The effect of iron on liquid film migration and sintering of an Al-Cu-Mg alloy

Analytical transmission electron microscopy indicates that liquid film migration occurs during sintering of an Al-Cu-Mg alloy, that intragranular liquid pools develop from migrating films and that iron segregates to these pools. It is suggested that a high localised iron concentration retards the liquid film migration rate by reducing the coherency strain in the retreating grain, causing a region of the film to detach from the boundary, thus forming an intragranular pool in the advancing grain. Alloys with low iron levels develop few intragranular pools and have high sintered densities. (C) 2003 Acta Materialia Inc. Published by Elsevier Science Ltd. All rights reserved.

Damage by eutectic particle cracking in aluminum casting alloys A356/357

The strain dependence of particle cracking in aluminum alloys A356/357 in the T6 temper has been studied in a range of microstructures produced by varying solidification rate and Mg content, and by chemical (Sr) modification of the eutectic silicon. The damage accumulates linearly with the applied strain for all microstructures, but the rate depends on the secondary dendrite arm spacing and modification state. Large and elongated eutectic silicon particles in the unmodified alloys and large pi-phase (Al9FeMg3Si5) particles in alloy A357 show the greatest tendency to cracking. In alloy A356, cracking of eutectic silicon particles dominates the accumulation of damage while cracking of Fe-rich particles is relatively unimportant. However, in alloy A357, especially with Sr modification, cracking of the large pi-phase intermetallics accounts for the majority of damage at low and intermediate strains but becomes comparable with silicon particle cracking at large strains. Fracture occurs when the volume fraction of cracked particles (eutectic silicon and Fe-rich intermetallics combined) approximates 45 pct of the total particle volume fraction or when the number fraction of cracked particles is about 20 pct. The results are discussed in terms of Weibull statistics and existing models for dispersion hardening.

On the sintering of uncompacted, pre-alloyed Al powder alloys

The effect of the addition of elemental Mg, Sri and Pb on the sintering of impressed prealloyed 2124 and 6061 powder has been investigated. Despite being sintered at a temperature that resulted in similar to20 vol.% liquid phase, high density was possible only upon the addition of similar to1% elemental Mg as well as trace amounts of Sri or Pb. Additions of Mg facilitated oxide disruption, while Sri and Pb segregated to the liquid phase, where they reduced the liquid's surface tension, thus improving sintering. (C) 2002 Elsevier Science B.V. All rights reserved.

Stress corrosion cracking and hydrogen embrittlement of an Al-Zn-Mg-Cu alloy

The age hardening, stress corrosion cracking (SCC) and hydrogen embrittlement (HE) of an Al-Zn-Mg-Cu 7175 alloy were investigated experimentally. There were two peak-aged states during ageing. For ageing at 413 K, the strength of the second peak-aged state was slightly higher than that of the first one, whereas the SCC susceptibility was lower, indicating that it is possible to heat treat 7175 to high strength and simultaneously to have high SCC resistance. The SCC susceptibility increased with increasing Mg segregation at the grain boundaries. Hydrogen embrittlement (HE) increased with increased hydrogen charging and decreased with increasing ageing time for the same hydrogen charging conditions. Computer simulations were carried out of (a) the Mg grain boundary segregation using the embedded atom method and (b) the effect of Mg and H segregation on the grain boundary strength using a quasi-chemical approach. The simulations showed that (a) Mg grain boundary segregation in Al-Zn-Mg-Cu alloys is spontaneous, (b) Mg segregation decreases the grain boundary strength, and (c) H embrittles the grain boundary more seriously than does Mg. Therefore, the SCC mechanism of Al-Zn-Mg Cu alloys is attributed to the combination of HE and Mg segregation induced grain boundary embrittlement. (C) 2004 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Grain size measurements in Mg-Al high pressure die castings using electron back-scattered diffraction (EBSD)

Optical metallographic techniques for grain-size measurement give unreliable results for high pressure diecast Mg-Al alloys and electron back-scattered diffraction mapping (EBSD) provides a good tool for improving the quality of these measurements. An application of EBSD mapping to this question is described, and data for some castings are presented. Ion-beam milling was needed to prepare suitable samples, and this technique is detailed. As is well-known for high pressure die castings, the grain size distribution comprises at least two populations. The mean grain size of the fine-grained population was similar in both AZ91 and AM60 and in two casting thicknesses (2 mm and 5 mm) and, contrary to previously published reports, it did not vary with depth below the surface.

Microstructure of MmM(5)/Mg multi-layer hydrogen storage films prepared by magnetron sputtering

Multi-layer hydrogen storage thin films with Mg and MmNi(3.5)(CoAlMn)(1.5) (here Mm denotes La-rich mischmetal) as alternative layers were prepared by direct current magnetron sputtering. Transmission electron microscopy investigation shows that the microstructure of the MmNi(3.5)(CoAlMn)(1.5) and Mg layers are significantly different although their deposition conditions are the same. The MmNi(3.5)(CoAlMn)(1.5) layer is composed of two regions: one is an amorphous region approximately 4 nm thick at the bottom of the layer and the other is a nanocrystalline region on top of the amorphous region. The Mg layer is also composed of two regions: one is a randomly orientated nanocrystalline region 50 nm thick at the bottom of the layer and the other is a columnar crystallite region on top of the nanocrystalline region. These Mg columnar crystallites have their [001] directions parallel to the growth direction and the average lateral size of these columnar crystallites is about 100 nm. A growth mechanism of the multi-layer thin films is discussed based on the experiment results. Wiley-Liss, Inc.

Grain coarsening of magnesium alloys by beryllium

A trace of beryllium can lead to dramatic grain coarsening in Mg-Al alloys at normal cooling rates. It is, however, unclear whether this effect applies to aluminium-free magnesium alloys or not. This work shows that a trace of beryllium also causes considerable grain coarsening in Mg-Zn, Mg-Ca, Mg-Ce and Mg-Nd alloys and hinders grain refinement of magnesium alloys by zirconium as well. (C) 2004 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

The effect of silicon content on the microstructure and creep behavior in die-cast magnesium AS alloys

The effect of increasing levels of silicon on the microstructure and creep properties of high-pressure die-cast Mg-Al-Si (AS) alloys has been investigated. The morphology of the Mg2Si phase in die-cast AS alloys was found to be a function of the silicon content. The Mg2Si particles in castings with up to 1.14 wt pct Si have a Chinese script morphology. For AS21 alloys with silicon contents greater than 1.4 wt pet Si (greater than the alpha-Mg2Si binary eutectic point), some Mg2Si particles have a coarse blocky shape. Increasing the silicon content above the eutectic level results in an increase in the number of coarse faceted Mg2Si particles in the microstructure. Creep rates at 100 hours were found to decrease with increasing silicon content in AS-type alloys. The decrease in creep rate was most dramatic for silicon contents up to 1.1 wt pct. Further additions of silicon of up to 2.64 wt pct also resulted in significant decreases in creep rate.

Native grain refinement of magnesium alloys

High purity Mg-Al type alloys have a naturally fine grain size compared to commercial purity alloys with the same basic composition. This is referred to as native grain refinement. It is shown that native grain refinement occurs only in magnesium alloys containing aluminium. The mechanism is attributed to the Al4C3 particles existing in these alloys. (c) 2005 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Age hardening of a sintered Al-Cu-Mg-Si-(Sn) alloy

The age hardening response of a sintered Al-3.8 wt% Cu-1.0 wt% Mg-0.70 wt% Si alloy with and without 0.1 wt% Sn was investigated. The sequence of precipitation was characterised using transmission electron microscopy. The ageing response of the sintered Al-Cu-Mg-Si-(Sn) alloy is similar to that of cognate wrought 2xxx series alloys. Peak hardness was associated with a fine, uniform dispersion of lath shaped precipitates, believed to be either the betaor Q phase, oriented along < 010 >. directions and theta' plates lying on {001}(alpha). planes. Natural ageing also resulted in comparable behaviour to that observed in wrought alloys. Porosity in the powder metallurgy alloys did not significantly affect the kinetics of precipitation during artificial ageing. Trace levels of tin, used to aid sintering, slightly reduced the hardening response of the alloy. However, this was compensated for by significant improvements in density and hardness. (c) 2005 Elsevier B.V. All rights reserved.

The role of Ti as a catalyst for the dissociation of hydrogen on a Mg(0001) surface

In this paper, the dissociative chemisorption of hydrogen on both pure and Ti-incorporated Mg(0001) surfaces are studied by ab initio density functional theory (DFT) calculations. The calculated dissociation barrier of hydrogen molecule on a pure Mg(0001) surface (1.05 eV) is in good agreement with comparable theoretical studies. For the Ti-incorporated Mg(0001) surface, the activated barrier decreases to 0.103 eV due to the strong interaction between the molecular orbital of hydrogen and the d metal state of Ti. This could explain the experimentally observed improvement in absorption kinetics of hydrogen when transition metals have been introduced into the magnesium materials.

Microstructure of MmM(5)/Mg multi-layer films prepared by magnetron sputtering

Microstructure of MmNi(3.5)(CoAlMn)(1.5)/Mg (here Mm denotes La-rich mischmetal) multi-layer hydrogen storage thin films prepared by direct current magnetron sputtering was investigated by cross-sectional transmission electron microscopy (XTEM). It was shown that the MMM5 layers are composed of two regions: an amorphous region with a thickness of similar to 4nm at the bottom of the layers and a randomly orientated nanocrystallite region on the top of the amorphous region and the Mg layers consist of typical columnar crystallite with their [001] direction nearly parallel to the growth direction. The mechanism for the formation of the above microstructure characteristics in the multi-layer thin films has been proposed. Based on the microstructure feature of the multi-layer films, mechanism for the apparent improvement of hydrogen absorption/desorption kinetics was discussed. (c) 2005 Elsevier B.V. All rights reserved.

The effect of aluminium content on the mechanical properties and microstructure of die cast binary magnesium-aluminium alloys

This paper investigates the relationship between mechanical properties and microstructure in high pressure die cast binary Mg-Al alloys. As-cast test bars produced using high pressure die casting have been tested in tension in order to determine the properties for castings produced using this technique. It has been shown that increasing aluminium levels results in increases in yield strength and a decrease in ductility for these alloys. Higher aluminium levels also result in a decrease in creep rate at 150 degrees C. It has also been shown that an increase in aluminium levels results in an increase in the volume fraction of eutectic Mg17Al12 in the microstructure.

Mg-based nanocomposites with high capacity and fast kinetics for hydrogen storage

Magnesium and its alloys have shown a great potential in effective hydrogen storage due to their advantages of high volumetric/ gravimetric hydrogen storage capacity and low cost. However, the use of these materials in fuel cells for automotive applications at the present time is limited by high hydrogenation temperature and sluggish sorption kinetics. This paper presents the recent results of design and development of magnesium-based nanocomposites demonstrating the catalytic effects of carbon nanotubes and transition metals on hydrogen adsorption in these materials. The results are promising for the application of magnesium materials for hydrogen storage, with significantly reduced absorption temperatures and enhanced ab/desorption kinetics. High level Density Functional Theory calculations support the analysis of the hydrogenation mechanisms by revealing the detailed atomic and molecular interactions that underpin the catalytic roles of incorporated carbon and titanium, providing clear guidance for further design and development of such materials with better hydrogen storage properties.