Search results

Proper selection of the stability parameter determines the accuracy of dendrite tip kinetics at a single crystal scale. Recently developed sophisticated phase field modelling of a single grain evolution provides evidence that this parameter is not constant during the process. Nevertheless, in the commonly used micro-macroscopic simulations of alloy solidification, it is a common practice to use a constant value of the stability parameter, resulting from the marginal stability theory. This paper aims to address the issue of how this inaccuracy in modelling crystal growth kinetics can influence numerically predicted zones of columnar and equiaxed dendrites and the macro-segregation formation.

Using the original authors’ micro-macroscopic computer simulation model of binary alloy solidification, the calculations have been performed for the Kurz-Giovanola-Trivedi (KGT) crystal growth kinetics with two different values of the stability parameter, and for two different compositions of Al-Cu alloys. The computational model is based on single domain-based formulation of transport equations, which are discretized on control-volume mesh. To identify zones of different grain structures, developing within the two-phase liquid-solid region, an envelope of columnar dendrite tips is tracked on a fixed non-orthogonal, triangular control volume grid. The models of porous and slurry media are used, along with the concept of the switching function, to account for diverse flow resistances in the columnar and equiaxed crystal zones. The numerical predictions are carefully studied to address the question of how the chosen stability parameter influences macroscopic structures of a cast, the most important issue from the engineering point of view.

The carried-out comprehensive numerical analysis shows that the value of the stability parameter of the KGT-constrained dendrite growth model does not have a direct significant impact on the macrosegregation formation. It, however, visibly influences the undercooling along the front, separating different dendritic structures and the size of the undercooled melt region where the equiaxed grains can develop. It also affects the amount of eutectic phase created.

To the best of the authors’ knowledge, this is the first attempt at estimating the influence of some inaccuracies, caused by possible ambiguities in choosing the stability constant of the KGT law, on numerically predicted macroscopic fields of solute concentration, the developing zones of columnar and equiaxed crystals and the macrosegregation patterns.

The general aim of this work is to calculate the extent of the equiaxed zone in continuously cast steel products. Free equiaxed grains can grow only in undercooled liquid regions. Undercooling of the bulk liquid occurs because the columnar dendrite tips growing from the mould reject solutes in the liquid. The specific aim of this contribution is to calculate the thermal and physical state of continuously cast steel long products assuming a columnar solidification mode, taking into account the tip undercooling at the solidification front. A 2‐D heat transfer model has been developed where the columnar solidification mode is assumed. The calculation of the undercooling at the advancing solidification front is coupled with the heat transfer equation. The comparison between the results of the present model and the classical heat transfer model indicates the importance of modelling the undercooling phenomenon. The influence of the secondary cooling has also been studied.

This paper aims to study the effect of Al‐Ti‐B grain refiners on the wear behaviour of hypoeutectic (Al‐0.2, 2, 3, 4, 5 and 7Si alloys) Al‐Si alloys against steel counterface using a Pin‐On‐Disc machine under dry sliding conditions.

In the present study, Al‐5Ti‐1B and Al‐1Ti‐3B grain refiners were used for the refinement of α‐Al dendrites in hypoeutectic Al‐Si alloys. Various parameters such as alloy composition, normal pressure, sliding speed and sliding distance were studied on Al‐Si alloys. Worn surfaces were characterized by SEM/EDX microanalysis.

Wear resistance of hypoeutectic Al‐Si alloys increases with the addition of Al‐Ti‐B refiners when compared with the absence of grain refiner.

The effects of normal pressure, sliding speed and sliding distance were studied by varying one parameter and keeping constant the other two parameters.

This paper provides information on improvement in wear properties of Al‐Si alloys by the addition of Al‐Ti‐B grain refiners. The effects of silicon and grain refiners containing Ti/B play a vital role and are responsible for the wear resistance of the alloys, which helps the industrialists in manufacturing Al‐Si alloy components.

Additive manufacturing is a fabrication technology with flexibility and economy. 18Ni300 is one of maraging steels with ultra-high strength, superior toughness, so it is an excellent candidate of structural material. This paper aims to explore the feasibility of using direct laser metal deposition method to fabricate18Ni300, and the evolution of its microstructure and defects is studied.

The experiments were conceived from single-trace-single-layer (STSL) test to multi-trace-multi-layers (MTML) test via single-trace-multi-layers (STML) test. The microstructure, defects and mechanical properties were analyzed.

The STML results showed that the columnar/equiaxed transformation occurred at the top part and the grain size increased with the layer number increasing, and it was explained by an innovative attempt combining columnar/equiaxed transformation model and the change of grain size. The MTML test with the interlayer orthogonal parallel reciprocating scanning pattern resulted in the grain growing along orthogonal directions; with the increase of overlap rate, the length and the area of the columnar grain decreased. What is more, the later deposition layer had lower micro-hardness value because of heat history.

Direct laser metal deposition method was a novel additive manufacturing method to manufacture 18Ni300 components, as 18Ni300 maraging steel was mainly manufactured by selective laser melting (SLM) method nowadays. It was useful to manufacture maraging steel parts using direct laser deposition method because it could manufacture larger parts than SLM method. Influence of processing parameters on forming quality and microstructure evolution was studied. The findings will be helpful to understand the forming mechanism of laser additive manufacturing of 18Ni300 components.

Understanding and tailoring the solidification characteristics and microstructure evolution in as-built parts fabricated by laser powder bed fusion (LPBF) is crucial as they influence the final properties. Experimental approaches to address this issue are time and capital-intensive. This study aims to develop an efficient numerical modeling approach to develop the process–structure (P-S) linkage for LPBF-processed Inconel 718.

In this study, a numerical approach based on the finite element method and cellular automata was used to model the multilayer, multitrack LPBF build for predicting the solidification characteristics (thermal gradient G and solidification rate R) and the average grain size. Validations from published experimental studies were also carried out to ensure the reliability of the proposed numerical approach. Furthermore, microstructure simulations were used to develop P-S linkage by evaluating the effects of key LPBF process parameters on G × R, G/R and average grain size. A solidification or G-R map was also developed to comprehend the P-S linkage.

It was concluded from the developed G-R map that low laser power and high scan speed will result in a finer microstructure due to an increase in G × R, but due to a decrease in G/R, columnar characteristics are also reduced. Moreover, increasing the layer thickness and decreasing the hatch spacing lowers the G × R, raises the G/R and generates a coarse columnar microstructure.

The proposed numerical modeling approach was used to parametrically investigate the effect of LPBF parameters on the resulting microstructure. A G-R map was also developed that enables the tailoring of the as-built LPBF microstructure through solidification characteristics by tuning the process parameters.

The paper presents a wide range of post processing heat treatment cycles performed to Electron Beam Melted (EBM) Ti6Al4V alloy and establishes correlations of heat treat process to microstructure and mechanical property (microhardness). The research also identifies the optimal heat treatment to obtain the best microstructure and mechanical properties (hardness and tensile).

Rectangular bars fabricated using EBM was used to study the different heat treatment cycles. A variety of heat treatments from sub ß-transus, super ß-transus, near ß-transus and solution aircool plus ageing were designed. After the heat treatment process, the samples were analysed for, α lath width, prior ß grain size, microhardness and nanohardness. Tensile tests were done for the heat treated samples showing most refined α lath structure with uniform globular grains.

A clear correlation was observed between α lath width and the microhardness values. The solution aircooled plus aged samples exhibited the best refinement in α-ß morphology with uniform equiaxed grains. The tensile properties of the solution aircooled plus aged samples were comparable to that of the EBM printed samples and better than ASTMF1472 specifications.

There is hardly any prior work related to post processing heat treatment of EBM built Ti6Al4V other than HIP treatments. The variety of heat treatment cycles and its influence in microstructure and properties, studied in this research, gives a clear understanding on how to tailor final microstructures and select the optimal heat treatment process.

The purpose of this paper is to endorse the idea of using a special post-calculating front tracking (FT) procedure, along with the enthalpy-porosity front tracking (EP-FT) single continuum model, in order to identify zones of different dendritic microstructures developing in the mushy zone during cooling and solidification of a binary alloy.

The 2D and 3D algorithms of the FT approach along with different crystal growth laws were implemented in macroscopic calculations of binary alloy solidification with the identification of different dendrite zones developing during the process.

Direct comparison of results predicted by the FT model with that based on the concept of the critical value of the solid volume fraction shows the sensitivity of the latter on an arbitrary assumed value of the dendrite coherency point (DCP). Moreover, for a carefully chosen DCP value the second model provides results that are close to those given by the FT-based approach. It is also observed that the macro-segregation pattern obtained by the proposed method is hardly influenced by chosen dendrite tip kinetics.

To the best authors’ knowledge, for the first time the 3D FT model has been used along with the enthalpy porosity approach to simulate the development of zones of different dendrite morphology during binary alloy solidification. And, a weak influence of assumed different dendrite tip kinetics on the macro-segregation pattern has been proved, what justifies this underlying assumption of the EP-FT method.

This paper aims to establish the microstructures and the process-structure relationships in duplex stainless steel powders consolidated by selective laser melting (SLM).

A priori data on energy density levels most appropriate to consolidation of duplex stainless steel powders through SLM served as the basis to converge on the laser settings. Experimental designs with varying laser power and scan speeds and test pieces generated allowed metallographic evaluations based on optical and scanning electron microscopy and electro backscatter diffraction analyses.

Duplex stainless steel powders are established for processing by SLM. However, the dynamic point heat source and associated transient thermal fields affect the microstructures to be predominantly ferritic, with grains elongated in the build direction. Austenite precipitated either at the grain boundaries or as Widmanstätten laths, whereas the crystallographic orientations and the grain growth are affected around the cavities. Considerable CrN precipitation is also evidenced.

Duplex stainless steels are relatively new candidates to be brought into the additive manufacturing realm. Considering the poor machinability and other difficulties, the overarching result indicating suitability of duplex powders by SLM is of considerable value to the industry. More significantly, the metallographic evaluation and results of the current research allowed further understanding of the material consolidation aspects and pave ways for fine tuning and establishment of the process-structure-property relationships for this important process-material combination.

This paper aims to analyze the effect of Y₂O₃ mass fraction on the tribological performance of CrNi coating, which solved the problem of wear resistance on AISI H13 steel.

Y₂O₃ reinforced CrNi coatings were fabricated on AISI H13 steel. The microstructure and phases of obtained coatings were analyzed using a super-depth of field microscope and X-ray diffraction, respectively, and the effects of Y₂O₃ mass fraction on the microstructure and wear resistance were methodically investigated using a wear tester.

The average coefficients of friction and wear rates of Y₂O₃ reinforced CrNi coatings decrease with the increase of Y₂O₃ mass fraction, in which the Y₂O₃ plays a role of friction reduction and wear resistance. The wear mechanism of Y₂O₃ reinforced CrNi coating is primary abrasive wear, accompanied by adhesive wear, which is contributed to the grain refinement and dense structure by the Y₂O₃ addition.

The Y₂O₃ was added to the CrNi coating by laser cladding, and the effect mechanism of Y₂O₃ mass fraction on the tribological performance of CrNi coating was established by the wear model.

The purpose of this paper is to study the influence of different rolling deformation parameters on the morphology, microstructure and mechanical properties of Inconel 718 superalloy in hybrid plasma arc and micro-rolling (HPAMR) additive manufacturing.

In this paper, different deformation strains are designed, which are as-deposited, 15% and 30%. Two straight walls are fabricated by HPAMR for each kind of deformation. One wall underwent post-deposition heat treatment, and the other wall is treated without heat treatment. These samples are further investigated to evaluate the effects of deformation on the morphology, microstructure and mechanical properties.

As compared to as-deposited samples, the morphology can be significantly improved, the generation of defects and microporosity inside the alloy can be suppressed, and finer equiaxed crystals can be obtained with deformation of 30%. With heat treatment and 30% deformation, the Laves phase at the grain boundary is completely disappearing, more γ” and γ' strengthening phase is precipitated in the crystal and the size of the strengthening phase is smaller. Mechanical properties have been significantly improved.

HPAMR technology is used to successfully manufacture Inconel 718 superalloy aero-engine casing.

Compared with plasma arc additive manufacturing, HPAMR technology adds a rolling process, which can effectively improve the morphology of walls, refine internal grains, eliminate defects and microporosity, increase precipitation of strengthening phase and improve mechanical properties. It provides an optional manufacturing method for the integrated manufacturing of Inconel 718 parts.