial trials verify that the electromagnetic stirring intensity of austenitic stainless steel should be higher than that of plain carbon steel. Electromagnetic stirring has somewhat affected the macrostructure of austenitic stainless steel even if the magnetic flux density of the electromagnetic stirring reaches 90 mT (amplitude reaches 141 mT ) in average at frequency f=3-4Hz, which provides a reference for the optimization of design and process parameters when applying the rotary electromagnetic stirrer

  10. 3D Stochastic Modeling of Grain Structure for Aluminum Alloy Casting

    Qingyan XU; Weiming FENG; Baicheng LIU


    A 3D stochastic modeling was carried out to simulate the dendritic grains during solidification of aluminum alloys,including time-dependent calculations for temperature field, solute redistribution in liquid, curvature of the dendritictip, and growth anisotropy. The nucleation process was treated by continuous nucleation. A 3D simplified grainshape model was established to represent the equiaxed dendritic grain. Based on the Cellular Automaton method,a grain growth model was proposed to capture the neighbor cells of the nucleated cell. During growing, each graincontinues to capture the nearest neighbor cells to form the final shape. When a neighbor cell was captured by othergrains, the grain growth along this direction would be stopped. Three-dimensional calculations were performed tosimulate the evolution of dendritic grain. In order to verify the modeling results, the predictions were compared withthe observation on samples cast in the sand mold and the metal mold.

  11. Prediction of as-cast grain size of inoculated aluminum alloys melt solidified under non-isothermal conditions

    Du, Qiang; Li, Yanjun


    In this paper, a multi-scale as-cast grain size prediction model is proposed to predict as-cast grain size of inoculated aluminum alloys melt solidified under non-isothermal condition, i.e., the existence of temperature gradient. Given melt composition, inoculation and heat extraction boundary conditions, the model is able to predict maximum nucleation undercooling, cooling curve, primary phase solidification path and final as-cast grain size of binary alloys. The proposed model has been applied to two Al-Mg alloys, and comparison with laboratory and industrial solidification experimental results have been carried out. The preliminary conclusion is that the proposed model is a promising suitable microscopic model used within the multi-scale casting simulation modelling framework.

  12. Complete grain boundaries from incomplete EBSD maps: the influence of segmentation on grain size determinations

    Heilbronner, Renée; Kilian, Ruediger


    Grain size analyses are carried out for a number of reasons, for example, the dynamically recrystallized grain size of quartz is used to assess the flow stresses during deformation. Typically a thin section or polished surface is used. If the expected grain size is large enough (10 µm or larger), the images can be obtained on a light microscope, if the grain size is smaller, the SEM is used. The grain boundaries are traced (the process is called segmentation and can be done manually or via image processing) and the size of the cross sectional areas (segments) is determined. From the resulting size distributions, 'the grain size' or 'average grain size', usually a mean diameter or similar, is derived. When carrying out such grain size analyses, a number of aspects are critical for the reproducibility of the result: the resolution of the imaging equipment (light microscope or SEM), the type of images that are used for segmentation (cross polarized, partial or full orientation images, CIP versus EBSD), the segmentation procedure (algorithm) itself, the quality of the segmentation and the mathematical definition and calculation of 'the average grain size'. The quality of the segmentation depends very strongly on the criteria that are used for identifying grain boundaries (for example, angles of misorientation versus shape considerations), on pre- and post-processing (filtering) and on the quality of the recorded images (most notably on the indexing ratio). In this contribution, we consider experimentally deformed Black Hills quartzite with dynamically re-crystallized grain sizes in the range of 2 - 15 µm. We compare two basic methods of segmentations of EBSD maps (orientation based versus shape based) and explore how the choice of methods influences the result of the grain size analysis. We also compare different measures for grain size (mean versus mode versus RMS, and 2D versus 3D) in order to determine which of the definitions of 'average grain size yields the

  13. Comparative Study on the Grain Refinement of Al-Si Alloy Solidified under the Impact of Pulsed Electric Current and Travelling Magnetic Field

    Yunhu Zhang


    Full Text Available It is high of commercial importance to generate the grain refinement in alloys during solidification by means of electromagnetic fields. Two typical patterns of electromagnetic fields, pulsed electric currents (ECP and traveling magnetic field (TMF, are frequently employed to produce the finer equiaxed grains in solidifying alloys. Various mechanisms were proposed to understand the grain refinement in alloys caused by ECP and TMF. In this paper, a comparative study is carried out in the same solidification regime to investigate the grain refinement of Al-7 wt. %Si alloy driven by ECP and TMF. Experimental results show that the application of ECP or TMF can cause the same grain refinement occurrence period, during which the refinement of primary Al continuously occurs. In addition, the related grain refinement mechanisms are reviewed and discussed, which shows the most likely one caused by ECP and TMF is the promoted dendrite fragmentation as the result of the ECP-induced or TMF-induced forced flow. It suggests that the same grain refinement process in alloys is provoked when ECP and TMF are applied in the same solidification regime, respectively.

  14. Influence of rare earth metals on the nucleation and solidification behavior of iron and 1045 steel

    Li, H.; McLean, A.; Rutter, J. W.; Sommerville, I. D.


    Two series of experiments have been conducted to determine the influence of rare earth additions on the nucleation and crystallization behavior of pure iron and 1045 steel. In the first series, additions of rare earth suicide or cerium dioxide powder to two-Kg 1045 steel ingots indicated that rare earth suicide can refine the as-cast structure of such ingots. However, if the holding time after rare earth silicide addition is over two minutes, the grain refinement decreases. With cerium dioxide additions, a relatively large columnar zone was obtained. In the second series, the effects of cerium metal or cerium dioxide powder additions on the degree of undercooling obtainable in pure iron and 1045 steel were examined by the lévitation melting method. Surface tension measurements of the levitated droplets were carried out at the same time to investigate the possible effects of surface tension variations on the nucleation and crystallization behavior of the metals. The experimental data show that rare earth inclusions can greatly reduce the degree of undercooling of iron and steel, and that a small amount of dissolved cerium can further reduce the degree of undercooling of levitated droplets. The structure and reaction products obtained with Fe-Ce levitated droplets were examined with both optical and scanning electron microscopy as well as X-ray diffraction analysis. The experimental results clearly indicated that cerium solute redistribution during solidification is the dominant factor in refining the as-cast structure. A nucleation and solidification model for the Fe-Ce levitated droplets has been developed, which can successfully explain the experimental results.

  15. Phase-field simulation of peritectic solidification closely coupled with directional solidification experiments in an Al-36 wt% Ni alloy.

    Siquieri, R; Doernberg, E; Emmerich, H; Schmid-Fetzer, R


    In this work we present experimental and theoretical investigations of the directional solidification of Al-36 wt% Ni alloy. A phase-field approach (Folch and Plapp 2005 Phys. Rev. E 72 011602) is coupled with the CALPHAD (calculation of phase diagrams) method to be able to simulate directional solidification of Al-Ni alloy including the peritectic phase Al(3)Ni. The model approach is calibrated by systematic comparison to microstructures grown under controlled conditions in directional solidification experiments. To illustrate the efficiency of the model it is employed to investigate the effect of temperature gradient on the microstructure evolution of Al-36 wt% Ni during solidification.

  16. Particle Trapping and Banding in Rapid Colloidal Solidification

    Elliott, J. A. W.


    We derive an expression for the nonequilibrium segregation coefficient of colloidal particles near a moving solid-liquid interface. The resulting kinetic phase diagram has applications for the rapid solidification of clay soils, gels, and related colloidal systems. We use it to explain the formation of bandlike defects in rapidly solidified alumina suspensions. © 2011 American Physical Society.

  17. Changes in porosity of foamed aluminum during solidification


    In order to control the porosity of foamed aluminum, the changes in the porosity of foamed aluminum melt in the processes of foaming and solidification, the distribution of the porosity of foamed aluminum, and the relationship between them were studied. The results indicated that the porosity of foamed aluminum coincides well with the foaming time.

  18. Overview of the Tusas Code for Simulation of Dendritic Solidification

    Trainer, Amelia J. [Massachusetts Inst. of Technology (MIT), Cambridge, MA (United States); Newman, Christopher Kyle [Los Alamos National Lab. (LANL), Los Alamos, NM (United States); Francois, Marianne M. [Los Alamos National Lab. (LANL), Los Alamos, NM (United States)


    The aim of this project is to conduct a parametric investigation into the modeling of two dimensional dendrite solidification, using the phase field model. Specifically, we use the Tusas code, which is for coupled heat and phase-field simulation of dendritic solidification. Dendritic solidification, which may occur in the presence of an unstable solidification interface, results in treelike microstructures that often grow perpendicular to the rest of the growth front. The interface may become unstable if the enthalpy of the solid material is less than that of the liquid material, or if the solute is less soluble in solid than it is in liquid, potentially causing a partition [1]. A key motivation behind this research is that a broadened understanding of phase-field formulation and microstructural developments can be utilized for macroscopic simulations of phase change. This may be directly implemented as a part of the Telluride project at Los Alamos National Laboratory (LANL), through which a computational additive manufacturing simulation tool is being developed, ultimately to become part of the Advanced Simulation and Computing Program within the U.S. Department of Energy [2].

  19. Three-dimensional solidification and melting using magnetic field control

    Dulikravich, George S.; Ahuja, Vineet


    A new two-fluid mathematical model for fully three dimensional steady solidification under the influence of an arbitrary acceleration vector and with or without an arbitrary externally applied steady magnetic field have been formulated and integrated numerically. The model includes Joule heating and allows for separate temperature dependent physical properties within the melt and the solid. Latent heat of phase change during melting/solidification was incorporated using an enthalpy method. Mushy region was automatically captured by varying viscosity orders of magnitude between liquidus and solidus temperature. Computational results were obtained for silicon melt solidification in a parallelepiped container cooled from above and from a side. The results confirm that the magnetic field has a profound influence on the solidifying melt flow field thus changing convective heat transfer through the boundaries and the amount and shape of the solid accrued. This suggests that development of a quick-response algorithm for active control of three dimensional solidification is feasible since it would require low strength magnetic fields.

  20. The Effect of Solidification Rate on Morphological Stability

    Sekerka, R. F.


    At low solidification rates, the criterion for the onset of morphological instability parallels closely the criterion of constitutional supercooling. At somewhat larger rates of solidification, however, the results of the perturbation theory of morphological instability differ significantly from the predictions of constitutional supercooling. This arises because the critical wave length for instability decreases as solidification rate increases and thus the effects of capillarity (solid-liquid surface tension) play a strong stabilizing role. This gives rise to the concept of absolute stability, according to which the system will always be stable for a sufficiently large rate of solidification. This enhanced stabilization by capillarity is present only so long as local equilibrium is maintained at the solid-liquid interface. If the interfacial temperature drops below its equilibrium value by an amount dependent on growth rate, oscillatory morphological instabilities can occur. The differences among these various stability criteria are illustrated by means of some simple two-dimensional diagrams that should supplant the conventional plots of (temperature gradient)/(growth rate) vs. alloy concentration.

  1. Microstructural Development in Al-Si Powder During Rapid Solidification

    Genau, Amber Lynn [Iowa State Univ., Ames, IA (United States)


    Powder metallurgy has become an increasingly important form of metal processing because of its ability to produce materials with superior mechanical properties. These properties are due in part to the unique and often desirable microstructures which arise as a result of the extreme levels of undercooling achieved, especially in the finest size powder, and the subsequent rapid solidification which occurs. A better understanding of the fundamental processes of nucleation and growth is required to further exploit the potential of rapid solidification processing. Aluminum-silicon, an alloy of significant industrial importance, was chosen as a model for simple eutectic systems displaying an unfaceted/faceted interface and skewed coupled eutectic growth zone, Al-Si powder produced by high pressure gas atomization was studied to determine the relationship between microstructure and alloy composition as a function of powder size and atomization gas. Critical experimental measurements of hypereutectic (Si-rich) compositions were used to determine undercooling and interface velocity, based on the theoretical models which are available. Solidification conditions were analyzed as a function of particle diameter and distance from nucleation site. A revised microstructural map is proposed which allows the prediction of particle morphology based on temperature and composition. It is hoped that this work, by providing enhanced understanding of the processes which govern the development of the solidification morphology of gas atomized powder, will eventually allow for better control of processing conditions so that particle microstructures can be optimized for specific applications.

  2. Solidification of Hypereutectic Thin Wall Ductile Cast Iron

    Pedersen, Karl Martin; Tiedje, Niels Skat


    Hypereutectic ductile iron was cast in green sand moulds with four plates with thickness of 1.5, 2, 3 and 4 mm in each mould. Temperatures were measured in the 3 and 4 mm plate. The temperature curves showed that eutectic solidification was divided into two stages: primary and secondary eutectic...

  3. Solidification paths in modified Inconel 625 weld overlay material

    Chandrasekaran, Karthik; Tiedje, Niels Skat; Hald, John


    Inconel 625 is commonly used for overlay welding to protect the base metal against high temperature corrosion. The efficiency of corrosion protection depends on effective mixing of the overlay weld with the base metal and the subsequent segregation of alloy elements during solidification...

  4. Microbiota of kefir grains

    Tomislav Pogačić


    Full Text Available Kefir grains represent the unique microbial community consisting of bacteria, yeasts, and sometimes filamentous moulds creating complex symbiotic community. The complexity of their physical and microbial structures is the reason that the kefir grains are still not unequivocally elucidated. Microbiota of kefir grains has been studied by many microbiological and molecular approaches. The development of metagenomics, based on the identification without cultivation, is opening new possibilities for identification of previously nonisolated and non-identified microbial species from the kefir grains. Considering recent studies, there are over 50 microbial species associated with kefir grains. The aim of this review is to summarise the microbiota composition of kefir grains. Moreover, because of technological and microbiological significance of the kefir grains, the paper provides an insight into the microbiological and molecular methods applied to study microbial biodiversity of kefir grains.

  5. The characteristic of crystal growth of Nd–Fe–B cast strips during the rapid solidification process

    Wang, Jingdai, E-mail:; Meng, Yu; Zhang, Huaxia; Tang, Hui; Lin, Rongbing; Sun, Chuanqi; Wu, Changxin; Xie, Fayin


    The microstructure of Nd–Fe–B cast strips with different thickness was investigated intensively. The cooling rate decreased with increasing thickness of the cast strips. When the thickness was more than 0.5 mm, α-Fe precipitated in the free side of the strips because the cooling rate was too low. However, the nucleation rate increased with increasing thickness. When the thickness was more than 0.5 mm, a layer of fine equiaxed grains formed near the wheel side. With the increased thickness, the volume fraction of columnar grain increased to maximum (91%) at 0.3 mm and then decreased. The characteristic of crystal growth of Nd–Fe–B cast strips with different thickness during solidification was discussed. - Highlights: • The cooling rate decreased with increasing thickness of the cast strips. • α-Fe precipitated in the free side of the strips with thickness more than 0.5 mm. • Fine equiaxed grains formed in the strips with thickness more than 0.5 mm. • The volume fraction of columnar grain increased to 91% at 0.3 mm and then decreased. • A schematic diagram of the characteristic of the crystal growth was proposed.

  6. Microstructure characteristics of Ni-43Ti-4Al-2Nb-2Hf alloy prepared by conventional casting and directional solidification

    Zhou Lei


    Full Text Available To further investigate the microstructure characteristic and solidification mechanism, so as to provide knowledge for the microstructure control of a NiTi-Al based high-temperature structural material, the microstructure of Ni-43Ti-4Al-2Nb-2Hf (at.% alloy ingots prepared by conventional casting (arc-melting and directional solidification (DS at various drawing velocities (2 mm·min-1, 18 mm·min-1, 30 mm·min-1 and 60 mm·min-1, respectively was investigated by means of electron probe microanalyses. Experimental results reveal that the microstructures are composed of NiTi matrix phase, β-Nb phase and Ti2Ni phase for samples obtained by both conventional casting and DS. Conventional casting has an equiaxial structure, while DS has a slender and acicular cellular structure which grows along the [001] orientation preferentially. Small amounts of white β-Nb phase and black Ti2Ni phase co-exist at the grain boundaries or intercellular regions. With an increase in drawing velocity, the NiTi matrix phase is inclined to grow along (100 and (200 crystallographic planes, and the cellular arm spacing reduce gradually, but the directionality of the solidified structure weakens significantly. The homogeneous dispersion of β-Nb phase and the decrease of Ti2Ni phase in DS samples are beneficial to improving the mechanical properties. Solidification mechanism analysis indicates that the dark grey NiTi matrix phase initially precipitates from the liquid phase, and then the divorced eutectic reaction takes place, which produces the light gray matrix phase and β-Nb phase. Finally, the peritectic reaction happens, which generates the black Ti2Ni phase. The complete solidified path of the alloy is L→ NiTi+L → NiTi+ β-Nb+L → NiTi+β-Nb + Ti2Ni.

  7. Improved stress corrosion cracking resistance of a novel biodegradable EW62 magnesium alloy by rapid solidification, in simulated electrolytes

    Hakimi, O.; Aghion, E. [Department of Materials Engineering, Ben-Gurion University of the Negev, P.O. Box 653, Beer-Sheva 84105 (Israel); Goldman, J., E-mail: [Biomedical Engineering Department, Michigan Technological University, Houghton, MI, 49931 (United States)


    The high corrosion rate of magnesium (Mg) and Mg-alloys precludes their widespread acceptance as implantable biomaterials. Here, we investigated the potential for rapid solidification (RS) to increase the stress corrosion cracking (SCC) resistance of a novel Mg alloy, Mg–6%Nd–2%Y–0.5%Zr (EW62), in comparison to its conventionally cast (CC) counterpart. RS ribbons were extrusion consolidated in order to generate bioimplant-relevant geometries for testing and practical use. Microstructural characteristics were examined by SEM. Corrosion rates were calculated based upon hydrogen evolution during immersion testing. The surface layer of the tested alloys was analyzed by X-ray photoelectron spectroscopy (XPS). Stress corrosion resistance was assessed by slow strain rate testing and fractography. The results indicate that the corrosion resistance of the RS alloy is significantly improved relative to the CC alloy due to a supersaturated Nd enrichment that increases the Nd{sub 2}O{sub 3} content in the external oxide layer, as well as a more homogeneous structure and reduced grain size. These improvements contributed to the reduced formation of hydrogen gas and hydrogen embrittlement, which reduced the SCC sensitivity relative to the CC alloy. Therefore, EW62 in the form of a rapidly solidified extruded structure may serve as a biodegradable implant for biomedical applications. - Highlights: • Here we have evaluated the corrosion resistance of a novel Mg alloy (EW62). • Rapid solidification reduces the hydrogen gas evolution and hydrogen embrittlement. • Rapid solidification increases the stress corrosion cracking resistance of EW62. • Improvement is due to enrichment with supersaturated Nd in the external oxide film. • Rapidly solidified and extruded EW62 may serve as a biodegradable medical implant.

  8. Effects of Plastic Mulching Modes on Soil Moisture and Grain Yield in Dryland Winter Wheat%不同覆膜方式对旱地冬小麦土壤水分和产量的影响

    柴守玺; 杨长刚; 张淑芳; 陈恒洪; 常磊


    Mulching strategies and practices are required to increase crop yields in arid and semiarid rainfed areas. This study was carried out to determine the effect of different mulching modes on soil moisture, grain yield, and water use efficiency for winter wheat in a semiarid rainfed region of Loess Plateau, Northwest China during 2008–2009 and 2009–2010 growing seasons. Winter wheat was grown under four cultivation patterns:whole field plastic mulching with soil cover on the top of the plastic mulch and bunch-seeding (T1), whole field plastic mulching without soil cover on the top of the plastic mulch and bunch-seeding (T2), ridges mulched with plastic film and row-seeding in the furrow (T3), and non-mulching with row-seeding as control (CK). Com-pared with CK, the three plastic mulching treatments showed the increase of water storage in the 0–200 cm soil layer before boot-ing stage by 2.3%in the 2008–2009 season and 1.7%in the 2009–2010 season and the decrease of 0–200 cm soil water storage from booting to harvest by 14.7%and 7.6%in the two seasons, respectively. In the three plastic mulching treatments, the 0–20 cm soil moisture during the whole growth season was obviously higher than that in CK, however the 20–90 cm soil moisture after jointing and the 90–200 cm soil moisture during the whole growth season were lower than that in CK. As a result, the 0–200 cm soil water storage at harvest in the plastic mulching treatments was 64.7 mm (2008–2009 growing season) and 47.0 mm (2009–2010 growing season) lower than that in CK. Although T1, T2 and T3 consumed 64.6 mm and 77.2 mm more soil water than CK in two growing seasons, the 0–200 cm soil water storage was 29.8 mm and 22.8 mm higher at seeding stage in autumn after the summer fallowing. This result indicated that soil water storage was restored rapidly during summer fallow in plastic mulching treatments. Compared with CK, plastic mulching treatments enhanced wheat yield by 49.4%in 2008

  9. Characterization on carbide of a novel steel for cold work roll during solidification process

    Guo, J.; Liu, L.G.; Li, Q.; Sun, Y.L. [State Key Laboratory of Metastable Materials Science and Technology, Yanshan University, Qinhuangdao 066004 (China); Gao, Y.K. [Institute of Aeronautical Materials, Beijing 100095 (China); Ren, X.J. [School of Engineering, Liverpool John Moores University, Liverpool L3 3AF (United Kingdom); Yang, Q.X., E-mail: [State Key Laboratory of Metastable Materials Science and Technology, Yanshan University, Qinhuangdao 066004 (China)


    A novel steel for cold work roll was developed in this work. Its phase structures were determined by X-ray diffraction, and phase transformation temperatures during the cooling process were measured by Differential Scanning Calorimeter. The Fe–C isopleths of the steel were calculated by Thermo-Calc to preliminarily determine the characteristic temperatures of the different phases. Then the specimens were quenched at these characteristic temperatures. The typical microstructures were observed by Optical Microscopy and Field Emission Scanning Electron Microscopy with Energy Disperse Spectroscopy. The results show that α-Fe, MC, M{sub 2}C and M{sub 7}C{sub 3} precipitate when the specimen is cooled slowly to room temperature. According to the DSC curve and the Fe–C isopleths, the characteristic temperatures of the phase transformation and carbide precipitation are chosen as 1380 °C, 1240 °C, 1200 °C and 1150 °C respectively. Primary austenite precipitates at 1380 °C, then eutectic reaction occurs in residual liquid after quenching and the eutectic microstructures distribute along the crystal grain boundary. The eutectic MC is leaf-like and eutectic M{sub 2}C is fibrous-like. Both of them precipitate in ternary eutectic reaction simultaneously at 1240 °C, grow together in the form of dendrite along the crystal grain boundary. Secondary MC precipitates from the austenitic matrix at 1200 °C and nucleates at the position where eutectic MC located accompanied by the dissolving of eutectic carbides. The mixed secondary M{sub 2}C and M{sub 7}C{sub 3} precipitate at 1150 °C. The secondary M{sub 2}C is strip-like and honeycomb-like, while the M{sub 7}C{sub 3} is chrysanthemum-like and maze-like. - Highlights: • The solidification process was analyzed by Thermo-Calc, DSC, XRD and SEM observation. • Primary and secondary carbides precipitated during solidification were determined. • The three dimensional morphologies of all carbides was observed. • The

  10. A study of aluminum-lithium alloy solidification using acoustic emission techniques. Ph.D. Thesis, 1991

    Henkel, Daniel P.


    Physical phenomena associated with the solidification of an aluminum lithium alloy was characterized using acoustic emission (AE) techniques. It is shown that repeatable patterns of AE activity may be correlated to microstructural changes that occur during solidification. The influence of the experimental system on generated signals was examined in the time and frequency domains. The analysis was used to show how an AE signal from solidifying aluminum is changed by each component in the detection system to produce a complex waveform. Conventional AE analysis has shown that a period of high AE activity occurs in pure aluminum, an Al-Cu alloy, and the Al-Li alloy, as the last fraction of solid forms. A model attributes this to the internal stresses of grain boundary formation. An additional period of activity occurs as the last fraction of solid forms, but only in the two alloys. A model attributes this to the formation of interdendritic porosity which was not present in the pure aluminum. The AE waveforms were dominated by resonant effects of the waveguide and the transducer.

  11. Influence of rare earth elements on solidification behavior of a high speed steel for roll using differential scanning calorimetry

    WANG Mingjia; CHEN Lei; WANG Zixi; BAO Er


    The influence of rare earths (RE) on solidification behavior of a high speed steel for roll was investigated by using differential scanning calorimetry (DSC) in combination of microstructure analysis.It was found that the sequence of solidification was L→γ,L→γ+MC,L→γ+M2C,L→γ+M6C,respectively.The start temperature and the latent heat liberated by unit mass of L→γ and L→γ+MC increased with increase of RE addition,indicating that RE could trigger the crystallization of the primary γ and the MC carbide more effectively.The promoting effect of RE on the heterogeneous nucleation was believed to be an important cause of this effect.Grain refinement,discontinuous network of eutectic carbides and disperse and finer MC were observed in the samples with RE addition,moreover,RES could act as the heterogeneous nucleus of the MC.RE addition was favorable for stable M6C at the expense of the metastable M2C.

  12. Fluctuations effect analysis of grain yield per hectare based on empirical mode decomposition and set pair analysis%基于经验模态分解和集对分析的粮食单产波动影响分析

    蒋尚明; 金菊良; 许浒; 周玉良; 王友贞


    , backbone River less, and far away from the rivers, lakes and reservoirs, no lead water conditions, irrigation guarantee rate lower, the suffering drought disasters, and the existence of a large number of easy to dry land, it is one of the most arid regions of Anhui province. Through integrated management of cultivated land in drought-prone areas, raising the level of grain yield per unit area is the important strategic task and the main way to guarantee the safety of grain production in the hilly region of the Huaihe and Yangtze Rivers. Therefore, how to fully exert the cultivated land potential yield and stable increase grain yield, appear particularly important. Based on this, application of empirical mode decomposition (EMD) for grain yield and influencing factors of multi-level, multi-time scale decomposition, and reasonable use of set pair analysis (SPA) theory were used to analyze correlations between fluctuations in grain yield per hectare components and corresponding impact factors. Then the data was used to formulate a quantitative analysis of the influence factors on comprehensive effect rates of fluctuation of grain yield per hectare. On this basis, through the analysis of the impact drought and natural disaster on grain production of hazard degree, the data was used calculate the comprehensive effect rates of drought on fluctuations of grain yield per hectare. The analysis results of the series models in easy arid regions of the Huaihe and Yangtze River watershed shows that the series models has been a good combination of EMD and SPA theory, achieved on grain yield per hectare fluctuation at different time scales and quantitative multi-factor analysis, to find out the comprehensive effect rates of drought on fluctuations of grain per unit yield in easy arid regions of the Huaihe and Yangtze River watershed. It can provide a scientific basis for the comprehensive management of drought and food production decision-making in the hilly region of the Huaihe and

  13. Structural Properties of Liquid SiC during Rapid Solidification

    WanJun Yan


    Full Text Available The rapid solidification of liquid silicon carbide (SiC is studied by molecular dynamic simulation using the Tersoff potential. The structural properties of liquid and amorphous SiC are analyzed by the radial distribution function, angular distribution function, coordination number, and visualization technology. Results show that both heteronuclear and homonuclear bonds exist and no atomic segregation occurs during solidification. The bond angles of silicon and carbon atoms are distributed at around 109° and 120°, respectively, and the average coordination number is <4. Threefold carbon atoms and fourfold silicon atoms are linked together by six typical structures and ultimately form a random network of amorphous structure. The simulated results help understand the structural properties of liquid and amorphous SiC, as well as other similar semiconductor alloys.

  14. Modeling of solidification of MMC composites during gravity casting process

    R. Zagórski


    Full Text Available The paper deals with computer simulation of gravity casting of the metal matrix composites reinforced with ceramics (MMC into sand mold. The subject of our interest is aluminum matrix composite (AlMMC reinforced with ceramic particles i.e. silicon carbide SiC and glass carbon Cg. The created model describes the process taking into account solidification and its influence on the distribution of reinforcement particles. The computer calculation has been carried out in 2D system with the use of Navier-Stokes equations using ANSYS FLUENT 13. The Volume of Fluid approach (VOF and enthalpy method have been used to model the air-fluid free surface (and also volume fraction of particular continuous phases and the solidification of the cast, respectively.

  15. Computer modelling of solidification of pure metals and alloys

    Barkhudarov, M R


    differencing advection algorithm used in the simulations, the Leith's method is incorporated into the public domain two-dimensional SOLA code. It is shown that the resulting scheme is unconditionally stable despite being explicit. Two numerical models have been developed to describe the volumetric changes during solidification in pure metals and alloys and to predict shrinkage defects in the castings of general three-dimensional configuration. The first model is based on the full system of the Continuity, Navier-Stokes and Enthalpy Equations. Volumetric changes are described by introducing a source term in the Continuity Equation which is a function of the rate of local phase transformation. The model is capable of simulating both volumetric shrinkage and expansion. The second simplified shrinkage model involves the solution of only the Enthalpy Equation. Simplifying assumptions that the feeding flow is governed only by gravity and solidification rate and that phase transformation proceeds only from liquid to...

  16. Solidification and ordering during directional drying of a colloidal dispersion.

    Goehring, Lucas; Clegg, William J; Routh, Alexander F


    During drying, colloidal dispersions undergo processes such as solidification, cracking, and the draining of interstitial pores. Here we show that the solidification of polystyrene and silica dispersions, during directional drying, occurs in two separate stages. These correspond to the initial ordering and subsequent aggregation of the colloidal particles. Transitions between these stages are observed as changes in transparency and color that propagate as distinct fronts along the drying layer. The dynamics of these fronts are shown to arise from a balance between compressive capillary forces and the electrostatic and van der Waals forces described by DLVO theory. This suggests a simple method by which the maximum interparticle repulsion between particles can be measured through the optical inspection of the dynamics of a drying dispersion, under a microscope.

  17. Inverse problem for porosity estimation during solidification of TNT

    Aldélio Bueno Caldeira


    Full Text Available In the present study, the porosity formed during the solidification process is estimated by an inverse problem technique based on particle swarm optimization. The effective heat capacity method is adopted to model the heat transfer problem. The transient-diffusive heat transfer equation is solved numerically by the finite volume method with an explicit scheme, employing the central difference interpolation function. The solution of the direct problem is compared to reference solutions. The model is applied to trinitrotoluene (TNT solidification process. The results show that the proposed procedure was able to estimate the porosity for different Stefan numbers. The analysis of the heat flux in the mold is indicated to predict the porosity formation during the casting process.

  18. Nonlinear instability and dynamic bifurcation of a planeinterface during solidification

    吴金平; 侯安新; 黄定华; 鲍征宇; 高志农; 屈松生


    By taking average over the curvature, the temperature and its gradient, the solute con-centration and its gradient at the flange of planar interface perturbed by sinusoidal ripple during solidifi-cation, the nonlinear dynamic equations of the sinusoidal perturbation wave have been set up. Analysisof the nonlinear instability and the behaviors of dynamic bifurcation of the solutions of these equationsshows that (i) the way of dynamic bifurcation of the flat-to-cellular interface transition vades with differ-ent thermal gradients. The quasi-subcritical-lag bifurcation occurs in the small interface thermal gradientscope, the supercritical-lag bifurcation in the medium thermal gradient scope and the supercritical bifur-cation in the large thermal gradient scope. (ii) The transition of cellular-to-flat interface is realizedthrough supercritical inverse bifurcation in the rapid solidification area.

  19. Growth directions of microstructures in directional solidification of crystalline materials.

    Deschamps, J; Georgelin, M; Pocheau, A


    In directional solidification, as the solidification velocity increases, the growth direction of cells or dendrites rotates from the direction of the thermal gradient to that of a preferred cristalline orientation. Meanwhile, their morphology varies with important implications for microsegregation. Here, we experimentally document the growth directions of these microstructures in a succinonitrile alloy in the whole accessible range of directions, velocities, and spacings. For this, we use a thin sample made of a single crystal on which the direction of the thermal gradient can be changed. This allows a fine monitoring of the misorientation angle between thermal gradient and preferred crystalline orientation. Data analysis shows evidence of an internal symmetry which traces back to a scale invariance of growth directions with respect to a Péclet number. This enables the identification of the relationship between growth directions and relevant variables, in fair agreement with experiment. Noticeable variations of growth directions with misorientation angles are evidenced and linked to a single parameter.

  20. Fluid mechanics of directional solidification at reduced gravity

    Chen, C. F.


    The primary objective of the proposed research is to provide additional groundbased support for the flight experiment 'Casting and Solidification Technology' (CAST). This experiment is to be performed in the International Microgravity Laboratory-1 (IML-1) scheduled to be flown on a space shuttle mission scheduled for 1992. In particular, we will provide data on the convective motion and freckle formation during directional solidification of NH4Cl from its aqueous solution at simulated parameter ranges equivalent to reducing the gravity from the sea-level value down to 0.1 g or lower. The secondary objectives of the proposed research are to examine the stability phenomena associated with the onset of freckles and the mechanisms for their subsequent growth and decline (to eventual demise of some) by state-of-the-art imaging techniques and to formulate mathematical models for the prediction of the observed phenomena.

  1. Dynamics of liquid solidification thermal resistance of contact layer

    Lipnicki, Zygmunt


    This monograph comprehensively describes phenomena of heat flow during phase change as well as the dynamics of liquid solidification, i.e. the development of a solidified layer. The book provides the reader with basic knowledge for practical designs, as well as with equations which describe processes of energy transformation. The target audience primarily comprises researchers and experts in the field of heat flow, but the book may also be beneficial for both practicing engineers and graduate students.

  2. Supporting the model of ductile iron dendritic solidification

    Santos, H.M.C.M. [Porto Univ. (Portugal). Metall. and Mater. Dept.; Pinto, A.M.P. [Minho Univ. (Portugal). Mechanical Engineering Dept.; Jacinto, M.C.P.L. [Porto Polytechnic Inst. and INEGI, Porto (Portugal). Mechanical Engineering Dept.; Sa, C.P.M. [Porto Univ. (Portugal). Materials Center


    Microsegregation in ductile iron is generally accepted as modelled by a regular pattern: the graphite promoter elements are assumed to concentrate in the neighborhood of the graphite nodules and the carbide forming elements in the eutectic cell boundaries. The authors have conducted several microanalyses in several ductile irons and concluded that the microsegregation pattern does not agree with this model but supports the mechanism of dendritic ductile iron solidification. (orig.)

  3. Solidification process and infrared image characteristics of permanent mold castings

    Viets, Roman; Breuer, Markus; Haferkamp, Heinz; Kruessel, Thomas; Niemeyer, Matthias


    Interdependence between the development of temperature gradients at the solid-liquid interface during solidification of metals and the formation of local defects demands for thermal investigation. In foundry practice thermocouples are used to control the die's overall cooling-rate, but fluctuations in product quality still occur. Capturing FIR- thermograms after opening the die visualizes the state, when most thermal throughput has already flattened the temperature gradients in the mold. Rapid dissipation of heat from liquid metal to the mold during solidification forces further approach of the process investigation by slowing down the heat flux or the use of transparent mold material. Aluminum gravity casting experiments under technical vacuum conditions lead to decelerated solidification by suppression of convection and image sequences containing explicit characteristics that could be assigned to local shrinkage of the casting. Hence relevant clusters are extracted and thermal profiles are drawn from image series, pointing out correlations between feeding performance from the sink heads and the appearance of local defects. Tracing thermal processes in vacuum casting can scarcely be transferred to image data in foundry practice, since only little analogies exist between atmospheric and vacuum casting. The diagnosis of the casting process requires detection of the still closed mold using a transparent silica- aerogel sheet as part of the die. Hereby thermograms of the initial heat input are recorded by adapting a NIR-camera in addition to the FIR-unit. Thus the entire thermal compensation at the joint face for each casting is visualized. This experimental set-up is used for image sequence analysis related to the intermediate casting phases of mold filling, body formation and solidification shrinkage.

  4. [Application of solidification technology in ecological protection of rural riverbank].

    Fu, Rong-bing; Chen, Xiao-hua; Luo, Qi-shi; Zhang, Shu-jiu; Li, Xiao-ping; Geng, Chun-nü


    A self-developed binder was used for the solidification of construction refuse piles and whole soil matrix, and a technology of this solidification combining with grass-planting was adopted to ecologically protect the rural riverbanks at Tianshan Village of Shanghai. This technology and other ecological engineering techniques were also employed to reconstruct the ecological environment of a sewage pond at the Village. The results showed that the solidified piles had an anti-compression strength of up to 7.3 MPa, with good hydraulic permeability, fast hardening rate, and low drying shrinkage, which met the requirements for ecological safety. The solidified stakes could be used at a low temperature of above -18 degrees C with addition of certain anti-freezing agents. The riverbank underpinned with the solidified stakes had higher anti-compressive strength, higher ability of anti-soil erosion, and better hydraulic permeability; and its soil had the similar moisture content to bare riverbank soil, with no detrimental effects on the root growth of planted grass. After soil solidification, the shearing strength of the riverbank increased by 50 times, and its soil loss was only 5% of the bare riverbank. In the first 10 days after adopting this technology, parts of Cynodon dactylon roots on the surface of solidified soil matrix began to extend into soil; after one month, 60% of the roots penetrated into deeper soil layer; and 11 months later, the grass roots completely grew in-depth in the soil. The combination of our solidification technique with vegetation reconstruction satisfied the requirements of both stabilizing riverbank and improving riparian habitat.

  5. Development Of A Magnetic Directional-Solidification Furnace

    Aldrich, Bill R.; Lehoczky, Sandor L.


    Report describes development of directional-solidification furnace in which axial magnetic field is imposed by surrounding ring permanent magnets and/or electromagnets and pole pieces. Furnace provides controlled axial temperature gradients in multiple zones, through which ampoule containing sample of material to be solidified is translated at controlled speed by low-vibration, lead-screw, stepping-motor-driven mechanism. Intended for use in low-gravity (spaceflight) experiments on melt growth of high-purity semiconductor crystals.

  6. Interface Pattern Selection Criterion for Cellular Structures in Directional Solidification

    Trivedi, R.; Tewari, S. N.; Kurtze, D.


    The aim of this investigation is to establish key scientific concepts that govern the selection of cellular and dendritic patterns during the directional solidification of alloys. We shall first address scientific concepts that are crucial in the selection of interface patterns. Next, the results of ground-based experimental studies in the Al-4.0 wt % Cu system will be described. Both experimental studies and theoretical calculations will be presented to establish the need for microgravity experiments.

  7. Advances on Microstructure Modeling of Solidification Process of Shape Casting

    柳百成; 许庆彦


    Simulation technology for shape casting at macro-scale has been successfully put into engineering application in a number of casting plants and as a result the quality of castings is assured, the research and development time is shortened, and the manufacturing cost is greatly saved as well. In this paper, modeling and simulation technologies of solidification process of shape casting at microstructure-scale, especially deterministic, cellular automaton, and phase field models are studied and reviewed.

  8. Fluid mechanics and solidification investigations in low-gravity environments

    Fichtl, G. H.; Lundquist, C. A.; Naumann, R. J.


    Fluid mechanics of gases and liquids and solidification processes were investigated under microgravity conditions during Skylab and Apollo-Soyuz missions. Electromagnetic, acoustic, and aerodynamic levitation devices, drop tubes, aircraft parabolic flight trajectories, and vertical sounding rockets were developed for low-g simulation. The Spacelab 3 mission will be carried out in a gravity gradient flight attitude; analyses of sources of vehicle dynamic accelerations with associated g-levels and angular rates will produce results for future specific experiments.

  9. Solidification and microstructure of thin walled ductile cast iron

    Pedersen, Karl Martin


    In the recent years there has been an increasing interest in light constructions in order to save weight in e.g. cars. Ductile cast iron has good mechanical properties but it is necessary to re­duce the wall thicknesses of the castings in order to reduce the weight. Reducing the wall thicknesses...... of the casting will increase the cooling rates and by that change the conditions for nucleation and growth during solidification....

  10. Solidification microstructures and solid-state parallels: Recent developments, future directions

    Asta, M. [Department of Chemical Engineering and Materials Science, University of California at Davis, Davis, CA 95616 (United States); Beckermann, C. [Department of Mechanical and Industrial Engineering, University of Iowa, Iowa City, IA 52242 (United States); Karma, A. [Department of Physics and Center for Interdisciplinary Research on Complex Systems, Northeastern University, Boston, MA 02115 (United States); Kurz, W. [Institute of Materials, Ecole Polytechnique Federale de Lausanne (EPFL), 1015 Lausanne (Switzerland)], E-mail:; Napolitano, R. [Department of Materials Science and Engineering, Iowa State University, and Ames Laboratory USDOE, Ames, IA 50011 (United States); Plapp, M. [Physique de la Matiere Condensee, Ecole Polytechnique, CNRS, 91128 Palaiseau (France); Purdy, G. [Department of Materials Science and Engineering, McMaster University, Hamilton, Ont., L8S 4L7 (Canada); Rappaz, M. [Institute of Materials, Ecole Polytechnique Federale de Lausanne (EPFL), 1015 Lausanne (Switzerland); Trivedi, R. [Department of Materials Science and Engineering, Iowa State University, and Ames Laboratory USDOE, Ames, IA 50011 (United States)


    Rapid advances in atomistic and phase-field modeling techniques as well as new experiments have led to major progress in solidification science during the first years of this century. Here we review the most important findings in this technologically important area that impact our quantitative understanding of: (i) key anisotropic properties of the solid-liquid interface that govern solidification pattern evolution, including the solid-liquid interface free energy and the kinetic coefficient; (ii) dendritic solidification at small and large growth rates, with particular emphasis on orientation selection; (iii) regular and irregular eutectic and peritectic microstructures; (iv) effects of convection on microstructure formation; (v) solidification at a high volume fraction of solid and the related formation of pores and hot cracks; and (vi) solid-state transformations as far as they relate to solidification models and techniques. In light of this progress, critical issues that point to directions for future research in both solidification and solid-state transformations are identified.

  11. The solidification of two-phase heterogeneous materials: Theory versus experiment

    ZHANG Bin; KIM Tongbeum; LU TianJian


    The solidification behavior of two-phase heterogeneous materials such as close-celled aluminum foams was analytically studied. The proposed analytical model can precisely predict the location of solidification front as well as the full solidification time for a two-phase heterogeneous material composed of aluminum melt and non-conducting air pores. Experiments using distilled water simulating the aluminum melt to be solidified (frozen) were subsequently conducted to validate the analytical model for two selected porosities (ε), ε=0 and 0.5. Full numerical simulations with the method of finite difference were also performed to examine the influence of pore shape on solidification. The remarkable agreement between theory and experiment suggests that the delay of solidification in the two-phase heterogeneous material is mainly caused by the reduction of bulk thermal conductivity due to the presence of pores, as this is the sole mechanism accounted for by the analytical model for solidification in a porous medium.

  12. Study on Rare Earth-Containing Phases in TiAl Based Alloys Prepared by Non-Equilibrium Solidification Processing

    马学著; 沈军; 贾均


    Microstructure evolution of rare earth rich phase of rapidly-solidified (RS) TiAl based alloys was investigated. The two rapid-solidification techniques employed are melt-spinning technique (MS) and Hammer-and-Anvil technique (HA). MS ribbons and HA foils were obtained in the experiment. The results demonstrate that with the increasing of cooling rates of TiAl based alloys great changes are taken place in the microstructures of rare earth rich phase, from scattering mainly on grain boundaries of as-cast ingot to distributing homogeneously as very fine fibers or powders (nanometer grade) on the matrix. The fine paralleling second phase fibers in the HA foils are considered to be connected with γ/α2 lamellar colonies. Selected area electronic diffraction (SAED) patterns of the rare earth rich phase is in accordance with that of intermetallic AlCe.

  13. A new approach for the automatic evaluation of the solidification structure in steel using orientational entropy filtering.

    Griesser, S; O'Leary, P


    We present a new method for the automatic evaluation of the dendritic solidification structure in metallurgical micrographs of solidified steel. The evaluation of the microstructural parameters such as the primary dendrite arm spacing and the primary grain size are of high importance due to their direct relationship with the internal quality and mechanical properties of the cast product. Given the repeated geometric features in the micrographs and the regular pattern in colour intensity, we applied a filter mask to determine the local entropies within the masks in order to detect the centre coordinates of each individual dendrite. The orientation of the dendrites was determined by rotating the filter mask over each pixel to find the orientation which corresponds to the lowest entropy value. The segmentation of the microstructure was then performed via Delaunay tessellation and subsequent transformation of the triangular mesh into a rectangular grid, enabling the determination of the desired microstructural parameters.

  14. Microstructural development of rapid solidification in Al-Si powder

    Jin, Feng [Iowa State Univ., Ames, IA (United States)


    The microstructure and the gradient of microstructure that forms in rapidly solidificated powder were investigated for different sized particles. High pressure gas atomization solidification process has been used to produce a series of Al-Si alloys powders between 0.2 μm to 150 μm diameter at the eutectic composition (12.6 wt pct Si). This processing technique provides powders of different sizes which solidify under different conditions (i.e. interface velocity and interface undercooling), and thus give different microstructures inside the powders. The large size powder shows dendritic and eutectic microstructures. As the powder size becomes smaller, the predominant morphology changes from eutectic to dendritic to cellular. Microstructures were quantitatively characterized by using optical microscope and SEM techniques. The variation in eutectic spacing within the powders were measured and compared with the theoretical model to obtain interface undercooling, and growth rate during the solidification of a given droplet. Also, nucleation temperature, which controls microstructures in rapidly solidified fine powders, was estimated. A microstructural map which correlates the microstructure with particle size and processing parameters is developed.

  15. Non-Equilibrium Solidification of Undercooled Metallic Melts

    Dieter M. Herlach


    Full Text Available If a liquid is undercooled below its equilibrium melting temperature an excess Gibbs free energy is created. This gives access to solidification of metastable solids under non-equilibrium conditions. In the present work, techniques of containerless processing are applied. Electromagnetic and electrostatic levitation enable to freely suspend a liquid drop of a few millimeters in diameter. Heterogeneous nucleation on container walls is completely avoided leading to large undercoolings. The freely suspended drop is accessible for direct observation of rapid solidification under conditions far away from equilibrium by applying proper diagnostic means. Nucleation of metastable crystalline phases is monitored by X-ray diffraction using synchrotron radiation during non-equilibrium solidification. While nucleation preselects the crystallographic phase, subsequent crystal growth controls the microstructure evolution. Metastable microstructures are obtained from deeply undercooled melts as supersaturated solid solutions, disordered superlattice structures of intermetallics. Nucleation and crystal growth take place by heat and mass transport. Comparative experiments in reduced gravity allow for investigations on how forced convection can be used to alter the transport processes and design materials by using undercooling and convection as process parameters.

  16. Impact of Metal Droplets: A Numerical Approach to Solidification

    Koldeweij, Robin; Mandamparambil, Rajesh; Lohse, Detlef


    Layer-wise deposition of material to produce complex products is a subject of increasing technological relevance. Subsequent deposition of droplets is one of the possible 3d printing technologies to accomplish this. The shape of the solidified droplet is crucial for product quality. We employ the volume-of-fluid method (in the form of the open-source code Gerris) to study liquid metal (in particular tin) droplet impact. Heat transfer has been implemented based on the enthalpy approach for the liquid-solid phase. Solidification is modeled by adding a sink term to the momentum equations, reducing Navier-Stokes to Darcy's law for high solid fraction. Good agreement is found when validating the results against experimental data. We then map out a phase diagram in which we distinguish between solidification behavior based on Weber and Stefan number. In an intermediate impact regime impact, solidification due to a retracting phase occurs. In this regime the maximum spreading diameter almost exclusively depends on Weber number. Droplet shape oscillations lead to a broad variation of the morphology of the solidified droplet and determine the final droplet height. TNO.

  17. Successful Completion of Outward Transport Disposal Stage Ⅰ of Radioactive Cement Solidification

    DU; Hong-ming; LIU; Fu-guo; JIN; Song


    As the last batch of solidification barrels arriving at the repository on May 5th,2013,the outward transport disposal stage I of radioactive cement solidification completed successfully.This project started in May,2011,lasted for 19 months,during which 9 batches,3 300 barrels of cement solidification,had been retrieved and transferred.It is a lot of preparation work and continuous improvement that to ensure the safety of the outbound work.

  18. Characterization of Solidification and Solid State Transformation in Duplex Cast Steel: Thermo-Calc Investigation


    The paper presents a characteristic of solidification process and changes occurring in the solid state in a duplex cast steel. Theoretical chemical composition of individual phases, its changes during solidification and cooling after solidification and also changes in volume fractions of phases versus temperature have been determined. Theoretical results of Thermo-Calc analysis have been correlated with the microstructure of as-cast cast steel as well as with analysis of chemical composition ...

  19. Effect of solidification rate on microstructure evolution in dual phase microalloyed steel.

    Kostryzhev, A G; Slater, C D; Marenych, O O; Davis, C L


    In steels the dependence of ambient temperature microstructure and mechanical properties on solidification rate is not well reported. In this work we investigate the microstructure and hardness evolution for a low C low Mn NbTi-microalloyed steel solidified in the cooling rate range of 1-50 Cs(-1). The maximum strength was obtained at the intermediate solidification rate of 30 Cs(-1). This result has been correlated to the microstructure variation with solidification rate.

  20. Analysis of a solidification interface stability Al - Cu by the heat balance integral method

    B. Magiera


    Full Text Available The aim of his thesis is the analysis of a planar interface solidification stability of alloys. The stability of a planar interface solidification is tested by means of solving the heat conduction equation for solids and liquid and a mass diffusion equation for liquid, under assumed boundary, initial and continuity conditions. The solidification equations are solved using the method of heat balance integral and the theorem of the derivative integrals, whose limitsdepend on the parameter.


    E. I. Marukovich


    Full Text Available The new method of continuously iterative casting of hollow cylindrical castings from cast iron without application of core, based on the principle of direction of metal solidification is presented in the work. the thermal condition of crystallizer at iterative temperature influences on its internal surface and solidification of casting in the conditions of intensive one-way heat sink and presence of constant overheat on front of solidification is examined.

  2. 2,4-二硝基苯甲醚与 TNT 凝固行为的差异性分析%Analysis on Differences of Solidification Behavior of DNAN and TNT

    罗一鸣; 蒋秋黎; 赵凯; 王浩


    为了解2,4-二硝基苯甲醚(DNAN)凝固缺陷的特征及产生的原因,采用量筒称量法测试了 DNAN 和 TNT样品的液相密度,并计算出样品的体积收缩率;用工业 CT 和扫描电镜对 DNAN 和 TNT 药柱的凝固缺陷分布情况进行观测;用 DSC 和导热系数测定仪测试了 DNAN 和 TNT 药柱的热性能参数;用自制的凝固速率测试装置测试了 DNAN 和 TNT 药柱中不同部位温度随时间的变化规律,计算了不同凝固层厚度下的平均凝固线速度。结果表明,DNAN 的体积收缩率为13.2%,高于 TNT;其凝固缺陷的分散度高于 TNT;在凝固过程初期,DNAN 的平均凝固线速率与 TNT 相当,随着凝固层厚度的增加,其凝固速率快速增加并显著高于 TNT。DNAN 的凝固行为不同于 TNT,不是逐层凝固,而属于中间凝固。%To understand the characteristics and the causes of 2,4-dinitroanisole(DNAN)solidification defects,the liquid-phase density of DNAN and TNT samples was measured by a cylinder weighing method and the two sample′s volume shrinkages were calculated.The distribution of solidification defect of DNAN and TNT grains was observed by industrial CT and SEM,respectively.Thermal property parameters of DNAN and TNT samples were tested by DSC and thermal conductivity measuring instrument.The change rule of temperature of the different position in DNAN and TNT grains with time was measured by a home-made solidification rate measuring device.The average linear solidification rate under different solidifying layer thicknesses was obtained through calculation.Results show that the volume shrinkage of DNAN is 13.2%,higher than that of TNT.The rate of divergence of solidification de-fect of DNAN is higher than that of TNT.The solidification rate of DNAN is close to that of TNT during the early solidification process.With increasing the solidified layer thickness,DNAN solidification rate increases rapidly, significantly

  3. A new Bcc-Fcc orientation relationship observed between ferrite and austenite in solidification structures of steels

    Headley, T. J.; Brooks, J. A.


    A new crystallographic orientation relationship (OR) between delta-ferrite and austenite has been observed in solidification microstructures of 304L and 309S austenitic stainless steels and a ternary Fe-Cr-Ni alloy. Evidence for the new OR was obtained from electron diffraction patterns in transmission electron microscopy (TEM). This relationship, (111)fcc//(110)bcc and [bar 110]_{fcc} //[bar 110]_{bcc} , has not been previously reported for bcc-fcc systems. The fcc//#x2329;110>bcc alignment is distinctive among known bcc-fcc ORs. The new OR is related to the Kurdjumov-Sachs (K-S) and Nishiyama-Wassermann (N-W) ORs by relative rotations of 35.26 and 30 deg, respectively, about the normal to the parallel close-packed planes. In 304L fabricated by laser-engineered net shaping (LENS), delta-ferrite with the new OR was found to coexist in the microstructure with both K-S and N-W oriented ferrite, but in separate austenite grains and with less frequent occurrence. In gas-tungsten arc (GTA) welds of 309S and the Fe-Cr-Ni alloy, the new OR was the only one observed within a few grains, whereas ferrite within other grains did not establish an apparent OR with the austenite matrix.

  4. The Solidification Velocity of Undercooled Nickel and Titanium Alloys with Dilute Solute

    Algoso, Paul R.; Altgilbers, A. S.; Hofmeister, William H.; Bayuzick, Robert J.


    The study of solidification velocity is important for two reasons. First, understanding the manner in which the degree of undercooling of the liquid and solidification velocity affect the microstructure of the solid is fundamental. Second, there is disagreement between theoretical predictions of the relationship between undercooling and solidification velocity and experimental results. Thus, the objective of this research is to accurately and systematically quantify the solidification velocity as a function of undercooling for dilute nickel-and titanium-based alloys. The alloys chosen for study cover a wide range of equilibrium partition coefficients, and the results are compared to current theory.

  5. Directional Solidification of AlSi Alloys with Fe Intermetallic Phases

    Mikołajczak P.


    Full Text Available Directional solidification technique is an important research instrument to study solidification of metals and alloys. In the paper the model [6,7,8] of directional solidification in special Artemis-3 facility was presented. The current work aimed to propose the ease and efficient way in calibrating the facility. The introduced M coefficient allowed effective calibration and implementation of defined thermal conditions. The specimens of AlSi alloys with Fe-rich intermetallics and especially deleterious β-Al5FeSi were processed by controlled solidification velocity, temperature gradient and cooling rate.

  6. Numerical investigation of a binary solidification design problem

    Hale, Scott Wayne

    This exposition presents the development and application of a methodology for control of unidirectional solidification of a binary alloy. In particular, it is desired to produce a casting that has a uniform cast structure throughout its entire length. Furthermore, the methodology allows the specification, a priori, of the cast structure with respect to both scale, i.e., fine or coarse, and morphology, i.e., dentritic or cellular. This specification is in the form of a map that relates solidification characteristics, i.e., scale and morphology, to the solidification velocity and liquid-side interfacial temperature gradient. Thus design is accomplished by controlling these two parameters during the solidification process. With this in mind, the goal of what is termed the binary solidification design problem is the prediction of a set of boundary temperatures and heat fluxes which when applied will result in the desired interfacial motion and temperature gradient and therefore cast structure. Mathematical models for problems of this type lead to what are termed ill-posed systems in that they may not exhibit existence, uniqueness, or continuous dependence on boundary data. The resolution of this class of problems requires advanced techniques to overcome the instabilities encountered due to their ill-posed nature. The methodology developed herein employs the classical weight residual approach in a innovative manner. Normally, in the solution of a parabolic partial differential equation, such as the heat equation, a spatial series expansion with time varying coefficients is utilized along with a minimization technique to reduce the partial differential equation to a set of first order ordinary differential equations. This set can be solved using any number of numerical technique, i.e., Runge-Kutta, to obtain the temporal variation of the coefficients. These types of time stepping techniques eventually lead to the onset of instability when employed for the resolution of

  7. Effect of Temperature and Sheet Temper on Isothermal Solidification Kinetics in Clad Aluminum Brazing Sheet

    Benoit, Michael J.; Whitney, Mark A.; Wells, Mary A.; Winkler, Sooky


    Isothermal solidification (IS) is a phenomenon observed in clad aluminum brazing sheets, wherein the amount of liquid clad metal is reduced by penetration of the liquid clad into the core. The objective of the current investigation is to quantify the rate of IS through the use of a previously derived parameter, the Interface Rate Constant (IRC). The effect of peak temperature and initial sheet temper on IS kinetics were investigated. The results demonstrated that IS is due to the diffusion of silicon (Si) from the liquid clad layer into the solid core. Reduced amounts of liquid clad at long liquid duration times, a roughened sheet surface, and differences in resolidified clad layer morphology between sheet tempers were observed. Increased IS kinetics were predicted at higher temperatures by an IRC model as well as by experimentally determined IRC values; however, the magnitudes of these values are not in good agreement due to deficiencies in the model when applied to alloys. IS kinetics were found to be higher for sheets in the fully annealed condition when compared with work-hardened sheets, due to the influence of core grain boundaries providing high diffusivity pathways for Si diffusion, resulting in more rapid liquid clad penetration.

  8. Near-isothermal furnace for in situ and real time X-ray radiography solidification experiments

    Becker, M., E-mail:; Dreißigacker, C.; Klein, S.; Kargl, F. [Institut für Materialphysik im Weltraum, Deutsches Zentrum für Luft- und Raumfahrt (DLR), 51170 Köln (Germany)


    In this paper, we present a newly developed near-isothermal X-ray transparent furnace for in situ imaging of solidification processes in thin metallic samples. We show that the furnace is ideally suited to study equiaxed microstructure evolution and grain interaction. To observe the growth dynamics of equiaxed dendritic structures, a minimal temperature gradient across the sample is required. A uniform thermal profile inside a circular sample is achieved by positioning the sample in the center of a cylindrical furnace body surrounded by a circular heater arrangement. Performance tests with the hypo-eutectic Al-15wt.%Cu and the near-eutectic Al-33wt.%Cu alloys validate the near-isothermal character of the sample environment. Controlled cooling rates of less than 0.5 K min{sup −1} up to 10 K min{sup −1} can be achieved in a temperature range of 720 K–1220 K. Integrated in our rotatable laboratory X-ray facility, X-RISE, the furnace provides a large field of view of 10.5 mm in diameter and a high spatial resolution of ∼4 μm. With the here presented furnace, equiaxed dendrite growth models can be rigorously tested against experiments on metal alloys by, e.g., enabling dendrite growth velocities to be determined as a function of undercooling or solutal fields in front of the growing dendrite to be measured.

  9. Microstructures of FeSi2 based thermoelectric materials prepared by rapid solidification and hot pressing

    Haiyan Chen; Xinbing Zhao; Eckhard Mueller; Yufeng Lu; Cestmir Drasar; Antje Mrotzek


    FeSi2 based thermoelectric materials have been prepared by melt spinning and vacuum hot pressing. Most of the rapidly solidified (melt spinning) powders are thin flakes with a thickness less than 0.1 mm. Scanning electron microscope (SEM) surface profiles show there are further finer grain structures with the characteristic size of about 100 nm in a flake. The samples obtained by hot uniaxial pressing (HUP) in vacuum have densities higher than 90% the theoretical density of the materials. It was found by SEM observations that the microstructures are very different for vertical and parallel sections of the HUP samples. X-ray diffraction (XRD)analyses show there are some texture features in the samples. It is considered that the textures of the samples are originated from the orientation of the flakes that tended to align perpendicular to the hot press axis. WSi2 was introduced into the powders unexpectedly during melting process before the rapid solidification, but it makes the microstructures more easily to be explained.

  10. Influence of mechanical vibration on the solidification of a lost foam cast 356 alloy

    Zhao Zhong


    Full Text Available Mechanical vibration was applied to the solidification of a lost foam cast (LFC 356 aluminum alloy. Effects of mechanical vibration, with different peak acceleration, on the size and morphology of α-Al phase, and also on the mechanical properties of the castings were studied. Results indicated that α-Al dendrites gradually grow into equiaxed grains as the peak acceleration of vibration is increased. When the peak acceleration is between about 1 to 4 g,α-Al phase distribution is uniform and is refined obviously. α-Al dendrites are reduced and the mechanical properties of the castings are improved significantly when compared to those of the castings that are produced without vibration. However, when the peak acceleration is higher than 4 g, strong vibration will lead to defects formation, such as sand adhesion, while the amount and size of pores will be increased. And due to theturbulent flow that caused by strong vibration, the chance of forming large pores in the matrix has been increased significantly. The increase in defects will result in the deterioration of mechanical properties.

  11. Secondary Solidification Behavior of A356 Aluminum Alloy Prepared by the Self-Inoculation Method

    Ming Li


    Full Text Available Semisolid slurry of A356 aluminum alloy was prepared by Self-Inoculation Method, and the secondary solidification behavior during rheo-diecasting forming process was researched. The results indicate that the component with non-dendritic and uniformly distributed microstructures can be produced by Rheo-Diecasting (RDC process (combining Self-inoculation Method (SIM with High Pressure Die Casting (HPDC. The isothermal holding time of the slurry has large effect on primary particles, but has little effect on secondary particles. Growth rate of the primary particles in the isothermal holding process conforms to the dynamic equation of Dt3 − D03 = Kt. The suitable holding time for rheo-diecasting of A356 aluminum alloy is 3 min. During filling process, the nucleation occurs throughout the entire remaining liquid, and nuclei grow stably into globular particles with the limited grain size of 6.5μm firstly, then both α1 and α2 particles appear unstable growth phenomenon due to the existence of constitutional undercooling. The average particle sizes and shape factors of both α1 and α2 are decreasing with the increase of filling distance due to different cooling rate in different positions. The growth rate of the eutectic in RDC is 4 times faster than HPDC, which is mainly due to the limitation of α2 particles in RDC process. The average eutectic spacings are decreasing with the increase of filling distance.

  12. Relationship between crystal growth mode, preferred orientation and magnetostriction of (Tb0.3Dy0.7)Fe1.95 alloys

    ZHANG Shirong; LI Kuoshe; YU Dunbo; LI Yongsheng; YANG Hongchuan; LI Hongwei; TU Ganfeng


    The relationship between crystal growth mode, preferred orientation and magnetostrictive properties of (Tb0.3Dy0.7)Fe1.95 alloys was investigated at different directional solidification rates. The results showed that preferred orientation had a strong influence on the characteristics of (Tb0.3Dy0.7)Fe1.95 alloys. At lower solidification rates, the sample with preferred orientation showed larger low-field magnetostriction and apparent compressive stress effect. The excessive solidification rate resulted in failure of preferred orientation and a poor magnetostrictive performance. With an increase in solidification rates, the crystal growth modes changed gradually from cellular and primary dendrite morphology to developed dendritic morphology. In addition, domain configurations were observed using magnetic force microscopy, and the change of magnetostrictive properties was interpreted in terms of revealing the domain configurations.

  13. Optimization of Melt Treatment for Austenitic Steel Grain Refinement

    Lekakh, Simon N.; Ge, Jun; Richards, Von; O'Malley, Ron; TerBush, Jessica R.


    Refinement of the as-cast grain structure of austenitic steels requires the presence of active solid nuclei during solidification. These nuclei can be formed in situ in the liquid alloy by promoting reactions between transition metals (Ti, Zr, Nb, and Hf) and metalloid elements (C, S, O, and N) dissolved in the melt. Using thermodynamic simulations, experiments were designed to evaluate the effectiveness of a predicted sequence of reactions targeted to form precipitates that could act as active nuclei for grain refinement in austenitic steel castings. Melt additions performed to promote the sequential precipitation of titanium nitride (TiN) onto previously formed spinel (Al2MgO4) inclusions in the melt resulted in a significant refinement of the as-cast grain structure in heavy section Cr-Ni-Mo stainless steel castings. A refined as-cast structure consisting of an inner fine-equiaxed grain structure and outer columnar dendrite zone structure of limited length was achieved in experimental castings. The sequential of precipitation of TiN onto Al2MgO4 was confirmed using automated SEM/EDX and TEM analyses.

  14. Against the Grain

    Pedersen, Peter Ole


    Katalog-tekst til udstillingen Against the Grain om atomar-fotografi og det antropocæne. Kurateret af Peter Ole Pedersen på Galleri Image, august-oktober 2016.......Katalog-tekst til udstillingen Against the Grain om atomar-fotografi og det antropocæne. Kurateret af Peter Ole Pedersen på Galleri Image, august-oktober 2016....

  15. GrainSpotter

    Schmidt, Søren


    A new approach for indexing multigrain diffraction data is presented. It is based on the use of a monochromatic beam simultaneously illuminating all grains. By operating in sub-volumes of Rodrigues space, a powerful vertex-finding algorithm can be applied, with a running time that is compatible...... with online analysis. The resulting program, GrainSpotter, is sufficiently fast to enable online analysis during synchrotron sessions. The program applies outlier rejection schemes, leading to more robust and accurate data. By simulations it is shown that several thousand grains can be retrieved. A new method...... to derive partial symmetries, called pseudo-twins, is introduced. Uniquely, GrainSpotter includes an analysis of pseudo-twins, which is shown to be critical to avoid erroneous grains resulting from the indexing....

  16. Physics of Grain Alignment

    Lazarian, A


    Aligned grains provide one of the easiest ways to study magnetic fields in diffuse gas and molecular clouds. How reliable our conclusions about the inferred magnetic field depends critically on our understanding of the physics of grain alignment. Although grain alignment is a problem of half a century standing recent progress achieved in the field makes us believe that we are approaching the solution of this mystery. I review basic physical processes involved in grain alignment and show why mechanisms that were favored for decades do not look so promising right now. I also discuss why the radiative torque mechanism ignored for more than 20 years looks right now the most powerful means of grain alignment.

  17. Studies on the effect of vibration on hot cracking and Grain size in AA7075 Aluminum alloy Welding


    The aim of this present study is to investigate the vibration effect which is applied during Gas tungsten Arc welding (GTAW) welding in order to improve the quality of high strength Aluminum alloy weldment. An important metallurgical difficulty in arc welding of high strength aluminum alloys is formation of hot cracking. When Aluminum alloy is welded by GTAW process, weld fusion zone shows coarse columnar grains during weld metal solidification. This often leads to poor resistance to hot crac...

  18. Solidification fronts in large magma chambers: insights from the anomalies

    VanTongeren, J. A.


    The emplacement of hot viscous magma into the cold rigid crust causes a thermal disturbance within both the country rock and the magma. With time, heat loss from the molten interior to the walls causes solidification at the floor, roof and margins of the magma chamber. As is observed in both experiment and theory, in the absence of hydrothermal convection, the majority of heat is lost via conduction through the roof of the intrusion. In basaltic sills and layered mafic intrusions (LMIs), this solidification front is manifest in the deposition of mineral assemblages and compositions that become progressively more evolved from the floor of the intrusion upwards (the 'Layered Series'; LS) and from the roof downwards (the UBS) such that the most chemically evolved rocks are found in the interior of the magma body at a 'Sandwich Horizon'. The formation of a UBS, as typified by the Skaergaard Intrusion, is a natural outcome of the progression of the solidification front from the cold roof to the hot center of the magma chamber. There are, however, a few unique LMIs for which little or no UBS exists. Convection of the molten magma, reinjection and mixing of new magma, compaction of cumulates, and porous flow of interstitial liquid, among other processes, can affect the final location and composition of the most differentiated liquids; but ultimately, all are linked to the nature of heat loss from the magma chamber. In this study, I examine the thermal evolution of several classic LMIs as it is recorded in the extent of the preserved upper solidification front (or Upper Border Series; 'UBS'). For those intrusions that have experienced crystallization at the roof, such as the Skaergaard Intrusion, the development of a UBS reduces the temperature gradient at the roof and effectively slows the rate of heat loss from the main magma body. However, for those intrusions that do not have an UBS, such as the Bushveld Complex, the cooling rate is controlled only by the maximum rate

  19. Minimizing Segregation during the Controlled Directional Solidification of Dendric Alloys

    Grugel, Richard N.; Fedoseyev, Alex; Kim, Shin-Woo


    Gravity-driven convection induced in the liquid by density gradients of temperature or composition disrupts uniform dendritic growth during controlled directional solidification and promotes severe macrosegregation. The solute-rich region about the dendrite tip appears to play a pivotal role in channel initiation. Allen and Hunt referred to this region as an "initial transient" or dynamic region constituting steep concentration gradients. Experimental investigation also point to the role the tip region plays in developing microstructure. Hellawell and co-workers showed that flow-through dendritic channels could be effectively disrupted, and segregation minimized, during the gradient freezing of bulk castings by rotating the melt through a slight angle with respect to Earth's gravity vector. Adapting this principle to controlled directional solidification, it has been shown" that segregation in dendritic alloys can be minimized, and properties improved, by processing the sample near horizontal in conjunction with a slow axial rotation of the crucible. It is postulated that the observed microstructural uniformity arises by maintaining the developing solute field about the dendrite tip. Solute rejected during vertical directional solidification will rise or sink parallel to the primary dendrite arms during axial rotation setting the stage for accumulation, instabilities, and segregation. In contrast, during horizontal growth, the rejected solute will sink or rise perpendicular to the primary dendrite. Now, in the presence of a slight axial rotation, solute that was initially sinking (or rising) will find itself above (or below) its parent dendrite, i.e., still about the tip region. The following is intended to experimentally demonstrate the viability of this concept in coordination with a model that gives predictive insight regarding solute distribution about growing dendrites. Alloys based on the lead-tin eutectic system were used in this study. The system is well

  20. Effect of solidification parameters on the secondary dendrite arm spacing in MAR M-247 superalloy determined by a novel approach

    Milenkovic S.; Rahimian M.; Sabirov I.; Maestro L.


    The effect of solidification parameters on the secondary dendrite arm spacing in a MAR-M247 Ni-based superalloy has been studied by a novel approach, based on physical simulation of melting/solidification experiment with a constant cooling rate and variable temperature gradient. The applied experimental method proved to be efficient as it yielded a spread of microstructures corresponding to a range of well controlled solidification rates in a single melting/solidification experiment. In addit...

  1. Folding of Pollen Grains

    Katifori, Eleni; Alben, Silas; Cerda, Enrique; Nelson, David; Dumais, Jacques


    At dehiscence, which occurs when the anther reaches maturity and opens, pollen grains dehydrate and their volume is reduced. The pollen wall deforms to accommodate the volume loss, and the deformation pathway depends on the initial turgid pollen grain geometry and the mechanical properties of the pollen wall. We demonstrate, using both experimental and theoretical approaches, that the design of the apertures (areas on the pollen wall where the stretching and the bending modulus are reduced) is critical for controlling the folding pattern, and ensures the pollen grain viability. An excellent fit to the experiments is obtained using a discretized version of the theory of thin elastic shells.

  2. Containerless Solidification and Characterization of Industrial Alloys (NEQUISOL)

    Ilbagi, A.; Henein, H.; Chen, J.; Herlach, D. M.; Lengsdorf, R.; Gandin, Ch-A.; Tourret, D.; Garcia-Escorial, A.


    Containerless solidification using electromagnetic levitator (EML), gas atomization and an instrumented drop tube, known as impulse atomization is investigated for Al-Fe and Al-Ni alloys. The effects of primary phase and eutectic undercooling on the microstructure of Al-Fe alloys are investigated using the impulse drop tube and parabolic flight. The TEM characterization on the eutectic microstructure of impulse-atomized Al-Fe powders with two compositions showed that the metastable AlmFe formed in these alloys. Also, the growth undercooling that the dendritic front experiences during the solidification of the droplet resulted in variation of dendrite growth direction from to . For Al-4 at%Fe, it was found that in reduced-gravity and in the impulse-atomized droplets the primary intermetallic forms with a flower-like morphology, whereas in the terrestrial EML sample it has a needle like morphology. For Al-Ni, the effect of primary phase undercooling on dendrite growth velocity under terrestrial and reduced-gravity condition is discussed. It is shown that under terrestrial conditions, in the Ni-rich alloys with increasing undercooling the growth velocity increases, whereas in the Al-rich alloys the growth velocity decreases. However, the Al-rich alloy that was studied in reduced-gravity showed similar behavior to that of Ni-rich alloys. Furthermore, the effect of cooling rate on the phase fractions and metastable phase formation of impulse-atomized Al-Ni alloys is compared with EML. A microsegregation model for the solidification of Al-Ni alloys is applied to impulse atomized powders. The model accounts for the occurrence of several phase transformations, including one or several peritectic reactions and one eutectic reaction.

  3. Development of Stable Solidification Method for Insoluble Ferrocyanides-13170

    Ikarashi, Yuki; Masud, Rana Syed; Mimura, Hitoshi [Dept. of Quantum Science and Energy Engineering, Graduate School of Engineering, Tohoku University, Aramaki-Aza-Aoba6-6-01-2, Sendai, 980-8579 (Japan); Ishizaki, Eiji; Matsukura, Minoru [UNION SHOWA K.K. 17-20, Mita 2-chome, Minato-ku, Tokyo 108-0073 (Japan)


    The development of stable solidification method of insoluble ferrocyanides sludge is an important subject for the safety decontamination in Fukushima NPP-1. By using the excellent immobilizing properties of zeolites such as gas trapping ability and self-sintering properties, the stable solidification of insoluble ferrocyanides was accomplished. The immobilization ratio of Cs for K{sub 2}[CoFe(CN){sub 6}].nH{sub 2}O saturated with Cs{sup +} ions (Cs{sub 2}[CoFe(CN){sub 6}].nH{sub 2}O) was estimated to be less than 0.1% above 1,000 deg. C; the adsorbed Cs{sup +} ions are completely volatilized. In contrast, the novel stable solid form was produced by the press-sintering of the mixture of Cs{sub 2}[CoFe(CN){sub 6}].nH{sub 2}O and zeolites at higher temperature of 1,000 deg. C and 1,100 deg. C; Cs volatilization and cyanide release were completely depressed. The immobilization ratio of Cs, under the mixing conditions of Cs{sub 2}[CoFe(CN){sub 6}].nH{sub 2}O:CP= 1:1 and calcining temperature: 1,000 deg. C, was estimated to be nearly 100%. As for the kinds of zeolites, natural mordenite (NM), clinoptilolite (CP) and Chabazite tended to have higher immobilization ratio compared to zeolite A. This may be due to the difference in the phase transformation between natural zeolites and synthetic zeolite A. In the case of the composites (K{sub 2-X}Ni{sub X/2}[NiFe(CN){sub 6}].nH{sub 2}O loaded natural mordenite), relatively high immobilization ratio of Cs was also obtained. This method using zeolite matrices can be applied to the stable solidification of the solid wastes of insoluble ferrocyanides sludge. (authors)

  4. Analysis of Solidification in the Presence of High Rayleigh Number Convection in an Enclosure


    A simple and convenient analysis of the process of time-dependent solidification in an enclosed liquid cooled from the side in the presence of natural convection is presented.the influence of each parameter on the process of solidification is carried out systematically,The accuracy of this model is justified by comparing its predicting values with the previous results.

  5. Feasibility of integrated seed making and directional solidification of TiAl alloy using cold crucible

    ZHANG Cheng-jun; FU Heng-zhi; XU Da-ming; GUO Jing-jie; BI Wei-sheng; SU Yan-qing


    A new seed making method with cold crucible by power off technique was proposed. The cold crucible quenched seed with columnar structure has a similar cross-section shape as that of the cold crucible, and can be directly used for the directional solidification processes. The proposed method can significantly simplify the seeded directional solidification process and avoid the contamination from the seed machining.

  6. Nucleation and solidification of thin walled ductile iron - Experiments and numerical simulation

    Pedersen, Karl Martin; Tiedje, Niels Skat


    Investigation of solidification of thin walled ductile cast iron has been performed based on experiments and numerical simulation. The experiments were based on temperature and microstructure examination. Results of the experiments have been compared with a 1-D numerical solidification model...

  7. Isothermal solidification based packaging of biosensors at low temperatures

    Sharma, R.P., E-mail: [Electronic Science Department, Kurukshetra University, Kurukshetra-136119, Haryana (India); Central Electronics Engineering Research Institute (CEERI)/Council of Scientific and Industrial Research (CSIR), Pilani-333031, Rajasthan (India); Khanna, P.K., E-mail: pkk@ceeri.ernet.i [Central Electronics Engineering Research Institute (CEERI)/Council of Scientific and Industrial Research (CSIR), Pilani-333031, Rajasthan (India); Kumar, D., E-mail: [Electronic Science Department, Kurukshetra University, Kurukshetra-136119, Haryana (India)


    Thick film Au printed square contact pads are interconnected to Cu substrates at constant pressure and temperature using the isothermal solidification of Bi-In alloy on the joining surfaces. The effect of reaction time on the mechanical strength of the package has been analyzed. Thermal stability of the fabricated specimens have been measured and discussed. The delaminated surfaces examined optically reveal the morphology of the metallization zones on the joining substrates. The scanning electron microscopy of these surfaces is reported in this paper. Tests for thermal shock, pH resistivity and shelf life have been carried out to predict the reliability of the packaging for long term applications.

  8. Numerical Simulation of Dendrite Evolution during Solidification Process

    LI Qiang; GUO Qiao-yi; REN Chuan-fu


    In order to precisely describe the dendrite evolution during solidification process, especially in microscale, a continuous method is presented to deal with the discontinuous physical properties beside the solid/liquid interface. In this method, the physical properties are used as averaging physical properties of solid phase and liquid phase in the interface zone, which can smooth the property gap between solid and liquid phases, and make the properties from liquid phase to solid phase. The simulated results show that the method can represent the sidebranches and the solute micro-segregation well.

  9. Divorced Eutectic Solidification of Mg-Al Alloys

    Monas, Alexander; Shchyglo, Oleg; Kim, Se-Jong; Yim, Chang Dong; Höche, Daniel; Steinbach, Ingo


    We present simulations of the nucleation and equiaxed dendritic growth of the primary hexagonal close-packed -Mg phase followed by the nucleation of the -phase in interdendritic regions. A zoomed-in region of a melt channel under eutectic conditions is investigated and compared with experiments. The presented simulations allow prediction of the final properties of an alloy based on process parameters. The obtained results give insight into the solidification processes governing the microstructure formation of Mg-Al alloys, allowing their targeted design for different applications.

  10. Micro/macro solidification modeling of columnar eutectic growth

    Judson, Ward Michael


    A general multidimensional model of alloy solidification is presented in which a velocity-dependent freezing temperature is coupled with the macroscale energy equation. The velocity dependence of the freezing temperature ( Tf˜v ) results from the microscale species diffusion for microstructures with coupled eutectic growth. At solidification rates ( ˜ 1--10 mm/s) that are representative of gravity permanent mold and die casting processes, consideration of the nonequilibrium conditions at the interface affects the prediction of the macroscale thermal field. Near-eutectic alloys freeze with a macroscopically discrete solid-liquid interface at a temperature below the equilibrium eutectic temperature. The model is illustrated with unidirectional solidification of a near-eutectic alloy in a finite domain and solved numerically with a fixed-grid Galerkin finite element method. The numerical algorithm includes inexpensive steps to compute the interface speed explicitly. By nondimensionalizing the governing equations the effect of coupled eutectic growth on heat transport is clearly identified so that the model's sensitivity to important parameters can be investigated. Additionally, the average eutectic spacing can be determined with the temperature field, rather than post-determination from a standard, uncoupled solution of the energy equation. The eutectic coupling results indicate that the predicted solid-liquid interface location lags behind the uncoupled solution; therefore, decreasing the amount of solid formed, increasing the total solidification time, and increasing the average eutectic spacing. A procedure is also illustrated for computing mechanical properties using experimental correlations and the computed interface velocity history. The effect of the eutectic undercooling is then studied in a square domain and a realistic three-dimensional production casting geometry. In order to address the multidimensional cases, a phase-field formulation is developed

  11. Fractal growth in impurity-controlled solidification in lipid monolayers

    Fogedby, Hans C.; Sørensen, Erik Schwartz; Mouritsen, Ole G.


    A simple two-dimensional microscopic model is proposed to describe solidifcation processes in systems with impurities which are miscible only in the fluid phase. Computer simulation of the model shows that the resulting solids are fractal over a wide range of impurity concentrations and impurity...... diffusional constants. A fractal-forming mechanism is suggested for impurity-controlled solidification which is consistent with recent experimental observations of fractal growth of solid phospholipid domains in monolayers. The Journal of Chemical Physics is copyrighted by The American Institute of Physics....

  12. Numerical prediction of the incremental melting and solidification process

    Jun Wang; Chengchang Jia; Sheng Yin


    A mathematical formulation is applied to represent the phenomena in the incremental melting and solidification process (IMSP), and the temperature and electromagnetic fields and the depth of steel liquid phase are calculated by a finite difference technique using the control volume method. The result shows that the predicted values are in good agreement with the observations. In accordance with the calculated values for different kinds of materials and different size of molds, the technological parameter of the IMS process such as the power supply and the descending speed rate can be determined.

  13. Algorithms of optimum location of sensors for solidification parameters estimation

    J. Mendakiewicz


    Full Text Available The algorithms of optimal sensor location for estimation of solidification parameters are discussed. These algorithms base on the Fisher Information Matrix and A-optimality or D-optimality criterion. Numerical examples of planning algorithms are presented and next foroptimal position of sensors the inverse problems connected with the identification of unknown parameters are solved. The examplespresented concern the simultaneous estimation of mould thermophysical parameters (volumetric specific heat and thermal conductivityand also the components of volumetric latent heat of cast iron.

  14. Boundary-layer model of pattern formation in solidification

    Ben-Jacob, E.; Goldenfeld, N.; Langer, J. S.; Schon, G.


    A model of pattern formation in crystal growth is proposed, and its analytic properties are investigated. The principal dynamical variables in this model are the curvature of the solidification front and the thickness (or heat content) of a thermal boundary layer, both taken to be functions of position along the interface. This model is mathematically much more tractable than the realistic, fully nonlocal version of the free-boundary problem, and still recaptures many of the features that seem essential for studying dendritic behavior, for example. Preliminary numerical solutions produce snowflakelike patterns similar to those seen in nature.

  15. Permeability in a state of partial solidification of aqueous solution

    Okada, Masashi; Kang, Chaedong; Okiyama, Haruhiko

    A mushy region was formed by solidifying NaCl aqueous solution in a circular tube or a rectangular tube. The measurements of permeability were performed by changing volume fraction of liquid region in the mushy region. The dendritic ice in the solidification process was observed with a CCD microscope. The following results were obtained. The permeability increases with the volume fraction of liquid phase, and decreases with increasing the super-cooling degree of the solution or increasing the initial concentration of the solution, and is constant after the mushy region was formed. The arm space of dendrite becomes narrower as the super-cooling degree of the solution increases.

  16. Crystal Growth and Fluid Mechanics Problems in Directional Solidification

    Tanveer, Saleh A.; Baker, Gregory R.; Foster, Michael R.


    Our work in directional solidification has been in the following areas: (1) Dynamics of dendrites including rigorous mathematical analysis of the resulting equations; (2) Examination of the near-structurally unstable features of the mathematically related Hele-Shaw dynamics; (3) Numerical studies of steady temperature distribution in a vertical Bridgman device; (4) Numerical study of transient effects in a vertical Bridgman device; (5) Asymptotic treatment of quasi-steady operation of a vertical Bridgman furnace for large Rayleigh numbers and small Biot number in 3D; and (6) Understanding of Mullins-Sererka transition in a Bridgman device with fluid dynamics is accounted for.

  17. Constrained/unconstrained solidification within the massive cast steel/iron ingots

    W. S. Wołczyński


    Full Text Available Some properties of the ingot and especially of the steel forging ingots depend on the ratio of a columnar structure area to an equiaxed structure area created during solidification. The C-E transition is fundamental phenomenon that can be applied to characterize massive cast steel ingots produced by the casting house. The mentioned ratio is created spontaneously due to the rate of heat transfer towards the ceramic mould and then to the environment. The ceramic mould operates as an isolator. So that the thickness of the mould together with a growing solid fraction control the heat transfer and finally the ratio of the columnar structure area to the equiaxed structure area. At first the increase of heat accumulation within the ceramic mould is observed. Next the stationary state for heat transfer is created and finally a gentle abatement of the mould temperature associated with the heat output to the environment is expected. The steep thermal gradients correspond to the increase of heat accumulation in the ceramic mould. The steep thermal gradients are required to promote the columnar structure formation. The full heat accumulation in the mould corresponds well with the C-E transformation while the appearance of the moderate thermal gradients is referred to the gentle temperature abatement within the ceramic mould. The equiaxed structure is expected within this period of heat transfer behavior. The steep thermal gradients involve the activity of viscosity gradient in the liquid. As the result a sedimentary cones are formed at the bottom of the ingot. The C-E transformation is associated with competition between columnar and equaixed structure formation. At the end of competition a fully equiaxed structure is formed. The viscosity gradient is replaced by the thermophoresis which is the driving force for the deposition of some equiaxed grain layers onto the surface of C+E zone. The convection together with the gravity allow the layers to be uniform

  18. Metallurgical phenomena in laser finishing: Interdependences between solidification morphologies and hot cracking in laser welding of mostly austenitic materials. Final reportc; Metallkundliche Phaenomene der Laserstrahlmaterialbearbeitung. Teilvorhaben: Zusammenhaenge zwischen Erstarrungsmorphologien und Heissrissentstehung beim Laserschweissen von vornehmlich austenitischen Werkstoffen. Abschlussbericht

    Schobbert, H.


    Austentic stainless steels are widely used in safety relevant applications such as chemical plant industry or off-shore industry. Due to the rapid development of laser welding processes, the economical efficiency increases and leads to a growing interest in industry for the production of, for example, straight bead welded pipes. A specific problem of laser welding is the economically desirable high welding speed, which leads in austenitic stainless steels to a change of solidification mode and thus, to a restricted hot cracking resistance. Thus, the solidification morphologies of austenitic stainless steels near the eutectic trough during laser welding were investigated. Thereby, the main aspect was the evaluation of a short-term metallurgical kinetic effects under rapid solidification conditions. It was proven that three widely used stainless steels (1.4828, 1.4306, and 1.4404) show a transition of primary solidifcation mode from primary ferritic to primary austenitic solidification depending on the solidification rate. The approximate value of the critical soldification rate can be determined using a newly developed model by analyzing the geometric structures of solidification. The critical solidification rate for the transition of the solidification mode depends on the chemical composition of the base metal. It was shown that austenitic stainless steels have a critical solidification rate of approximately 1 m/min. As a main result, it was proven that a transition of the solidification mode to primary austenitic solidification promotes the predicted susceptibiliyy of hot cracking. For this, a hot cracking test assembly has been developed in order to determine the hot cracking behavior under laser beam conditions. In contrast to existing hot crack tests, a critical strain rate for hot crack initiation could be measured. A classification of the materials with respect to their hot cracking susceptibility under the solidification conditions during laser welding can

  19. Verification of a binary fluid solidification model in the finite-volume flow solver

    Waclawczyk, Tomasz


    The aim of this paper is to verify the new numerical implementation of a binary fluid, heat conduction dominated solidification model. First, we extend a semi-analytical solution to the heat diffusion equation, next, the range of its applicability is investigated. It was found that the linearization introduced to the heat diffusion equation negatively affects the ability to predict solidus and liquidus lines positions whenever the magnitude of latent heat of fusion exceeds a certain value. Next, a binary fluid solidification model is coupled with a flow solver, and is used in a numerical study of Al-4.1%Cu alloy solidification in a two-dimensional rectangular cavity. An accurate coupling between the solidification model and the flow solver is crucial for the correct forecast of solidification front positions and macrosegregation patterns.

  20. Effect of Coating on Instantaneous Interracial Heat Transfer During Near-Rapid Solidification

    ZHANG Wei; YU Yan; FANG Yuan; LI Jian-guo


    For many rapid or near-rapid solidification processes, the interracial heat transfer between the melt and the substrate is a key issue on the cooling and solidification rate of castings. For the purpose of controlling and adjusting of the interfacial thermal resistance, the effects of C/BN, Zn and organic coatings on the instantaneous interracial heat flux and the solidified structure of AISI304 stainless steel solidification on copper substrate have been investiga- ted by using an experimental simulator. The results show that C/BN coatings can improve the uniformity of heat flux and solidified structure; Zn coating can increase the heat flux and solidification rate in the growth stage of the solidified shell; organic coating will decrease the heat flux and the solidification rate and make re-melted structure on the surface of the solidified shell.

  1. Solidification microstructure selection of the peritectic Nd-Fe-B alloys

    ZHONG Hong; LI ShuangMing; L(U) HaiYan; LIU Lin; ZOU GuangRong; FU HengZhi


    Bridgman directional solidification and laser remelting experiments were carried out on Nd11.76Fe82.36B5.88 and Nd13.5Fe79.75B6.75 alloys. Microstructure evolutions along with solidification parameters (temperature gradient G, growth velocity V and initial alloy composition C0) were investigated. A solidification microstructure selection map was established, based on the consideration of solidification characteristics of peritectic T1 phase. In Bridgman directional solidification experiments, with the increasing growth velocities, the morphology of T1 phase changed from plane front or faceted plane front to dendrites. In laser remelting experiments, a transition from primary γ-Fe dendrites to T1 dendrites was found. Theoretical predictions are in good agreement with experimental results.

  2. Fabrication of directional solidification components of nickel-base superalloys by laser metal forming

    Liping Feng; Weidong Huang; Darong Chen; Xin Lin; Haiou Yang


    Straight plates, hollow columns, ear-like blade tips, twist plates with directional solidification microstructure made of Rene 95 superalloys were successfully fabricated on Nickel-base superalloy and DD3 substrates, respectively. The processing conditions for production of the parts with corresponding shapes were obtained. The fabrication precision was high and the components were compact. The solidification microstructure of the parts was analyzed by optical microscopy. The results show that the solidification microstructure is composed of columnar dendrites, by epitaxial growth onto the directional solidification substrates. The crystallography orientation of the parts was parallel to that of the substrates. The primary arm spacing was about 10 μm, which is in the range of superfine dendrites, and the secondary arm was small or even degenerated. It is concluded that the laser metal forming technique provides a method to manufacture directional solidification components.

  3. Solidification analysis of a centrifugal atomizer using the Al-32.7wt.% Cu alloy

    Osborne, Matthew G. [Iowa State Univ., Ames, IA (United States)


    A centrifugal atomizer (spinning disk variety) was designed and constructed for the production of spherical metal powders, 100-1,000 microns in diameter in an inert atmosphere. Initial atomization experiments revealed the need for a better understanding of how the liquid metal was atomized and how the liquid droplets solidified. To investigate particle atomization, Ag was atomized in air and the process recorded on high-speed film. To investigate particle solidification, Al-32.7 wt.% Cu was atomized under inert atmosphere and the subsequent particles were examined microscopically to determine solidification structure and rate. This dissertation details the experimental procedures used in producing the Al-Cu eutectic alloy particles, examination of the particle microstructures, and determination of the solidification characteristics (e.g., solidification rate) of various phases. Finally, correlations are proposed between the operation of the centrifugal atomizer and the observed solidification spacings.

  4. Solidification microstructure selection of the peritectic Nd-Fe-B alloys


    Bridgman directional solidification and laser remelting experiments were carried out on Nd11.76Fe82.36B5.88 and Nd13.5Fe79.75B6.75 alloys.Microstructure evolutions along with solidification parameters(temperature gradient G,growth velocity V and initial alloy composition C0)were investigated.A solidification microstructure selection map was established,based on the consideration of solidification characteristics of peritectic T1 phase.In Bridgman directional solidification experiments,with the increasing growth velocities,the morphology of T1 phase changed from plane front or faceted plane front to dendrites.In laser remelting experiments,a transition from primary γ-Fe dendrites to T1 dendrites was found.Theoretical predictions are in good agreement with experimental results.

  5. Crystallization kinetics of amorphous Nd3.6 Pr5.4 Fe83Co3B5 and preparation of α-Fe/Nd2Fe14B nanocomposite magnets by controlled melt-solidification technique

    杨丽; 尚勇


    The crystallization kinetics of amorphous Nd3. 6 Pr5.4 Fe83 Co3 B5 and the preparation of α-Fe/Nd2 Fe14 B nanocomposite magnets by controlled melt-solidification of Nd3.6Pr5.4Fe83Co3B5 was investigated by employing DTA, XRD, and TEM. The results show that a metastable intermediate phase Nd8Fe27B24 prior to α-Fe and Nd2 Fe14 B phases is crystallized as the amorphous Nd3.6 Pr5.4 Fe83 Co3 B5 is heated to 1 223 K. The crystallization activation energy of α-Fe and Nd8 Fe27324 phases is larger at the beginning stage of crystallization, and then it decreases with crystallized fraction x for the former and has little change when x is below 70% for the latter, which essentially results in an α-Fe/Nd2 Fe14 B microstructure with a relatively coarse grain size about 20-60 nm and a non-uniform distribution of grain size in the annealed alloy. The a-Fe/Nd2 Fe14 B nanocomposite magnets with a small average grain size about 14 nm and a quite uniform grain size distribution were prepared by controlled melt-solidification of nealing the amorphous Nd3. 6 Pr5. 4 Fe83 Co3 B5 precursor alloy.

  6. Influence of Zirconium on the Grain Refinement of Al 6063 alloy

    A.E. Mahmoud


    Full Text Available The influence of zirconium on the grain refinement of Al 6063 alloy has been experimentally investigated. The microstructure and macrostructure of the refined alloy were investigated. The experimental results reveal that, the coarse dendrites in the microstructure of the alloy are effectively refined with the addition of zirconium to the melt prior to solidification. Grains of Al 6063 alloy can be refined from 256 μm to 95 μm via addition of 0.2 wt. % Zr at holding time 90 seconds. The grain refinement effect of zirconium is found to be due to addition of zirconium to the melt in the form of master alloy introduces Al3Zr particles which are effective nucleating sites for the primary aluminium phase.

  7. Gas tungsten arc welding and friction stir welding of ultrafine grained AISI 304L stainless steel: Microstructural and mechanical behavior characterization

    Sabooni, S., E-mail: [Department of Materials Engineering, Isfahan University of Technology, 84156-83111 Isfahan (Iran, Islamic Republic of); Karimzadeh, F.; Enayati, M.H. [Department of Materials Engineering, Isfahan University of Technology, 84156-83111 Isfahan (Iran, Islamic Republic of); Ngan, A.H.W. [Department of Mechanical Engineering, The University of Hong Kong, Pokfulam Road, Hong Kong (China); Jabbari, H. [Department of Materials Engineering, Isfahan University of Technology, 84156-83111 Isfahan (Iran, Islamic Republic of)


    In the present study, an ultrafine grained (UFG) AISI 304L stainless steel with the average grain size of 650 nm was successfully welded by both gas tungsten arc welding (GTAW) and friction stir welding (FSW). GTAW was applied without any filler metal. FSW was also performed at a constant rotational speed of 630 rpm and different welding speeds from 20 to 80 mm/min. Microstructural characterization was carried out by High Resolution Scanning Electron Microscopy (HRSEM) with Electron Backscattered Diffraction (EBSD) and Transmission Electron Microscopy (TEM). Nanoindentation, microhardness measurements and tensile tests were also performed to study the mechanical properties of the base metal and weldments. The results showed that the solidification mode in the GTAW welded sample is FA (ferrite–austenite) type with the microstructure consisting of an austenite matrix embedded with lath type and skeletal type ferrite. The nugget zone microstructure in the FSW welded samples consisted of equiaxed dynamically recrystallized austenite grains with some amount of elongated delta ferrite. Sigma phase precipitates were formed in the region ahead the rotating tool during the heating cycle of FSW, which were finally fragmented into nanometric particles and distributed in the weld nugget. Also there is a high possibility that the existing delta ferrite in the microstructure rapidly transforms into sigma phase particles during the short thermal cycle of FSW. These suggest that high strain and deformation during FSW can promote sigma phase formation. The final austenite grain size in the nugget zone was found to decrease with increasing Zener–Hollomon parameter, which was obtained quantitatively by measuring the peak temperature, calculating the strain rate during FSW and exact examination of hot deformation activation energy by considering the actual grain size before the occurrence of dynamic recrystallization. Mechanical properties observations showed that the welding

  8. Solidification/Stabilization of Elemental Mercury Waste by Amalgamation

    Yim, S. P.; Ahn, B. G.; Lee, H. J.; Shon, J. S.; Chung, H.; Kim, K. J.; Lee, C. K.


    Experiments on solidification of elemental mercury waste were conducted by amalgamation with several metal powders such as copper, zinc, tin, brass and bronze. Unlike the previous studies which showed a dispersible nature after solidification, the waste forms were found to possess quite large compressive strengths in both copper and bronze amalgam forms. The durability was also confirmed by showing very minor changes of strength after 90 days of water immersion. Leachability from the amalgam forms is also shown to be low: measured mercury concentration in the leachate by the Toxicity Characteristic Leaching Procedure (TCLP) was well below the Environmental Protection Agency (EPA) limit. Long term leaching behavior by Accelerated Leach Test (ALT) has shown that the leaching process was dominated by diffusion and the effective diffusion coefficient was quite low (around 10-19 cm2/sec). The mercury vapor concentration from the amalgam forms were reduced to a 20% level of that for elemental mercury and to one-hundredth after 3 months.

  9. Numerical modelling of the binary alloys solidification with solutal undercooling

    T. Skrzypczak


    Full Text Available In thc papcr descrip~ion of mathcmn~icaI and numerical modcl of binay alloy sot idification is prcscntcd. Mctal alloy consisting of maincomponent and solulc is introduced. Moving, sharp solidification rmnt is assumcd. Conaitulional undcrcooling phcnomcnon is tnkcn intoconsidcralion. As a solidifica~ionf ront advances, solutc is rcdistributcd at thc intcrfacc. Commonly, solutc is rejccted into Itlc liquid. whcrcit accumuIatcs into solittc boundary laycr. Depending on thc tcmpcrature gradient, such tiquid may be undcrcoolcd hclow its mclting point,cvcn though it is hot~crth an liquid at thc Front. This phcnomcnon is orten callcd constitutional or soIr~talu ndcrcool ing, to cmphasizc that itariscs from variations in solutal distribution or I iquid. An important conscqucncc of this accurnulntion of saIutc is that it can cause thc frontto brcak down into cclls or dendri~csT. his occurs bccausc thcrc is a liquid ahcad of thc front with lowcr solutc contcnt, and hcncc a highcrme1 ting tcmpcraturcs than liquid at thc front. In rhc papcr locarion and shapc of wndcrcoolcd rcgion dcpcnding on solidification pararnctcrsis discussed. Nurncrical mcthod basing on Fini tc Elelncnt Mctbod (FEM allowi~lgp rcdiction of breakdown of inoving planar front duringsolidification or binary alloy is proposed.

  10. Modified enthalpy method for the simulation of melting and solidification

    Niranjan N Gudibande; Kannan N Iyer


    Enthalpy method is commonly used in the simulation of melting and solidification owing to its ease of implementation. It however has a few shortcomings. When it is used to simulate melting/solidification on a coarse grid, the temperature time history of a point close to the interface shows waviness. While simulatingmelting with natural convection, in order to impose no-slip and impermeability boundary conditions, momentum sink terms are used with some arbitrary constants called mushy zone constants. The values of these are very large and have no physical basis. Further, the chosen values affect the predictions and hence have to be tuned for satisfactory comparison with experimental data. To overcome these deficiencies, a new cell splitting method under the framework of the enthalpy method has been proposed. This method does not produce waviness nor requires mushy zone constants for simulating melting with natural convection. The method is then demonstrated for a simple onedimensional melting problem and the results are compared with analytical solutions. The method is then demonstrated to work in two-dimensions and comparisons are shown with analytical solutions for problems with planar and curvilinear interfaces. To further benchmark the present method, simulations are performed for melting in a rectangular cavity with natural convection in the liquid melt. The solid–liquid interface obtained is compared satisfactorily with the experimental results available in literature.

  11. Simulation of spreading with solidification: assessment synthesis of Thema code

    Spindler, B.; Veteau, J.M. [CEA Grenoble, Direction de l' Energie Nucleaire, Dept. de Technologie Nucleaire, Service d' Etudes Thermohydrauliques et Technologiques, 38 (France)


    After a presentation of the models included in THEMA code, which simulates the spreading of a fluid with solidification, the whole assessment calculations are presented. The first series concerns the comparison with analytical or numerical solutions: dam break, conduction for the heat transfer in the substrate, crust growth. The second series concerns the comparison with the CORINE isothermal tests (simulating fluid at low temperature). The third series concerns the CORINE tests with heat transfer. The fourth series concerns the tests with simulating materials at medium or high temperature (RIT, KATS). The fifth series concerns the tests with prototypical materials (COMAS, FARO, VULCANO). Finally the blind simulations of the ECOKATS tests are presented. All the calculations are performed with the same physical models (THEMA version 2.5), without any variable tuning parameter according to the test under consideration. Sensitivity studies concern the influence of the viscosity model in the solidification interval, and for the tests with prototypical materials the inlet temperature and the solid fraction. The relative difference between the calculated and measured spreading areas is generally less than 20 % except for the test with prototypical materials, for which the assessment is not easy due to the large experimental uncertainties. The level of validation of THEMA is considered as satisfactory, taking into account the required accuracy. (authors)

  12. Wax solidification of drying agents containing tritiated water

    Mishikawa, M.; Kido, H.


    It is necessary to immobilize the tritium not to give any impact on the environmental biosphere because tritium may give profound effects in the metabolic pathway. One of the most probable methods of immobilizing tritium would be incorporation of tritiated water in solid forms. Any drying or dehydration technique would be effective in a tritium cleanup system for off-gas streams containing tritium or tritiated water. Commonly used drying agents such as activated alumina, silica gel, molecular sieves and calcium sulfate are of value for removal of water vapour from air or other gases. For long term tritium storage, however, these adsorptive materials should be enveloped to prevent contact with water or water vapour because the rate of leaching, evaporation or diffusion of tritium from these porous materials is so large. The beeswax solidification method of the packed bed of drying agents adsorbing tritiated water is developed in this study, where the wax solidification procedure is performed by pouring the melt of wax into the void space of the packed bed of the drying agents and successive gradual cooling. The observed values of diffusivity or permeability of tritium in the wax solidified materials are about one-thousandth of those obtained for the cement block. Effect of coating on the rate of leaching is also discussed.

  13. Stability of a directional solidification front in subdiffusive media.

    Hamed, Mohammad Abu; Nepomnyashchy, Alexander A


    The efficiency of crystal growth in alloys is limited by the morphological instability, which is caused by a positive feedback between the interface deformation and the diffusive flux of solute at the front of the phase transition. Usually this phenomenon is described in the framework of the normal diffusion equation, which stems from the linear relation between time and the mean squared displacement of molecules 〈x2(t)〉∼K1t (K1 is the classical diffusion coefficient) that is characteristic of Brownian motion. However, in some media (e.g., in gels and porous media) the random walk of molecules is hindered by obstacles, which leads to another power law, 〈x2(t)〉∼Kαtα, where 0directional solidification front in the case of an anomalous diffusion. Linear stability of a moving planar directional solidification front is studied, and a generalization of the Mullins-Sekerka stability criterion is obtained. Also, an asymptotic nonlinear long-wave evolution equation of Sivashinsky's type, which governs the cellular structures at the interface, is derived.

  14. Microdomain patterns from directional eutectic solidification and epitaxy

    De Rosa C; Park; Thomas; Lotz


    Creating a regular surface pattern on the nanometre scale is important for many technological applications, such as the periodic arrays constructed by optical microlithography that are used as separation media in electrophoresis, and island structures used for high-density magnetic recording devices. Block copolymer patterns can also be used for lithography on length scales below 30 nanometres (refs 3-5). But for such polymers to prove useful for thin-film technologies, chemically patterned surfaces need to be made substantially defect-free over large areas, and with tailored domain orientation and periodicity. So far, control over domain orientation has been achieved by several routes, using electric fields, temperature gradients, patterned substrates and neutral confining surfaces. Here we describe an extremely fast process that leads the formation of two-dimensional periodic thin films having large area and uniform thickness, and which possess vertically aligned cylindrical domains each containing precisely one crystalline lamella. The process involves rapid solidification of a semicrystalline block copolymer from a crystallizable solvent between glass substrates using directional solidification and epitaxy. The film is both chemically and structurally periodic, thereby providing new opportunities for more selective and versatile nanopatterned surfaces.

  15. A study on polypropylene encapsulation and solidification of textile sludge.

    Kumari, V Krishna; Kanmani, S


    The textile sludge is an inevitable solid waste from the textile wastewater process and is categorised under toxic substances by statutory authorities. In this study, an attempt has been made to encapsulate and solidify heavy metals and dyes present in textile sludge using polypropylene and Portland cement. Sludge samples (2 Nos.) were characterized for pH (8.5, 9.5), moisture content (1.5%, 1.96%) and chlorides (245mg/L, 425.4mg/L). Sludge samples were encapsulated into polypropylene with calcium carbonate (additive) and solidified with cement at four different proportions (20, 30, 40, 50%) of sludge. Encapsulated and solidified cubes were made and then tested for compressive strength. Maximum compressive strength of cubes (size, 7.06cm) containing sludge (50%) for encapsulation (16.72 N/mm2) and solidification (18.84 N/mm2) was more than that of standard M15 mortar cubes. The leachability of copper, nickel and chromium has been effectively reduced from 0.58 mg/L, 0.53 mg/L and 0.07 mg/L to 0.28mg/L, 0.26mg/L and BDL respectively in encapsulated products and to 0.24mg/L, BDL and BDL respectively in solidified products. This study has shown that the solidification process is slightly more effective than encapsulation process. Both the products were recommended for use in the construction of non-load bearing walls.

  16. Solidification and crystal growth of solid solution semiconducting alloys

    Lehoczky, S.L.; Szofran, F.R.


    Problems associated with the solidification and crytal growth of solid-solution semiconducting alloy crystals in a terrestrial environment are described. A detailed description is given of the results for the growth of mercury cadmium telluride (HgCdTe) alloy crystals by directional solidification, because of their considerable technological importance. A series of HgCdTe alloy crystals are grown from pseudobinary melts by a vertical Bridgman method using a wide range of growth rates and thermal conditions. Precision measurements are performed to establish compositional profiles for the crystals. The compositional variations are related to compositional variations in the melts that can result from two-dimensional diffusion or density gradient driven flow effects ahead of the growth interface. These effects are discussed in terms of the alloy phase equilibrium properties, the recent high temperature thermophysical data for the alloys and the highly unusual heat transfer characteristics of the alloy/ampule/furnace system that may readily lead to double diffusive convective flows in a gravitational environment.

  17. Investigation of solidification dynamics of Zr-based alloys

    Kobold, Raphael; Herlach, Dieter [Institut fuer Materialphysik im Weltraum, Deutsches Zentrum fuer Luft- und Raumfahrt, 51170 Koeln (Germany); Ruhr-Universitaet Bochum, 44780 Bochum (Germany)


    In contrast to experiments with most undercooled binary alloys the velocity of dendritic growth of a Cu50Zr50 alloy does not increase monotonically with undercooling but passes through a maximum and then decreases. To study this behaviour we investigate Zr-based alloys such as CuZr, NiZr and NiZrAl with Zirconium concentrations ranging from 36 to 64 at.% including eutectic and intermetallic phases. We use electrostatic levitation technique to melt and undercool samples with a diameter of 2-3 mm under ultra-high-vacuum conditions. Containerless processing is an effective tool for undercooling metallic melts far below their equilibrium melting temperatures since heterogeneous nucleation on container walls is completely avoided. During crystallisation of the undercooled melt the heat of crystallisation is released. The rapid increase of the temperature at the solid-liquid interface makes the solidification front visible. The velocities of the solidification front are recorded by using a high-speed camera with a maximum rate of 50.000 frames per second and are analyzed with a software for optical ray tracing. Furthermore, we try to model the growth velocity vs. the undercooling temperature and perform sample EBSD analysis with a scanning electron microscope.

  18. A Review of Permanent Magnet Stirring During Metal Solidification

    Zeng, Jie; Chen, Weiqing; Yang, Yindong; Mclean, Alexander


    Rather than using conventional electromagnetic stirring (EMS) with three-phase alternating current, permanent magnet stirring (PMS), based on the use of sintered NdFeB material which has excellent magnetic characteristics, can be employed to generate a magnetic field for the stirring of liquid metal during solidification. Recent experience with steel casting indicates that PMS requires less than 20 pct of the total energy compared with EMS. Despite the excellent magnetic density properties and low power consumption, this relatively new technology has received comparatively little attention by the metal casting community. This paper reviews simulation modeling, experimental studies, and industrial trials of PMS conducted during recent years. With the development of magnetic simulation software, the magnetic field and associated flow patterns generated by PMS have been evaluated. Based on the results obtained from laboratory experiments, the effects of PMS on metal solidification structures and typical defects such as surface pinholes and center cavities are summarized. The significance of findings obtained from trials of PMS within the metals processing sector, including the continuous casting of steel, are discussed with the aim of providing an overview of the relevant parameters that are of importance for further development and industrial application of this innovative technology.

  19. Energetics of nonequilibrium solidification in Al-Sm

    Zhou, S. H.; Napolitano, R. E.


    Solution-based thermodynamic modeling, aided by first-principles calculations, is employed here to examine phase transformations in the Al-Sm binary system which may give rise to product phases that are metastable or have a composition that deviates substantially from equilibrium. In addition to describing the pure undercooled Al liquid with a two-state model that accounts for structural ordering, thermodynamic descriptions of the fcc phase, and intermediate compounds ( Al4Sm-β , Al11Sm3-α , Al3Sm-δ , and Al2Sm-σ ) are reanalyzed using special quasirandom structure and first-principles calculations. The possible phase compositions are presented over a range of temperatures using a “Baker-Cahn” analysis of the energetics of solidification and compared with reports of rapid solidification. The energetics associated with varying degrees of chemical partitioning are quantified and compared with experimental observations of the metastable Al11Sm3-α primary phase and reports of amorphous solids.

  20. Solidification and crystal growth of solid solution semiconducting alloys

    Lehoczky, S. L.; Szofran, F. R.


    Problems associated with the solidification and crytal growth of solid-solution semiconducting alloy crystals in a terrestrial environment are described. A detailed description is given of the results for the growth of mercury cadmium telluride (HgCdTe) alloy crystals by directional solidification, because of their considerable technological importance. A series of HgCdTe alloy crystals are grown from pseudobinary melts by a vertical Bridgman method using a wide range of growth rates and thermal conditions. Precision measurements are performed to establish compositional profiles for the crystals. The compositional variations are related to compositional variations in the melts that can result from two-dimensional diffusion or density gradient driven flow effects ahead of the growth interface. These effects are discussed in terms of the alloy phase equilibrium properties, the recent high temperature thermophysical data for the alloys and the highly unusual heat transfer characteristics of the alloy/ampule/furnace system that may readily lead to double diffusive convective flows in a gravitational environment.

  1. Effect of Melt Convection and Solid Transport on Macrosegregation and Grain Structure in Equiaxed Al-Cu Alloys

    Rerko, Rodney S.; deGroh, Henry C., III; Beckermann, Christoph; Gray, Hugh R. (Technical Monitor)


    Macrosegregation in metal casting can be caused by thermal and solutal melt convection, and the transport of unattached solid crystals. These free grains can be a result of, for example, nucleation in the bulk liquid or dendrite fragmentation. In an effort to develop a comprehensive numerical model for the casting of alloys, an experimental study has been conducted to generate benchmark data with which such a solidification model could be tested. The specific goal of the experiments was to examine equiaxed solidification in situations where sinking of grains is (and is not) expected. The objectives were: 1) experimentally study the effects of solid transport and thermosolutal convection on macrosegregation and grain size distribution patterns; and 2) provide a complete set of controlled thermal boundary conditions, temperature data, segregation data, and grain size data, to validate numerical codes. The alloys used were Al-1 wt. pct. Cu, and Al-10 wt. pct. Cu with various amounts of the grain refiner TiB2 added. Cylindrical samples were either cooled from the top, or the bottom. Several trends in the data stand out. In attempting to model these experiments, concentrating on experiments that show clear trends or differences is recommended.

  2. Solidification of Trapped Liquid in Rocks and Crystals

    Morse, S. A.


    Trapped liquid in an igneous cumulate solidifies over a range of time and temperature that can be retrieved by use of the lever rule in binary solutions applied to plagioclase using the range in the An content found for the individual rock studied. The resident crystals in the cumulate count in the phase equilibria as though deposited by the resident liquid in pure fractional crystallization at the moment of trapping. The An range (Morse JPet 53:891, 2012) when measured in sufficient detail, defines the solidification history. The instantaneous solid composition along the solidus defines the zoning of the plagioclase as it follows the trapped liquid on the liquidus. The reference bulk composition of the trapped liquid is given by an intercept on the initial solid-liquid lever, defined by the fraction of plagioclase in the trapped parent magma times the residual porosity. The mafic fraction is assumed to solidify by reaction independently of the plagioclase zoning. The residual porosity is calculated from the An range when that is calibrated to a value independently determined from the evolved components. Examples from a recent treatment of residual porosity (cited above) will be given for the solidification of selected rock compositions from the Kiglapait and Skaergaard intrusions. The same principles apply to the solidification of melt inclusions, with the difference that the latter tend to sample an evolved sheath by capture, rather than a parent magma trapped by closure of a cumulate. Melt inclusions are evolved from birth, and then are likely to evolve further with continued growth and re-equilibration of the container. The cumulate, by contrast, given any small degree of adcumulus growth, has had time to exchange the evolved rejected solute owing to its slow solidification, so its trapped liquid is the contemporaneous magma at the cumulate interface. Experimental results on melt inclusions in mafic magma demonstrate their intrinsic evolved nature. For example

  3. Microstructural Development during Directional Solidification of Peritectic Alloys

    Lograsso, Thomas A.


    A thorough understanding of the microstructures produced through solidification in peritectic systems has yet to be achieved, even though a large number of industrially and scientifically significant materials are in this class. One type of microstructure frequently observed during directional solidification consists of alternating layers of primary solid and peritectic solid oriented perpendicular to the growth direction. This layer formation is usually reported for alloy compositions within the two-phase region of the peritectic isotherm and for temperature gradient and growth rate conditions that result in a planar solid-liquid interface. Layered growth in peritectic alloys has not previously been characterized on a quantitative basis, nor has a mechanism for its formation been verified. The mechanisms that have been proposed for layer formation can be categorized as either extrinsic or intrinsic to the alloy system. The extrinsic mechanisms rely on externally induced perturbations to the system for layer formation, such as temperature oscillations, growth velocity variations, or vibrations. The intrinsic mechanisms approach layer formation as an alternative type of two phase growth that is inherent for certain peritectic systems and solidification conditions. Convective mixing of the liquid is an additional variable which can strongly influence the development and appearance of layers due to the requisite slow growth rate. The first quantitative description of layer formation is a model recently developed by Trivedi based on the intrinsic mechanism of cyclic accumulation and depiction of solute in the liquid ahead of the interface, linked to repeated nucleation events in the absence of convection. The objective of this research is to characterize the layered microstructures developed during ground-based experiments in which external influences have been minimized as much as possible and to compare these results to the current the model. Also, the differences

  4. Revisiting Acceleration of Charged Grains in Magnetohydrodynamic Turbulence

    Hoang, Thiem; Schlickeiser, R


    We study the acceleration of charged grains by magnetohydrodynamics (MHD) turbulence in the interstellar medium (ISM). We begin with revisiting gyroresonance acceleration by taking into account fluctuations of the grain guiding center along a uniform magnetic field (i.e. non-linear theory, NLT). We calculate grain velocity due to gyroresonance acceleration by fast modes using the NLT for different phases of the ISM, and compare with results obtained using quasi-linear theory (QLT). We find that the fluctuations of the grain guiding center reduce the grain velocity by less than 15 percent, but large grains are still accelerated to super-Alfvenic speed. For such super-Alfvenic grains, we investigate the effect of transit time damping (TTD) by fast modes. We find that due to the broadening of resonance condition in the NLT, the TTD acceleration is not only important for the cosine pitch angle $\\mu>V_{A}/v$, but also for $\\mugrain velocity and $V_{\\A}$ is Alfven speed. We show that t...

  5. In-Situ Observation of Growth Behavior of Niobium Carbide during Dual-Phase Rapid Solidification of SUS347H

    Yonemura, Mitsuharu; Osuki, Takahiro; Hirata, Hiroyuki; Ogawa, Kazuhiro


    In order to improve solidification cracking susceptibility, the crystallization of a heterophase such as the niobium carbide in the brittle temperature range is one of the effective techniques. In such a system, not only the growth behavior of dendrites during the rapid cooling but also the crystallization behavior of heterophase is very important. Therefore, diffraction patterns of a dual-phase mode Nb-bearing stainless steel during rapid cooling were investigated by in-situ two-dimensional time-resolved X-ray diffraction for the first time in order to reveal the microstructure formation. We discuss the growth behavior of dendrites with crystallization of niobium carbides. Subsequently, the niobium carbide formed epitaxially to the dendrite of the preferred in-plane orientation, having a small distorted orientation. With undercooling of several degree Celsius, the coherent growth on the δ-ferrite was stable for niobium carbide.

  6. Global stabilities, selection of steady cellular growth, and origin of side branches in directional solidification.

    Xu, Jian-Jun; Chen, Yong-Qiang


    The present paper investigates the global instability mechanisms of arrayed-cellular growth with asymptotic approach. We find that the system of directional solidification involves two types of global instability mechanisms: the low-frequency instability and the global oscillatory instability, which are profoundly similar to that found in the system of viscous fingering and free dendritic growth. Based on these global instabilities, the neutral mode selection principle for the limiting state of growth is proposed; the origin and essence of side branching on the interface are elucidated with the so-called global trapped wave mechanism, which involves the interfacial wave reflection and amplification along the interface. It is demonstrated that side branching is self-sustaining and can persist without continuously applying the external noise; the effect of the anisotropy of interfacial energy is not essential for the selection of steady cellular growth and for the origin and formation of side branching at the interface. The comparisons of theoretical results are made with the most recent experimental works and the numerical simulations which show very good quantitative agreement.

  7. Fingering phenomena during grain-grain displacement

    Mello, Nathália M. P.; Paiva, Humberto A.; Combe, G.; Atman, A. P. F.


    Spontaneous formation of fingered patterns during the displacement of dense granular assemblies was experimentally reported few years ago, in a radial Hele-Shaw cell. Here, by means of discrete element simulations, we have recovered the experimental findings and extended the original study to explore the control parameters space. In particular, using assemblies of grains with different geometries (monodisperse, bidisperse, or polydisperse), we measured the macroscopic stress tensor in the samples in order to confirm some conjectures proposed in analogy with Saffman-Taylor viscous fingering phenomena for immiscible fluids. Considering an axial setup which allows to control the discharge of grains and to follow the trajectory and the pressure gradient along the displacing interface, we have applied the Darcy law for laminar flow in fluids in order to measure an "effective viscosity" for each assembly combination, in an attempt to mimic variation of the viscosity ratio between the injected/displaced fluids in the Saffman-Taylor experiment. The results corroborate the analogy with the viscous fluids displacement, with the bidisperse assembly corresponding to the less viscous geometry. But, differently to fluid case, granular fingers only develop for a specific combination of displaced/injected geometries, and we have demonstrated that it is always related with the formation of a force chain network along the finger direction.

  8. On the toughening of brittle materials by grain bridging:promoting intergranular fracture through grain angle, strength, andtoughness

    Foulk III, J.W.; Johnson, G.C.; Klein, P.A.; Ritchie, R.O.


    The structural reliability of many brittle materials such asstructural ceramics relies on the occurrence of intergranular, as opposedto transgranular, fracture in order to induce toughening by grainbridging. For a constant grain boundary strength and grain boundarytoughness, the current work examines the role of grain strength, graintoughness, and grain angle in promoting intergranular fracture in orderto maintain such toughening. Previous studies have illustrated that anintergranular path and the consequent grain bridging process can bepartitioned into five distinct regimes, namely: propagate, kink, arrest,stall and bridge. To determine the validity of the assumed intergranularpath, the classical penentration/deflection problem of a crack impingingon an interface is reexamined within a cohesive zone framework forintergranular and transgranular fracture. Results considering both modesof propagation, i.e., a transgranular and intergranular path, reveal thatcrack-tip shielding is a natural outcome of the cohesive zone approach tofracture. Cohesive zone growth in one mode shields the opposing mode fromthe stresses required for cohesive zone initiation. Although stablepropagation occurs when the required driving force is equivalent to thetoughness for either transgranular or intergranular fracture, the mode ofpropagation depends on the normalized grain strength, normalized graintoughness, and grain angle. For each grain angle, the intersection ofsingle path and multiple path solutions demarcates "strong" grains thatincrease the macroscopic toughness and "weak" grains that decrease it.The unstable transition to intergranular fracture reveals that anincreasinggrain toughness requires a growing region of the transgranularcohesive zone be at and near the peak cohesive strength. The inability ofthe body to provide the requisite stress field yields an overdriven andunstable configuration. The current results provide restrictions for theachievement of substantial toughening

  9. Microstructure, corrosion behavior and cytotoxicity of biodegradable Mg–Sn implant alloys prepared by sub-rapid solidification

    Zhao, Chaoyong [College of Materials Science and Engineering, Chongqing University, Chongqing 400044 (China); Pan, Fusheng, E-mail: [College of Materials Science and Engineering, Chongqing University, Chongqing 400044 (China); National Engineering Research Center for Magnesium Alloys, Chongqing University, Chongqing 400044 (China); Chongqing Academy of Science and Technology, Chongqing 401123 (China); Zhao, Shuang; Pan, Hucheng; Song, Kai [College of Materials Science and Engineering, Chongqing University, Chongqing 400044 (China); Tang, Aitao [College of Materials Science and Engineering, Chongqing University, Chongqing 400044 (China); National Engineering Research Center for Magnesium Alloys, Chongqing University, Chongqing 400044 (China)


    In this study, biodegradable Mg–Sn alloys were fabricated by sub-rapid solidification, and their microstructure, corrosion behavior and cytotoxicity were investigated by using optical microscopy, scanning electron microscopy equipped with an energy dispersive X-ray spectroscopy, X-ray diffraction, immersion test, potentiodynamic polarization test and cytotoxicity test. The results showed that the microstructure of Mg–1Sn alloy was almost equiaxed grain, while the Mg–Sn alloys with higher Sn content (Sn ≥ 3 wt.%) displayed α-Mg dendrites, and the secondary dendrite arm spacing of the primary α-Mg decreased significantly with increasing Sn content. The Mg–Sn alloys consisted of primary α-Mg matrix, Sn-rich segregation and Mg{sub 2}Sn phase, and the amount of Mg{sub 2}Sn phases increased with increasing Sn content. Potentiodynamic polarization and immersion tests revealed that the corrosion rates of Mg–Sn alloys increased with increasing Sn content. Cytotoxicity test showed that Mg–1Sn and Mg–3Sn alloys were harmless to MG63 cells. These results of the present study indicated that Mg–1Sn and Mg–3Sn alloys were promising to be used as biodegradable implants. - Highlights: • Biodegradable Mg–Sn implant alloys were prepared by sub-rapid solidification. • Secondary dendrite arm spacing of alloys decreased with increasing Sn content. • Corrosion rates of alloys increased significantly with increasing Sn content. • Mg–1Sn and Mg–3Sn alloys were harmless to MG63 cells.

  10. Analysis on characteristics and influential factors of grain yield fluctuation in China based on empirical mode decomposition%基于经验模态分解的中国粮食单产波动特征及影响因素

    刘忠; 黄峰; 李保国


    。当前中国的农业已经进入了新的发展阶段,农业政策的调整势在必行,该研究结果可为新阶段农业宏观调控政策的制定提供决策依据。%There is an important significance for China’s food security to explore the fluctuation characteristics and influence factors of grain output per sown area (hereinafter referred to as grain yield), and then to take corresponding measures to stabilize and improve the grain yield level. In this paper, the time-series yields of grain and main crops (rice, wheat and maize) from 1978 to 2012 in China were decomposed using empirical mode decomposition (EMD) method, and then multi-scale fluctuation characteristics and its main influence factors of grain yield were analyzed. The results showed: 1) the time series of grain yield could be decomposed into two intrinsic mode functions (IMF) and a residual item. The residual item denotes a slow and steady rising trend in grain yield which is dominated by the technological progress. The IMF1 and IMF2 represent a short-term fluctuation in about 4-yr cycle and a medium-term fluctuation in about 9-yr cycle, which respectively reflect the influence of meteorological and policy factors on grain yields according to the analysis of grain production system. The variance contribution rate of the residual item was greatly larger than that of the IMFs, which means the upward trend in grain yield was more pronounced than fluctuations. 2) Fluctuation of trend yield of grain was distinct before and after 1997: fast rise with an average annual growth rate of 2.28% before 1997 and slow rise with an average annual growth rate of only 0.69% after 1997. The change of trend yield was similar between rice and grain, but the former seemed to rise more slowly after 1997. For wheat and maize, the trend yield was still increased obviously although the growing rate had been significantly slowing down after 1997. 3) The IMF2 included 3 complete cycles (1979-1988, 1989-1993, and

  11. Effect of Melt Superheating Treatment on Directional Solidification Interface Morphology of Multi-component Alloy

    Changshuai Wang; Jun Zhang; Lin Liu; Hengzhi Fu


    The influence of melt superheating treatment on the solid/liquid (S/L) interface morphology of directionally solidified Ni-based superalloy DZ125 is investigated to elucidate the relationship between melt characteristic and S/L interface stability. The results indicate that the interface morphology is not only related to the withdrawal velocity (R) but also to the melt superheating temperature (Ts) when the thermal gradient of solidification interface remains constant for different Ts with appropriate superheating treatment regulation. The interface morphology changes from cell to plane at R of 1.1 μm/s when Ts increases from 1500°C to 1650°C, and maintains plane with further elevated Ts of 1750°C. However, the interface morphology changes from coarse dendrite to cell and then to cellular dendrite at R of 2.25 μm/s when Ts increases from 1500°C to 1650°C and then to 1750°C. It is proved that the solidification onset temperature and the solidification interval undergo the nonlinear variation when Ts increases from 1500°C to 1680°C, and the turning point is 1650°C at which the solidification onset temperature and the solidification interval are all minimum. This indicates that the melt superheating treatment enhances the solidification interface stability and has important effect on the solidification characteristics.

  12. ThermoCalc Application for the Assessment of Binary Alloys Non-Equilibrium Solidification

    Zyska A.


    Full Text Available The paper presents the possibility of application of the developed computer script which allows the assessment of non-equilibrium solidification of binary alloys in the ThermoCalc program. The script makes use of databases and calculation procedures of the POLY-3 module. A solidification model including diffusion in the solid state, developed by Wołczyński, is used to describe the non-equilibrium solidification. The model takes into account the influence of the degree of solute segregation on the solidification process by applying the so-called back-diffusion parameter. The core of the script is the iteration procedure with implemented model equation. The possibility of application of the presented calculation method is illustrated on the example of the Cr-30% Ni alloy. Computer simulations carried out with use of the developed script allow to determine the influence of the back-diffusion parameter on the course of solidification curves, solidus temperature, phase composition of the alloy and the fraction of each phase after the solidification completion, the profile of solute concentration in liquid during solidification process, the average solute concentration in solid phase at the eutectic temperature and many other quantities which are usually calculated in the ThermoCalc program.

  13. Directional solidification of flake and nodular cast iron during KC-135 low-g maneuvers

    Curreri, P. A.; Stefanescu, D. M.; Hendrix, J. C.


    Alloys solidified in a low-gravity environment can, due to the elimination of sedimentation and convection, form unique and often desirable microstructures. One method of studying the effects of low-gravity (low-g) on alloy solidification was the use of the NASA KC-135 aircraft flying repetitive low-g maneuvers. Each maneuver gives from 20 to 30 seconds of low-g which is between about 0.1 and 0.001 gravity. A directional solidification furnace was used to study the behavior of off eutectic composition case irons in a low-g environment. The solidification interface of hypereutectic flake and spheroidal graphite case irons was slowly advanced through a rod sample, 5 mm in diameter. Controlled solidification was continued through a number of aircraft parabolas. The known solidification rate of the sample was then correlated with accelerometer data to determine the gravity level during solidification for any location of the sample. The thermal gradient and solidification rate were controlled independently. Samples run on the KC-135 aircraft exhibited bands of coarser graphite or of larger nodules usually corresponding to the regions solidified under low-g. Samples containing high phosphorous (used in order to determine the eutectic cell) exhibited larger eutectic cells in the low-g zone, followed by a band of coarser graphite.

  14. Composite circumstellar dust grains

    Gupta, Ranjan; Vaidya, Dipak B.; Dutta, Rajeshwari


    We calculate the absorption efficiencies of composite silicate grains with inclusions of graphite and silicon carbide in the spectral range 5-25 μm. We study the variation in absorption profiles with volume fractions of inclusions. In particular we study the variation in the wavelength of peak absorption at 10 and 18 μm. We also study the variation of the absorption of porous silicate grains. We use the absorption efficiencies to calculate the infrared flux at various dust temperatures and compare with the observed infrared emission flux from the circumstellar dust around some M-type and asymptotic giant branch stars obtained from IRAS and a few stars from Spitzer satellite. We interpret the observed data in terms of the circumstellar dust grain sizes, shape, composition and dust temperature.

  15. Composite Circumstellar Dust Grains

    Gupta, Ranjan; Dutta, Rajeshwari


    We calculate the absorption efficiencies of composite silicate grains with inclusions of graphite and silicon carbide in the spectral range 5--25$\\rm \\mu m$. We study the variation in absorption profiles with volume fractions of inclusions. In particular we study the variation in the wavelength of peak absorption at 10 and 18$\\rm \\mu m$. We also study the variation of the absorption of porous silicate grains. We use the absorption efficiencies to calculate the infrared flux at various dust temperatures and compare with the observed infrared emission flux from the circumstellar dust around some M-Type \\& AGB stars obtained from IRAS and a few stars from Spitzer satellite. We interpret the observed data in terms of the circumstellar dust grain sizes; shape; composition and dust temperature.

  16. A Successful Synthesis of the CoCrFeNiAl0.3 Single-Crystal, High-Entropy Alloy by Bridgman Solidification

    Ma, S. G.; Zhang, S. F.; Gao, M. C.; Liaw, P. K.; Zhang, Y.


    For the first time, a face-centered-cubic, single-crystal CoCrFeNiAl{sub 0.3} (designated as Al0.3), high-entropy alloy (HEA) was successfully synthesized by the Bridgman solidification (BS) method, at an extremely low withdrawal velocity through a constant temperature gradient, for which it underwent two BS steps. Specially, at the first BS step, the alloy sample underwent several morphological transitions accompanying the crystal growth from the melt. This microstructure evolves from as-cast dendrites, to equiaxed grains, and then to columnar crystals, and last to the single crystal. In particular, at the equiaxed-grain region, some visible annealing twins were observed, which indicates a low stacking fault energy of the Al0.3 alloy. Although a body-centered- cubic CoCrFeNiAl (Al1) HEA was also prepared under the same conditions, only a single columnar-crystal structure with instinctively preferential crystallographic orientations was obtained by the same procedure. A similar morphological transition from dendrites to equiaxed grains occurred at the equiaxed-grain region in Al1 alloy, but the annealing twins were not observed probably because a higher Al addition leads to a higher stacking fault energy for this alloy.

  17. Immobilisation/solidification of hazardous toxic waste in cement matrices

    Macías, A.


    Full Text Available Immobilization and solidification of polluting waste, introduced into the industrial sector more than 20 years ago, and throughout last 10 years is being the object of a growing interest for engineers and environment scientists, has become a remarkable standardized process for treatment and management of toxic and hazardous liquid wastes, with special to those containing toxic metals. Experimental monitorization of the behaviour of immobilized waste by solidification and stabilisation in life time safe deposits is not possible, reason why it is essential to develop models predicting adequately the behaviour of structures that have to undergo a range of conditions simulating the environment where they are to be exposed. Such models can be developed only if the basic physical and chemical properties of the system matrix/solidifying-waste are known. In this work immobilization/solidification systems are analyzed stressing out the formulation systems based on Portland cement. Finally, some examples of the results obtained from the study of interaction of specific species of wastes and fixation systems are presented.

    La inmovilización y solidificación de residuos contaminantes, implantada en el sector comercial desde hace más de 20 años y que desde hace diez es objeto de creciente interés por parte de ingenieros y científicos medioambientales, se ha convertido en un proceso estandarizado único para el tratamiento y gestión de residuos tóxicos y peligrosos líquidos y, en especial, de los que contienen metales pesados. La monitorización experimental del comportamiento de un residuo inmovilizado por solidificación y estabilización en el tiempo de vida de un depósito de seguridad no es posible, por lo que es imprescindible desarrollar modelos que predigan satisfactoriamente el comportamiento del sistema bajo un rango representativo de condiciones del entorno de exposición. Tales modelos sólo pueden ser desarrollados si se

  18. Immiscible phase incorporation during directional solidification of hypermonotectics

    Andrews, J. Barry; Merrick, Roger A.


    Solidification processes in immiscible samples were investigated by directly observing the events taking place at the solid-liquid interface during directional solidification. Visualization of these events was made possible through the use of a transparent metal analog system and a temperature gradient stage assembly fitted to an optical microscope. The immiscible transparent analog system utilized was the succinonitrile-glycerol system. This system has been shown to exhibit the same morphological transitions as observed in metallic alloys of monotectic composition. Both monotectic and hypermonotectic composition samples were directionally solidified in order to gain an improved understanding of the manner in which the excess hypermonotectic liquid is incorporated into the solidifying structure. The processing conditions utilized prevented sedimentation of the excess hypermonotectic liquid by directionally solidifying the samples in very thin (13 microns), horizontally oriented cells. High thermal gradient to growth rate ratios (G/R) were used in an effort to prevent constitutional supercooling and the subsequent formation of L(sub 2) droplets in advance of the solidification front during the growth of fibrous composite structures. Results demonstrated that hypermonotectic composites could be produced in samples up to two weight percent off of the monotectic composition by using a G/R ratio greater than or equal to 4.6 x 10(exp 4) C(s)/mm(sup 2) to avoid constitutional supercooling. For hypermonotectic samples processed with G/R ratios below 4.6 x 10(exp 4) C(s)/mm(sup 2), constitutional supercooling occurred and resulted in slight interfacial instability. For these samples, two methods of incorporation of the hypermonotectic liquid were observed and are reported. The correlation between the phase spacing, lambda, and the growth rate, R, was examined and was found to obey a relationship generally associated with a diffusion controlled coupled growth process. For

  19. Numerical analysis on solidification process and heat transfer of FGH95 superalloy droplets during PREP

    Huanming Chen; Benfu Hu; Yiwen Zhang; Quanmao Yu; Huiying Li


    In order to understand the relation between microstructure of superalloy powders and its solidification progress, the processing parameters are optimized during plasma rotating electrode processing (PREP). It was predicted from the results that the droplet velocities, droplet temperature, and fractional solidification with flight time about FGH95 superalloy droplet have been carried out based on Newtonian heat transfer formulation coupled with the classical heterogeneous nucleation and the specific solidification process. It has been found that the droplet dynamic and thermal behavior is strongly affected by the distribution of droplet diameters,the proportion of cooling atmosphere, but is relatively unaffected by the droplet superheat.

  20. Numerical calculation on temperature field of FGH95 alloy droplet during rapid solidification

    Huanming Chen; Benfu Hu


    The temperature field of FGH95 alloy droplet atomized by plasma rotating electrode processing (PREP) during solidifica-tion has been calculated through numerical analysis based on equivalent sensible heat capacity method. And thus the relational cul-ves among temperature gradient of solid-liquid interface, moving velocity of solid-liquid interface and solid fraction during solidifi-cation have been presented. The results indicate that the relation between average temperature gradient of solid-liquid interface anddroplet size, and the relation between average moving velocity of solid-liquid interface and droplet size can be expressed during solidification.

  1. Elimination of Hot Tears in Steel Castings by Means of Solidification Pattern Optimization

    Kotas, Petr; Tutum, Cem Celal; Thorborg, Jesper


    the solidification pattern, i.e., establishing directional and progressive solidification with the help of the Niyama criterion, macrosegregation and hot tearing issues can be both minimized or eliminated entirely. An original casting layout was simulated using a transient three-dimensional (3-D) thermal fluid model...... incorporated in a commercial simulation software package to determine potential flaws and inadequacies. Based on the initial casting process assessment, multiobjective optimization of the solidification pattern of the considered steel part followed. That is, the multiobjective optimization problem of choosing...

  2. Investigation of the physical properties of iron nanoparticles in the course of the melting and solidification

    Fedorov, A. V.; Shul'gin, A. V.; Lavruk, S. A.


    The processes of iron-nanoparticles melting and iron-nanodroes solidification have been studied under different thermal actions. The determined values of the phase-transition temperatures for particles with radii of 1.5-4 nm agree with the data calculated by other authors. In the course of calculating the solidification of iron nanoparticles, the dependence of the solidification temperature on the rate of heat removal has been found and the hysteresis of the phase transition has been demonstrated. Based on the determined caloric curves, the heat capacity of the particles has been found and their approximation in the form of dependences on temperature and particle size has been suggested.

  3. Long-time dynamics of the directional solidification of rodlike eutectics.

    Perrut, Mikaël; Akamatsu, Silvère; Bottin-Rousseau, Sabine; Faivre, Gabriel


    We report long-duration real-time observations of the dynamics of hexagonal (rodlike) directional-solidification patterns in bulk samples of a transparent eutectic alloy. A slight forward curvature of the isotherms induces a slow dilatation of the growth pattern at constant solidification rate and triggers the rod-splitting instability. At long times, the rod-splitting frequency exactly balances the dilatation driven by the curved isotherms. The growth pattern is then disordered and nonstationary but has a sharply selected mean spacing. Well-ordered growth patterns can be grown using time-dependent solidification rates.

  4. Control of dendrite growth by a magnetic field during directional solidification

    Dai, Yanchao; Du, Dafan; Hou, Long; Gagnoud, Annie; Ren, Zhongming; Fautrelle, Yves; Moreau, Rene; Li, Xi


    In this work, the alignment behavior of three kinds of dendrites (Al3Ni, α-Al and Al2Cu dendrites) with a remarkable crystalline anisotropy during directional solidification under an axial magnetic field is studied by the EBSD technology. Experimental results reveal that the magnetic field is capable of tailoring the dendrite alignment during directional solidification. Further, based on the crystalline anisotropy, a method to control the dendrite alignment by adjusting the angle between the magnetic field and the solidification direction is proposed.

  5. Three Dimensional Numerical Simulation for the Driving Force of Weld Solidification Cracking

    Zhibo DONG; Yanhong WEI; Renpei LIU; Zujue DONG


    The double ellipsoidal model of heat source is used to analyze the thermal distributions with a three dimensional finite element method (FEM). In the mechanical model, solidification effects are treated by a dynamic element rebirth scheme. The driving force is obtained in the cracking susceptible temperature range. Moreover, this paper presents the effect of solidification shrinkage, external restraint, weld start locations and material properties on the driving force. The comparison between the simulated driving force and the experimental measurements of the material resistance predicts the susceptibility of weld metal solidification cracking.

  6. Assessment of mathematical models for the flow in directional solidification

    Lu, Jay W.; Chen, Falin


    In a binary solution unidirectionally solidified from below, the bulk melt and the eutectic solid is separated by a dendritic mushy zone. The mathematical formulation governing the fluid motion shall thus consist of the equations in the bulk melt and the mushy zone and the associated boundary conditions. In the bulk melt, assuming that the melt is a Newtonian fluid, the governing equations are the continuity equation, the Navier-Stokes equations, the heat conservation equation, and the solute conservation equation. In the mushy layer, however, the formulation of the momentum equation and the associated boundary conditions are diversified in previous investigations. In this paper, we discuss three mathematical models, which had been previously applied to study the flow induced by the solidification of binary solutions cooling from below. The assessment is given on the bases of the stability characteristics of the convective flow and the comparison between the numerical and experimental results.

  7. Melting and solidification of Bi nanoparticles in a germanate glass

    Haro-Poniatowski, E.; Jiménez de Castro, M.; Fernández Navarro, J. M.; Morhange, J. F.; Ricolleau, C.


    A very large melting-solidification hysteresis of Bi nanoparticles embedded in a bulk alkali germanate glass is reported. Heating and cooling cycles are reproducible and show reversible transitions. High resolution transmission electron microscopy reveals that the glass contains nanocrystals of elementary Bi which are a few tenths of a nanometre in size. Upon heating above the Bi melting temperature the glass transmission increases up to 10% with respect to the initial value, which is most likely related to Bi melting. Upon cooling this high transmission state remains up to temperatures as low as 436 K. This behaviour is confirmed by Raman spectroscopy measurements. This nanostructured glass with a high refractive index can be used in nonlinear optical applications as well as an optical thermo-sensor.

  8. Polymer solidification of mixed wastes at the Rocky Flats Plant

    Faucette, A.M.; Logsdon, B.W.; Lucerna, J.J.; Yudnich, R.J.


    The Rocky Flats Plant is pursuing polymer solidification as a viable treatment option for several mixed waste streams that are subject to land disposal restrictions within the Resource Conservation and Recovery Act provisions. Tests completed to date using both surrogate and actual wastes indicate that polyethylene microencapsulation is a viable treatment option for several mixed wastes at the Rocky Flats Plant, including nitrate salts, sludges, and secondary wastes such as ash. Treatability studies conducted on actual salt waste demonstrated that the process is capable of producing waste forms that comply with all applicable regulatory criteria, including the Toxicity Characteristic Leaching Procedure. Tests have also been conducted to evaluate the feasibility of macroencapsulating certain debris wastes in polymers. Several methods and plastics have been tested for macroencapsulation, including post-consumer recycle and regrind polyethylene.

  9. Modeling of Mold Filling and Solidification in Lost Foam Casting

    Fengjun LI; Houfa SHEN; Baicheng LIU


    Based on the characteristics of the lost foam casting (LFC) and the artificial neural network technique, a mathematicalmodel for the simulation of the melt-pattern interface movement during the mold filling of LFC has been proposed andexperimentally verified. The simulation results are consistent with the experiments in both the shapes of melt frontand filling sequences. According to the calculated interface locations, the fluid flow and the temperature distributionsduring the mold filling and solidification processes were calculated, and the shrinkage defect of a lost foam ductileiron casting was predicted by considering the mold wall movement in LFC. The simulation method was applied tooptimize the casting design of lost foam ductile iron castings. It is shown that the model can be used for the defectsprediction and for casting design optimization in the practical LFC production.

  10. Existence of needle crystals in local models of solidification

    Langer, J. S.


    The way in which surface tension acts as a singular perturbation to destroy the continuous family of needle-crystal solutions of the steady-state growth equations is analyzed in detail for two local models of solidification. All calculations are performed in the limit of small surface tension or, equivalently, small velocity. The basic mathematical ideas are introduced in connection with a quasilinear, isotropic version of the geometrical model of Brower et al., in which case the continuous family of solutions dissappears completely. The formalism is then applied to a simplified boundary-layer model with an anisotropic kinetic attachment coefficient. In the latter case, the solvability condition for the existence of needle crystals can be satisfied whenever the coefficient of anisotropy is arbitrarily small but nonzero.

  11. Modelling of binary alloy solidification in the MEPHISTO experiment

    Leonardi, Eddie; de Vahl Davis, Graham; Timchenko, Victoria; Chen, Peter; Abbaschian, Reza


    A modified enthalpy method was used to numerically model experiments on solidification of a bismuth-tin alloy which were performed during the 1997 flight of the MEPHISTO-4 experiment on the US Space Shuttle Columbia. This modified enthalpy method was incorporated into an in-house code SOLCON and a commercial CFD code CFX; Soret effect was taken into account by including an additional thermo-diffusion term into the solute transport equation and the effects of thermal and solutal convection in the microgravity environment and of concentration-dependent melting temperature on the phase change processes were also included. In this paper an overview of the results obtained as part of MEPHISTO project is presented. The numerical solutions are compared with actual microprobe results obtained from the MEPHISTO experiment. To cite this article: E. Leonardi et al., C. R. Mecanique 332 (2004).

  12. Advanced powder metallurgy aluminum alloys via rapid solidification technology

    Ray, R.


    Aluminum alloys containing 10 to 11.5 wt. pct. of iron and 1.5 to 3 wt. pct. of chromium using the technique of rapid solidification powder metallurgy were studied. Alloys were prepared as thin ribbons (.002 inch thick) rapidly solidified at uniform rate of 10(6) C/second by the melt spinning process. The melt spun ribbons were pulverized into powders (-60 to 400 mesh) by a rotating hammer mill. The powders were consolidated by hot extrusion at a high reduction ratio of 50:1. The powder extrusion temperature was varied to determine the range of desirable processing conditions necessary to yield useful properties. Powders and consolidated alloys were characterized by SEM and optical metallography. The consolidated alloys were evaluated for (1) thermal stability, (2) tensile properties in the range, room temperature to 450 F, and (3) notch toughness in the range, room temperature to 450 F.

  13. Solidification of Spent Ion Exchange Resin Using ASC Cement

    周耀中; 云桂春; 叶裕才


    Ion exchange resins (IERs) have been widely used in nuclear facilities. However, the spent radioactive IERs result in major quantities of low and intermediate level radioactive wastes. This article describes a laboratory experimental study on solidification processing of IERs using a new type of cement named ASC cement. The strength of the cementation matrix is in the range of 18-20 MPa (28 d); the loading of the spent IER in the cement-resin matrix is over 45% and leaching rates of 137Cs, 90Sr and 60Co are 7.92×10-5, 5.7×10-6, and 1.19×10-8 cm/d. The results show that ASC cement can be a preferable cementation material for immobilization of radioactive spent IER.

  14. Self Assembled Structures by Directional Solidification of Eutectics

    Dynys, Frederick W.; Sayir, Ali


    Interest in ordered porous structures has grown because of there unique properties such as photonic bandgaps, high backing packing density and high surface to volume ratio. Inspired by nature, biometric strategies using self assembled organic molecules dominate the development of hierarchical inorganic structures. Directional solidification of eutectics (DSE) also exhibit self assembly characteristics to form hierarchical metallic and inorganic structures. Crystallization of diphasic materials by DSE can produce two dimensional ordered structures consisting of rods or lamella. By selective removal of phases, DSE is capable to fabricate ordered pore arrays or ordered pin arrays. Criteria and limitations to fabricate hierarchical structures will be presented. Porous structures in silicon base alloys and ceramic systems will be reported.

  15. Nonlinear theory of autooscillations of quasiplanar interface during directional solidification

    Lubashevsky, I A; Keijan, M G


    Within the framework of the frozen temperature approximation we develop a strongly-nonlinear theory of one-dimensional pattern formation during directional solidification of binary mixture under nonequilibrium segregation. In the case of small partition coefficient the full problem is reduced to the system of two ordinary differential equations describing the interface motion in terms of its velocity and position coordinate. The type of the oscillatory instability bifurcation is studied in detail in different limits. For the subcrytical bifurcaton relaxation interface oscillations are analyzed analytically and numerically. We show that these oscillation exibit a number of anomalous properies. In particular, such oscillations can be weakly- or strongly-dissipative depending on the physical parameters and the amplitude of the strongly-dissipative oscillations is determined not only by the form of the corresponding nullcline but also by the behavior of the system for small values of the interface velocity. Chara...

  16. Solidification of hypermonotectic Al-In alloys under microgravity conditions

    Potard, C.


    Four samples of the Al-In system having monotectic and hypermonotectic compositions that were solidified under microgravity during the NASA-SPAR IX flight of January 20, 1981, are considered. The experimental thermal and physicochemical conditions that were actually achieved are analyzed. Radiographic and metallographic observations of the samples reveal a nonregular dispersed primary phase inside the monotectic matrix. These observations are discussed in relation to capillarity and solidification aspects. A key finding is the preservation of a certain degree of dispersion of the indium primary phase. This result differs fundamentally from the results obtained under microgravity conditions on the same system and compositions (Gelles and Markworth, 1980; Alborn and Loehberg, 1979). The results are seen as clearly establishing that the space environment can be used to obtain dispersed structures from hypermonotectic alloys.

  17. Application of simplified model to sensitivity analysis of solidification process

    R. Szopa


    Full Text Available The sensitivity models of thermal processes proceeding in the system casting-mould-environment give the essential information concerning the influence of physical and technological parameters on a course of solidification. Knowledge of time-dependent sensitivity field is also very useful in a case of inverse problems numerical solution. The sensitivity models can be constructed using the direct approach, this means by differentiation of basic energy equations and boundary-initial conditions with respect to parameter considered. Unfortunately, the analytical form of equations and conditions obtained can be very complex both from the mathematical and numerical points of view. Then the other approach consisting in the application of differential quotient can be applied. In the paper the exact and approximate approaches to the modelling of sensitivity fields are discussed, the examples of computations are also shown.

  18. Influence of gravity on the solidification of a drop

    Sanz, A.; Meseguer, J.; Mayo, L.


    In this paper the influence of gravity on the solidification of a drop formed at the end of a rod is analyzed. Although similar studies (but ignoring gravity effects) already exist, a theoretical analysis including gravity effects allows one to improve the experimental procedure to measure on Earth relevant properties of crystals (mainly the receding contact angle phi/sub i/) which are of importance in shaped crystal growth processes. One of the main results here obtained are the shapes of the solidified drops, which are strongly dependent on the value of phi/sub i/. Therefore, fitting theoretical shapes to experimental ones is a way to perform accurate measurements of phi/sub i/.

  19. Melting and solidification of Bi nanoparticles in a germanate glass

    Haro-Poniatowski, E [Departamento de Fisica, Universidad Autonoma Metropolitana Iztapalapa, Avenida San Rafael Atlixco No. 186 Colonia Vicentina, CP 09340 Mexico DF (Mexico); Castro, M Jimenez de [Instituto de Optica, CSIC, Serrano 121, 28006 Madrid (Spain); Navarro, J M Fernandez [Instituto de Optica, CSIC, Serrano 121, 28006 Madrid (Spain); Morhange, J F [Institut des Nanosciences de Paris, UMR-CNRS 7588, Universite Paris VI et Paris VII, 4 Place Jussieu, Paris (France); Ricolleau, C [Laboratoire Materiaux et Phenomenes Quantiques and Laboratoire de Physique du Solide, UMR 7162, CNRS/Universite Paris 7-Denis Diderot, ESPCI, 10 rue Vauquelin, 75005 Paris Cedex (France)


    A very large melting-solidification hysteresis of Bi nanoparticles embedded in a bulk alkali germanate glass is reported. Heating and cooling cycles are reproducible and show reversible transitions. High resolution transmission electron microscopy reveals that the glass contains nanocrystals of elementary Bi which are a few tenths of a nanometre in size. Upon heating above the Bi melting temperature the glass transmission increases up to 10% with respect to the initial value, which is most likely related to Bi melting. Upon cooling this high transmission state remains up to temperatures as low as 436 K. This behaviour is confirmed by Raman spectroscopy measurements. This nanostructured glass with a high refractive index can be used in nonlinear optical applications as well as an optical thermo-sensor.

  20. Rapid solidification of Cu-Fe-Ni alloys

    Baricco, M.; Bosco, E.; Acconciaioco, G.; Rizzi, P.; Coisson, M


    Cu{sub 80-x}Ni{sub x}Fe{sub 20} (x=0, 5 and 20) alloys have been rapidly solidified by planar flow casting. X-ray diffraction (XRD) analysis of as-quenched ribbons shows bcc-Fe precipitates embedded in an fcc phase (x=0), two co-existing fcc solid solutions (x=5) and a complete solid solution of the parent elements (x=20). Thermal treatments in the temperature range between 400 and 600 deg. C give precipitation and spinodal decomposition reactions. These phase transformations have been evidenced from a variation of lattice constants, from a broadening of diffraction peaks and from TEM observations. The role of Ni content on competition between precipitation and decomposition reactions during rapid solidification and annealing is discussed in terms of thermodynamic arguments. Recent CALPHAD assessment of thermodynamic properties for Cu-Fe-Ni system has been used for an estimation of composition and volume fraction of equilibrium phases.

  1. Modelling of Mould Filling and Solidification of Castings

    Xu Zhian


    An experimental casting for validation has been designed. The casting is composed of two 50×600×2.5 (width×length×thick) thin-wall pieces. One downsprue is located in the middle. A pouring cup with a stopper is used. This design allows to using two different types of moulds simultaneously. An Al-10%Si alloy has been poured at different temperatures. Two effects have been studied: one is the pouring temperature and the other is the moulding method (namely by machine or manually). The filling length is proportional to the pouring temperature. The influence of different moulding methods on mould filling is more complicated. The filling length in the manual-made mould is 1.5 times as long as the one in the machine-made mould due to the different thermal conductivities. Vents have little influence. A finite volume based computer code which can simulate fluid flow during mould filling coupled with heat transfer as well as solidification has been developed in WTCM Foundry Center.. The code can predict cold shut during mould filling and shrinkage defects during solidification. The simulated results are in good agreement with the experiments.In the second part of the paper, an example is given which illustrates how to use computer simulation to aid designing the casting system. The final computational result is compared with the industrial casting. The process of designing castings by using simulation is completely different from the traditional way. The computer aided casting design offers the possibility to obtain a sound casting from the first time.

  2. Directional Solidification of Mercury Cadmium Telluride in Microgravity

    Lechoczhy, Sandor L.; Gillies, Donald C.; Szofran, Frank R.; Watring, Dale A.


    Mercury cadmium telluride (MCT) has been directionally solidified for ten days in the Advanced Automated Directional Solidification Furnace (AADSF) on the second United States Microgravity Payload Mission (USMP-2). A second growth experiment is planned for the USMP-4 mission in November 1997. Results from USMP-2 demonstrated significant changes between microgravity and ground-based experiments, particularly in the compositional homogeneity. Changes were also observed during the microgravity mission which were dependent on the attitude of the space shuttle and the relative magnitudes of axial and transverse residual accelerations with respect to the growth axis of the crystal. Issues of shuttle operation, especially those concerned with safety and navigation, and the science needs of other payloads dictated the need for changes in attitude. One consequence for solidification of MCT in the USMP4 mission is the desire for a shorter growth time to complete the experiment without subjecting the sample to shuttle maneuvers. By using a seeded technique and a pre-processed boule of MCT with an established diffusion layer quenched into the solid, equilibrium steady state growth can be established within 24 hours, rather than the three days needed in USMP-2. The growth of MCT in AADSF during the USMP-4 mission has been planned to take less than 72 hours with 48 hours of actual growth time. A review of the USMP-2 results will be presented, and the rationale for the USMP-4 explained. Pre-mission ground based tests for the USN4P-4 mission will be presented, as will any available preliminary flight results from the mission.

  3. Whole Grains and Fiber

    ... whole grains. Does not contain partially hydrogenated oils. Dietary Fiber Dietary fiber is the term for several materials that make ... water. When eaten regularly as part of a diet low in saturated fat and trans fat soluble fiber has been associated with increased diet quality and ...

  4. Formation on grain surfaces

    Cazaux, S; Tielens, AGGM


    The most abundant interstellar molecule, H-2, is generally thought to form by recombination of H atoms on grain surfaces. On surfaces, hydrogen atoms can be physisorbed and chemisorbed and their mobility can be governed by quantum mechanical tunneling or thermal hopping. We have developed a model fo

  5. The effect of interface heat transfer on solidification, microstructure evolution, and mold wear in permanent mold casting of titanium-aluminum-vanadium

    Kobryn, Pamela Astra

    Recently, a permanent mold casting approach for titanium alloys (Ti PMC) was developed. This process generated a lot of interest in the titanium casting industry due to its potential to decrease cost and improve mechanical properties. However, little research has been conducted in this area. Hence, the research described in this dissertation was performed to augment and complement prior work on Ti PMC. The current research dealt with the development of computer simulation capabilities for predicting characteristics of solidification, microstructure evolution, and mold wear for Ti PMC. It focused on the effect of interface heat transfer on ProCASTTM simulation results. A combination of physical and numerical experiments were used to determine interface heat transfer coefficients for Ti PMC, the sensitivity of FEM results to input parameters, and the validity of using the chosen modeling approach and input parameters to simulate various casting geometries. Laboratory and in-plant casting trials were conducted to obtain casting data. Thermocouple data were compared to simulation results to determine interface heat transfer coefficients for "shrink off" and "shrink on" geometries. Both a conventional thermocouple technique and a novel microstructure-based mold temperature signature analysis technique were used to determine mold temperatures for model validation. The validated models were used as a starting point for the application of two microstructure prediction techniques (solidification mapping and the parabolic grain growth law) and the study of mold wear causes and mechanisms. The importance of properly accounting for the casting-mold interface contact condition was stressed throughout. The results demonstrated the importance of considering the casting-mold interface geometry when selecting interface heat transfer coefficients for casting simulations, as the coefficient varied from an initial value of 2000 W/m2-K to less than 50 W/m2-K in the "shrink off" case

  6. The effective degeneracy of protein normal modes.

    Na, Hyuntae; Song, Guang


    Normal modes are frequently computed and used to portray protein dynamics and interpret protein conformational changes. In this work, we investigate the nature of normal modes and find that the normal modes of proteins, especially those at the low frequency range (0-600 cm(-1)), are highly susceptible to degeneracy. Two or more modes are degenerate if they have the same frequency and consequently any orthogonal transformation of them also is a valid representation of the mode subspace. Thus, degenerate modes can no longer characterize unique directions of motions as regular modes do. Though the normal modes of proteins are usually of different frequencies, the difference in frequency between neighboring modes is so small that, under even slight structural uncertainty that unavoidably exists in structure determination, it can easily vanish and as a result, a mode becomes effectively degenerate with its neighboring modes. This can be easily observed in that some modes seem to disappear and their matching modes cannot be found when the structure used to compute the modes is modified only slightly. We term this degeneracy the effective degeneracy of normal modes. This work is built upon our recent discovery that the vibrational spectrum of globular proteins is universal. The high density of modes observed in the vibrational frequency spectra of proteins renders their normal modes highly susceptible to degeneracy, under even the smallest structural uncertainty. Indeed, we find the degree of degeneracy of modes is proportional to the density of modes in the vibrational spectrum. This means that for modes at the same frequency, degeneracy is more severe for larger proteins. Degeneracy exists also in the modes of coarse-grained models, but to a much lesser extent than those of all-atom models. In closing, we discuss the implications of the effective degeneracy of normal modes: how it may significantly affect the ways in which normal modes are used in various normal modes

  7. 3D Modeling and Simulation of Dendritic Growth during Solidification

    Zuojian LIANG; Qingyan XU; Baicheng LIU


    A mathematical model for the three-dimensional simulation of free dendritic growth and microstructure evolutionwas developed based on the growth mechanism of crystal grains and basic transfer equations such as heat, massand momentum transfer equations. Ma

  8. Effect of pulse magnetic field on solidification structure and properties of pure copper

    LIAO Xi-liang; GONG Yong-yong; LI Ren-xing; CHEN Wen-jie; ZHAI Qi-jie


    The application of pulse magnetic field to metal solidification is an advanced technique which can remarkably refine solidification structure. In this paper, the effect of pulse magnetic field on solidification structure,mechanical properties and conductivity of pure copper was experimentally investigated. The results showed that the solidification structure transformed from coarse columnar crystal to fine globular crystal with increasing pulse voltage.Increasing pulse voltage also improved the tensile strength. However, with the increase of pulse voltage, the elongation and electrical resistivity firstly decreased, then increased when the pulse voltage beyond a critical value. Moreover,in some conditions, pulse magnetic field can simultaneously improve the conductivity and mechanical property of pure copper.


    I. A. Pugachev


    Full Text Available A process of heat transfer in continuous casting mould is considered. The substantiated equations predict shell growth, temperature distributions, solidification rates and can be used for continuous casters control systems.

  10. Density and Mechanical Properties of Aluminum Lost Foam Casting by Pressurization during Solidification


    Porosity is thought to be severe in aluminum alloy castings produced by lost foam process due to the pyrolysis of the polystyrene foam pattern during pouring, which results in detrimental effect in mechanical property.The slow solidification rate promotes the formation of gassing pin holes, and relative weakness of the thermal gradients can cause micro-shrinkage if the outline of the part complicates feeding in the lost foam casting. One of the methods to eliminate the porosity is to apply high pressure to the molten metal like an isostatic forging during solidification. Fundamental experiments were carried out to evaluate the effect of the external pressure on the porosity and mechanical properties of A356.2 alloy bar in the lost foam casting. Solidification time and porosity decreased with increasing the applied pressure during solidification. Applying external pressure was effective in decreasing the porosity and increasing the elongation of the lost foam casting.

  11. Effect of Solidification Condition on Microstructure and Mechanical Properties of Single Crystal Superalloy


    CMSX-2 single crystals with different primary dendrite arm spacing were obtained on directional solidification apparatus with high temperature gradient (250 K/cm). The microstructure and elevated temperature stress rupture properties of these single crystals were examined and analyzed.

  12. Microstructure Characteristics of Ni-Nb Near Eutectic Alloy during EBFZM Directional Solidification


    Microstructure Characteristic of Ni-Nb near eutectic alloy is systematically investigated during directional solidification with electron beam floating zone melting (EBFZM). The effect of the zone melting rate on the microstructure has also been studied.

  13. Stress/strain distributions for weld metal solidification crack in stainless steels


    This paper has simulated the driving force of solidification crack of stainless steels, that is, stress/strain field in the trail of molten pool. Firstly, the effect of the deformation in the molten pool was eliminated after the element rebirth method was adopted. Secondly, the influence of solidification shrinkage was taken into account by increasing thermal expansion coefficients of the steels at elevated temperatures. Finally, the stress/strain distributions of different conditions have been computed and analyzed. Furthermore, the driving force curves of the solidification crack of the steels have been obtained by converting strain-time curves into strain-temperature curves, which founds a basis for predicting welding solidification crack.

  14. Grain Boundary Segregation in Metals

    Lejcek, Pavel


    Grain boundaries are important structural components of polycrystalline materials used in the vast majority of technical applications. Because grain boundaries form a continuous network throughout such materials, their properties may limit their practical use. One of the serious phenomena which evoke these limitations is the grain boundary segregation of impurities. It results in the loss of grain boundary cohesion and consequently, in brittle fracture of the materials. The current book deals with fundamentals of grain boundary segregation in metallic materials and its relationship to the grain boundary structure, classification and other materials properties.

  15. Why Is It Important to Eat Grains, Especially Whole Grains?

    ... Nutrients and health benefits Print Share Why is it important to eat grains, especially whole grains? Eating ... diabetes. Fiber is important for proper bowel function. It helps reduce constipation and diverticulosis. Fiber-containing foods ...

  16. Effect of high-intensity ultrasonic irradiation on the modification of solidification microstructure in a Si-rich hypoeutectic Al-Si alloy

    Das, A., E-mail: [Materials Research Centre, School of Engineering, Swansea University, Singleton Park, Swansea, SA2 8PP (United Kingdom); Kotadia, H.R. [Brunel Centre for Advanced Solidification Technology, Brunel University, Uxbridge, UB8 3PH (United Kingdom)


    Effect of high-intensity ultrasound irradiation in modifying complex solidification microstructure is explored in a high Si containing Al-Si alloy and the origin of microstructural changes explained on the basis of nucleation and growth behaviour. Complete suppression of dendritic growth and dramatic refinement to globular morphology were observed for primary {alpha}-Al grains. Strong supportive evidence is presented towards enhanced and prolonged heterogeneous nucleation triggered by cavitation induced increase in the equilibrium melting point and effective dissipation of latent heat at the solidification front. Morphological evolution of eutectic Si and intermetallic particles is found to be dominated by coarsening and spherodisation from strong fluid flow in areas of intense cavitation near the ultrasonic radiator. Outside the region of direct energy transfer, Si particle morphology appears to be controlled predominantly by the imposed cooling conditions. Extremely fine and short Si-platelets observed in the intergranular spaces near the radiator are explained on the basis of probable rapid cooling of final liquid pockets of small volume and large surface area, rather than refinement through ultrasound.

  17. Application of the dual reciprocity boundary element method for numerical modelling of solidification process

    E. Majchrzak


    Full Text Available The dual reciprocity boundary element method is applied for numerical modelling of solidification process. This variant of the BEM is connected with the transformation of the domain integral to the boundary integrals. In the paper the details of the dual reciprocity boundary element method are presented and the usefulness of this approach to solidification process modelling is demonstrated. In the final part of the paper the examples of computations are shown.

  18. Part III. Kinetics of the (Zn - Coating Deposition During Stable and Meta-Stable Solidifications

    Wołczyński W.


    Full Text Available Two different steel substrates are applied to the hot dip (Zn - coating formation. The influence of the substrate composition on the (Zn - coating thickening is recorded. Morphologies of both coatings are compared to each other. The transition from stable into meta-stable solidification is revealed. The criterion for the competition between stable and meta-stable solidification is applied to justify the analyzed transition.

  19. Mechanics of transport phenomena in multi-component sessile drops with solidification

    Su, Yeong-Jen; Yang, Wen-Jei; Liu, Jiaching


    The mechanics of transport phenomena in multicomponent sessile drops with internal solidification is determined on the basis of an experimental study. A shadowgraph-schlieren system and a microscope-video system are used for the study. It is suggested that present data can be used to enhance the solid or crystal quality in a reduced-gravity environment where both thermo- and diffuso-capillary effects of solidification and crystal growth are dominant.

  20. Derivation and application of time step model in solidification process simulation


    The heat transfer during the casting solidification process includes the heat radiation of the high temperature casting and the mold, the heat convection between the casting and the mold, and the heat conduction inside the casting and from the casting to the mold. In this paper, a formula of time step in simulation of solidification is derived, considering the heat radiation, convection and conduction based on the conservation of energy. The different heat transfer conditions between the conv...

  1. Turbulent Fluid Flow and Heat Transfer Calculation in Mold Filling and Solidification Processes of Castings


    Based on the time-averaging equations and a modified engineering turbulence model, the mold filling and solidification processes of castings are approximately described. The algorithm for the control equations is briefly introduced, and some problems and improvement methods for the traditional method are also presented. Both calculation and tests proved that, comparing with the laminar fluid flow and heat transfer, the simulation results by using the turbulence model are closer to the real mold filling and solidification processes of castings.

  2. Modeling of Coalescence and Separation of Liquid Droplets During Solidification of Immiscible Alloys

    Lirong; Tong; Nagy; El-Kaddah


    Directional solidification methods are being used f or in-situ production of metallic immiscible composites. A quantitative understa nding of the dynamic behavior and growth kinetics of the nucleated second phase during solidification is necessary to produce homogeneous dispersion in solidifi ed composites. This paper presents a mathematical model for describing the grow th of nucleated dispersed phase in the two-liquid phase region ahead of the sol idification front and the entrapment of these droplets...

  3. Effect of temperature field on solidification structure of pure Al under pulse magneto-oscillation

    Li Bo; Yin Zhenxing; Gong Yongyong


    This article discusses the effect of temperature field on the Pulse Magneto-Oscillation (PMO) induced solidification refinement of pure aluminium to provide more information for the industrial application of the PMO solidification technology. The temperature field is altered mainly by applied variable cooling conditions and pulse parameters. Experimental results show that the refinement effect in the case of full sand mould applied is weakened with the decreasing of cooling rate, however, in ...

  4. Investigation of solidification behavior of the Sn-rich ternary Sn–Bi–Zn alloys

    S Mladenović


    Full Text Available Solidification properties and microstructure of six as-cast Sn–Bi–Zn alloys with 80 at.% of Sn and variable contents of Bi and Zn were experimentally investigated using the scanning electron microscopy (SEM with energy-dispersive X-ray spectroscopy (EDS and differential scanning calorimetry (DSC. The experimentally obtained results were compared with predicted phase equilibria according to the calculation of phase diagram (CALPHAD method and by the Scheil solidification simulation.

  5. Utilization of coal fly ash in solidification of liquid radioactive waste from research reactor.

    Osmanlioglu, Ahmet Erdal


    In this study, the potential utilization of fly ash was investigated as an additive in solidification process of radioactive waste sludge from research reactor. Coal formations include various percentages of natural radioactive elements; therefore, coal fly ash includes various levels of radioactivity. For this reason, fly ashes have to be evaluated for potential environmental implications in case of further usage in any construction material. But for use in solidification of radioactive sludge, the radiological effects of fly ash are in the range of radioactive waste management limits. The results show that fly ash has a strong fixing capacity for radioactive isotopes. Specimens with addition of 5-15% fly ash to concrete was observed to be sufficient to achieve the target compressive strength of 20 MPa required for near-surface disposal. An optimum mixture comprising 15% fly ash, 35% cement, and 50% radioactive waste sludge could provide the solidification required for long-term storage and disposal. The codisposal of radioactive fly ash with radioactive sludge by solidification decreases the usage of cement in solidification process. By this method, radioactive fly ash can become a valuable additive instead of industrial waste. This study supports the utilization of fly ash in industry and the solidification of radioactive waste in the nuclear industry.

  6. Geometrical modulus of a casting and its influence on solidification process

    F. Havlicek


    Full Text Available Object: The work analyses the importance of the known criterion for evaluating the controlled solidification of castings, so called geometrical modulus defined by N. Chvorinov as the first one. Geometrical modulus influences the solidification process. The modulus has such specificity that during the process of casting formation it is not a constant but its initial value decreases with the solidification progress because the remaining melt volume can decrease faster than its cooling surface.Methodology: The modulus is determined by a simple calculation from the ratio of the casting volume after pouring the metal in the mould to the cooled mould surface. The solidified metal volume and the cooled surface too are changed during solidification. That calculation is much more complicated. Results were checked up experimentally by measuring the temperatures in the cross-section of heavy steel castings during cooling them.Results: The given experimental results have completed the original theoretical calculations by Chvorinov and recent researches done with use of numerical calculations. The contribution explains how the geometrical modulus together with the thermal process in the casting causes the higher solidification rate in the axial part of the casting cross-section and shortening of solidification time. Practical implications: Change of the geometrical modulus negatively affects the casting internal quality. Melt feeding by capillary filtration in the dendritic network in the casting central part decreases and in such a way the shrinkage porosity volume increases. State of stress character in the casting is changed too and it increases.

  7. Microstructures, micro-segregation and solidification path of directionally solidified Ti-45Al-5Nb alloy

    Liang-shun Luo


    Full Text Available To investigate the effect of solidification parameters on the solidification path and microstructure evolution of Ti-45Al-5Nb (at.% alloy, Bridgman-type directional solidification and thermodynamics calculations were performed on the alloy. The microstructures, micro-segregation and solidification path were investigated. The results show that the β phase is the primary phase of the alloy at growth rates of 5-20 μm•s-1 under the temperature gradients of 15-20 K•mm-1, and the primary phase is transformed into an α phase at relatively higher growth rates (V >20 μm•s-1. The mainly S-segregation and β-segregation can be observed in Ti-45Al-5Nb alloy at a growth rate of 10 μm•s-1 under a temperature gradient of 15 K•mm-1. The increase of temperature gradient to 20 K•mm-1 can eliminate β-segregation, but has no obvious effect on S-segregation. The results also show that 5 at.% Nb addition can expand the β phase region, increase the melting point of the alloy and induce the solidification path to become complicated. The equilibrium solidification path of Ti-45Al-5Nb alloy can be described as , in which βR and γR mean the residual β and γ.

  8. Modeling of Cooling and Solidification of TNT based Cast High Explosive Charges

    A. Srinivas Kumar


    Full Text Available Cast trinitrotoluene (TNT based high explosive charges suffer from different defects such as cracks, voids, etc. One of the quality control measures is to cool the castings gradually, so that the entire charge solidifies without a large temperature gradient from core to the periphery of the cast charge. The fact that the solidification of high explosive casting starts from the periphery (cooler side and travels towards the center enables us to predict the solidification profile of TNT based explosive castings. Growth of solidification thickness and cooling temperature profiles of TNT based cast high explosive charges are predicted as functions of time and space using unsteady state heat transfer principles, associated with heat balance at solid to liquid interface as a moving boundary of solidification. This will enable adoption of proper quality control during solidification of the molten TNT to eliminate inherent drawbacks of cast high explosive charges. The solidification profiles of TNT based cast charges under controlled and natural conditions are predicted and the model is validated against 145 mm diameter TNT cast charge which is found to be in broad agreement with experiments.Defence Science Journal, Vol. 64, No. 4, July 2014, pp.339-343, DOI:

  9. The solidification of two-phase heterogeneous materials:Theory versus experiment

    KIM; Tongbeum


    The solidification behavior of two-phase heterogeneous materials such as close-celled aluminum foams was analytically studied.The proposed analytical model can precisely predict the location of solidification front as well as the full solidification time for a two-phase heterogeneous material composed of aluminum melt and non-conducting air pores.Experiments using distilled water simulating the aluminum melt to be solidified(frozen)were subsequently conducted to validate the analytical model for two selected porosities(ε),ε=0 and 0.5.Full numerical simulations with the method of finite difference were also performed to examine the influence of pore shape on solidification.The remarkable agreement between theory and experiment suggests that the delay of solidification in the two-phase heterogeneous material is mainly caused by the reduction of bulk thermal conductivity due to the presence of pores,as this is the sole mechanism accounted for by the analytical model for solidification in a porous medium.

  10. Solidification kinetics of a Cu-Zr alloy: ground-based and microgravity experiments

    Galenko, P. K.; Hanke, R.; Paul, P.; Koch, S.; Rettenmayr, M.; Gegner, J.; Herlach, D. M.; Dreier, W.; Kharanzhevski, E. V.


    Experimental and theoretical results obtained in the MULTIPHAS-project (ESA-European Space Agency and DLR-German Aerospace Center) are critically discussed regarding solidification kinetics of congruently melting and glass forming Cu50Zr50 alloy samples. The samples are investigated during solidification using a containerless technique in the Electromagnetic Levitation Facility [1]. Applying elaborated methodologies for ground-based and microgravity experimental investigations [2], the kinetics of primary dendritic solidification is quantitatively evaluated. Electromagnetic Levitator in microgravity (parabolic flights and on board of the International Space Station) and Electrostatic Levitator on Ground are employed. The solidification kinetics is determined using a high-speed camera and applying two evaluation methods: “Frame by Frame” (FFM) and “First Frame - Last Frame” (FLM). In the theoretical interpretation of the solidification experiments, special attention is given to the behavior of the cluster structure in Cu50Zr50 samples with the increase of undercooling. Experimental results on solidification kinetics are interpreted using a theoretical model of diffusion controlled dendrite growth.

  11. Predictive coarse-graining

    Schöberl, Markus; Zabaras, Nicholas; Koutsourelakis, Phaedon-Stelios


    We propose a data-driven, coarse-graining formulation in the context of equilibrium statistical mechanics. In contrast to existing techniques which are based on a fine-to-coarse map, we adopt the opposite strategy by prescribing a probabilistic coarse-to-fine map. This corresponds to a directed probabilistic model where the coarse variables play the role of latent generators of the fine scale (all-atom) data. From an information-theoretic perspective, the framework proposed provides an improvement upon the relative entropy method [1] and is capable of quantifying the uncertainty due to the information loss that unavoidably takes place during the coarse-graining process. Furthermore, it can be readily extended to a fully Bayesian model where various sources of uncertainties are reflected in the posterior of the model parameters. The latter can be used to produce not only point estimates of fine-scale reconstructions or macroscopic observables, but more importantly, predictive posterior distributions on these quantities. Predictive posterior distributions reflect the confidence of the model as a function of the amount of data and the level of coarse-graining. The issues of model complexity and model selection are seamlessly addressed by employing a hierarchical prior that favors the discovery of sparse solutions, revealing the most prominent features in the coarse-grained model. A flexible and parallelizable Monte Carlo - Expectation-Maximization (MC-EM) scheme is proposed for carrying out inference and learning tasks. A comparative assessment of the proposed methodology is presented for a lattice spin system and the SPC/E water model.

  12. Molecular dynamics study of grain boundary structure and properties at high temperatures

    Fensin, Saryu Jindal

    This thesis reports research involving the development and application of atomistic simulation methods to study the effects of high homologous temperatures on the structural, thermodynamic, kinetic and mechanical properties of grain boundaries in metals. Our interest in these properties is due to the role they play in governing the evolution of microstructure and deformation of metals during solidification processing. The interest in developing more predictive models for the formation of solidification defects highlights a need to better understand the thermodynamic driving forces underlying grain-boundary premelting and the mobility and shear strength of these interfaces at high temperatures. In this work we study two different elemental systems, namely Ni and Cu, and consider a variety of grain boundary structures characterized by different misorientation angles, twist/tilt character and zero-temperature energies. A method to calculate the disjoining potential from molecular dynamics (MD) is developed and applied to grain boundaries in Ni. The disjoining potential characterizes the variation in grain-boundary free energy as a function of the width of a premelted interfacial layer. The MD method for the calculation of this property is applied to grain boundaries that display continuous premelting transitions, as well as a boundary characterized by a disordered atomic structure displaying a finite interfacial width at the melting temperature. The disjoining potential represents an important input property to larger scale models of solidification and grain coalescence. We further develop analysis methods to characterize the change in the atomic structure of an asymmetric tilt grain boundary in elemental Cu as a function of temperature. This boundary is characterized by a potential-energy surface with multiple minima as a function of the relative translation of the grains parallel to the interface plane. The more complex structure of this boundary, relative to the

  13. Grain alcohol study: summary

    The study has concentrated upon a detailed examination of all considerations involved in the production, use, and marketing of ethyl alcohol (Ethanol) as produced from the fermentation of agricultural grains. Each parameter was examined in the light of current energy markets and trends; new sources and technological, and processes for fermentation, the capability of the agricultural industry to support fermentaton demand; the optimization of value of agricultureal crops; and the efficiencies of combining related industries. Anhydrous (200 proof) ethanol makes an excellent blending component for all present automotive fuels and an excellent octane additive for unleaded fuels in proportions up to 35% without requiring modifications to current engines. There is no difference between ethanol produced by fermentation and ethanol produced synthetically from petroleum. The decision to produce ethanol one way or the other is purely economic. The agricultural industry can support a major expansion in the fermentation industry. The residue (distillers grains) from the fermentation of corn for ethanol is an excellent and economical feed for livestock and poultry. A reliable supply of distillers grains can assist in making the large beef feedlot operations more economically viable. The source materials, fuels, products and by-products of an ethanol plant, beef feedlot, gas biodigester plant, municipal waste recovery plant and a steam generated electrical plant are interrelated and mutually beneficial for energy efficiencies and economic gains when co-located. The study concludes that the establishment of such agricultural-environment industrial energy complexes, would provide a broad range of significant benefits to Indiana.

  14. Grain alcohol study: summary

    The study has concentrated upon a detailed examination of all considerations involved in the production, use, and marketing of ethyl alcohol (ethanol) as produced from the fermentation of agricultural grains. Each parameter was examined in the light of current energy markets and trends; new sources and technological, and processes for fermentation, the capability of the agricultural industry to support fermentation demand; the optimizaton of value of agricultural crops; and the efficiencies of combining related industries. Ahydrous (200 proof) ethanol makes an excellent blending component for all present automotive fuels and an excellent octane additive for unleaded fuels in proportions up to 35% without requiring modifications to current engines. There is no difference between ethanol produced by fermentation and ethanol produced synthetically from petroleum. The decision to produce ethanol one way or the other is purely economic. The agricultural industry can support a major expansion in the fermentation industry. The residue (distillers grains) from the fermentation of corn for ethanol is an excellent and economical feed for livestock and poultry. A reliable supply of distillers grain can assist in making the large beef feedlot operations more economically viable. The source materials, fuels, products and by-products of an ethanol plant, beef feedlot, gas biodigester plant, municipal waste recovery plant and a steam generated electrical plant are interrelated and mutually beneficial for energy efficiencies and economic gains when co-located. The study concludes that the establishment of such agricultural- environment industrial energy complexes, would provide a broad range of significant benefits to Indiana.

  15. Effects of Si Content and the Addition Amount of Al-3B Master Alloy on the Solidification Structures of Hypoeutectic Al-Si Alloys


    Effects of Si content and the addition amount of Al-3B master alloy on the solidification structures of hypoeutectic Al-Si alloys were studied. The addition amounts of the master alloy were 0.2%, 0.4%, 0.7% and 1% (mass fraction, so as the follows), respectively. The Si content of Al-Si binary alloys investigated varied from 1% to 11%. The observation of macrostructures of non-refined samples showed that 3% Si constitutes a transition point at which the minimum grain size can be obtained. It was also found that Al-3B master alloy can shift the transition point towards a higher Si value when its addition amount increases, making this point appear at 4%, 5% and 6% Si as its addition amount increases up to 0.4%, 0.7% and 1%, respectively.

  16. Impact-activated solidification of cornstarch and water suspensions

    Waitukaitis, Scott Russell

    Liquids typically offer little resistance to impacting objects . Surprisingly, dense suspensions of liquids mixed with micron-sized particles can provide tremendous impact resistance, even though they appear liquid like when left at rest or perturbed lightly. The most well-known example is a dense mixture of cornstarch and water, which can easily provide enough impact resistance to allow a full-grown person to run across its surface. Previous studies have linked this so-called ``shear thickening'' to experiments carried out under steady state shear and attributed it to hydrodynamic interactions or granular dilation. However, neither of these explanations alone can account for the stress scales required to keep a running person above the free surface. This thesis investigates the mechanism for this impact resistance in dense suspensions. We begin by studying impact directly and watching a rod as it strikes the surface of a dense suspension of cornstarch and water. Using high-speed video and embedded force and acceleration sensing, we show that the rod motion leads to the rapid growth of a solid-like object below the impact site. With X-ray videography to see the dynamics of the suspension interior and laser sheet measurements of the surface profile, we show how this solid drags on the surrounding suspension, creating substantial peripheral flow and leading to the rapid extraction of the impactor's momentum. Suspecting that the solidification below the rod may be related to jamming of the particle sub-phase, we carry out 2D experiments with macroscopic disks to show how uniaxial compression of an initially unjammed system can lead to dynamic jamming fronts. In doing so, we show how these fronts are sensitive to the system's initial packing fraction relative to the point at which it jams and also discover that the widths of these fronts are related to a diverging correlation length. Finally, we take these results back to the suspension, where we perform careful, speed


    N. A. Mazukha


    Full Text Available The scheme for economy of electric energy during the work for an example of a grain thrower of the ZME 60 type (Voronezh Region, Semiluki on grain flows in rural economy is offered. Grain thrower can carry out the following technological operations: loading of grain in vehicles; loading and unloading of grain stores; mechanical shoveling of grain on the open areas; separation of grain with office of light impurity. In the scheme the relay 3UG3521/22t (SIEMENS firm is used. The relay can carry out multipurpose protection of engines and comprises the relay of the maximum current, the relay of the minimum current, a timer and the index relay. Temporary charts of the relay 3UG3521/22t are provided in the mode "without preservation" and in the mode with "preservation" for the OVER functions (reaction to growth of current and the UNDER function (reaction to recession of current. Use of the relay 3UG3521/22t allowed to receive protection at long start-up of electric motors, at an overload of electric motors, when idling (for economy of electric energy due to automatic shutdown of the conveyor and at break or jamming of the conveyor. Besides, in the scheme it is offered the multipurpose relay of tension (the relay of control of phases for protection of three engines of a grain thrower at not full-phase modes of a power line. The economy of electric energy can be received in case of, for example, the late actions of the operator for timely shutdown of the engine of a self-feed upon transition of a grain thrower to idling. In practice transition of a grain thrower to the mode of idling is quite often possible in process of reduction of amount of the thrown grain on a platform before a grain thrower. In practice transition of a grain thrower to the mode of idling is quite often possible in process of reduction of amount of the thrown grain on a platform before a grain thrower. The offered electric circuit can be used in the grain thrower and grain loaders

  18. Effects of Static Magnetic Field on Solidification Structure of 2024 Aluminum Alloy%静磁场对2024铝合金凝固组织的影响

    程常桂; 余乐; 万文成; 刘中天; 金焱


    Effects of static magnetic on the microscopic grain density, solidification rate and distribution of alloy elements in 2024 aluminum alloy were investigated by means of thermal simulation experiment and scanning electron microscope (SEM). The results show that the solidification structure can be refined with increasing in magnetic intensity, and the solidification time is decreased, which are closely related to the Seebeck effect acting on liquid metal in solidification front as a result of enhancing the flow of liquid metal and inhibiting the electromagnetic brake effects. Furthermore, the static magnetic field can promote disfussion of solute atoms in aluminum alloy, and it is favorable to improving solid solubility of alloy elements and decreasing macro-segregation of 2024 aluminum alloy.%通过热模拟试验及扫描电镜分析,研究了静磁场对2024铝合金显微晶粒度、凝固速度、合金元素分布的影响.结果表明,随着磁感应强度的增大,合金凝固组织明显细化,凝固时间变短,这与凝固前沿熔体内的塞贝克效应有关,使得熔体对流效应强于静磁场的制动效应;应用静磁场能够增强溶质原子在铝中的扩散,有利于提高合金元素的固溶度,减轻凝固组织的宏观偏析.

  19. Texturing of high T(sub c) superconducting polycrystalline fibers/wires by laser-driven directional solidification in an thermal gradient

    Varshney, Usha; Eichelberger, B. Davis, III


    This paper summarizes the technique of laser-driven directional solidification in a controlled thermal gradient of yttria stabilized zirconia core coated Y-Ba-Cu-O materials to produce textured high T(sub c) superconducting polycrystalline fibers/wires with improved critical current densities in the extended range of magnetic fields at temperatures greater than 77 K. The approach involves laser heating to minimize phase segregation by heating very rapidly through the two-phase incongruent melt region to the single phase melt region and directionally solidifying in a controlled thermal gradient to achieve highly textured grains in the fiber axis direction. The technique offers a higher grain growth rate and a lower thermal budget compared with a conventional thermal gradient and is amenable as a continuous process for improving the J(sub c) of high T(sub c) superconducting polycrystalline fibers/wires. The technique has the advantage of suppressing weak-link behavior by orientation of crystals, formation of dense structures with enhanced connectivity, formation of fewer and cleaner grain boundaries, and minimization of phase segregation in the incongruent melt region.

  20. Zr在K4169合金凝固过程中作用的研究%Effects of Zr in Solidification Process of K4169 Superalloy

    李亚敏; 陈毅; 郝远


    利用手工电弧炉熔炼制备了Zr质量分数为0.00%~0.07%的K4169合金,采用金相显微镜、扫描电镜、能谱仪以及差热分析对合金的凝固组织、元素偏析及熔点进行了研究.结果表明,Zr的加入促进了合金中Nb、Mo、Ti等元素的偏析,使铸态合金晶界析出的Laves相和碳化物数量增多,但随着Zr含量的增加Laves相又有所减少.Zr的加入提高了Laves相初熔温度,降低了合金的熔点.另外,微量Zr对K4169合金的凝固组织不利.%A manual electric arc furnace was used for preparing K4169 superalloy with different Zr content up to 0.07% (mass percentage content). The solidification structure, segregation and the melting point were observed by OM, SEM, SEM-EDS and DSC. The results show that Zr has strong grain boundary segregation tendency, and Zr can promote the segregation of Nb, Mo and Ti, meanwhile, Zr can significantly promote the precipitation of Laves phase and MC carbide at the grain boundaries. However, the amount of Laves phase decreases with the content of Zr increasing. In the meantime, the incipient melting temperature of Laves phase greatly increases, but the melting point of the alloy decreases with the addition of Zr. The analysis shows that the content of Zr is harmful to the solidification microstructure of K4169 superalloy.