Reflection of structural waves at a solid/liquid interface

This paper investigates the reflection characteristics of structural or guided waves in rods at a solid/liquid interface. Structural waves, whose wavelengths are much larger than the diameter of the rod, are described in a first approximation by classical one-dimensional wave theory. The reflection characteristics of such waves at a solid/liquid (melting) interface has been reported by two different ultrasonic measurement techniques: first, measuring the fast regression rate of a melting interface during the burning of metal rod samples in an oxygen-enriched environment, and second, monitoring the propagation of the solid/liquid interface during the slow melting and solidification of a rod sample in a furnace. The second work clearly shows that the major reflection occurs from the solid/liquid interface and not the liquid/gas interface as predicted by plane longitudinal wave reflectivity theory. The present work confirms this observation by reporting on the results of some specially designed experiments to identify the main interface of reflection for structural waves in rods. Hence, it helps in explaining the fundamental discrepancy between the reflection characteristics at a solid/liquid interface between low frequency structural waves and high frequency bulk waves, and confirms that the detected echo within a burning metallic rod clearly represents a reflection from the solid/liquid interface. (C) 2003 Elsevier Science B.V. All rights reserved.

The effect of resin type on the sintering of freeformed maraging steel

The role of the resin type on the sintering of maraging steel with boron additions has been investigated. Two different resins were added to the steel mixture and their subsequent debinding was evaluated and sintering responses compared with that of a resin-free alloy. The two resins used, nylon and a mixture of phenolic resin and synthetic wax, possessed different debinding behaviour, with the latter causing significant carbon contamination of the parts. This caused the formation of a Ti-Mo carbide, depleting the matrix of these elements. Consequently, the microstructure consisted of the equilibrium Fe-Fe2B eutectic, as well as a Mo-rich boride. The liquid phase also appeared to contain significant amounts of carbon, which lowered the temperature at which the liquid formed, resulting in high density occurring at a much lower temperature. When nylon was used as the binder, a similar sintering response to the resin-free alloy was observed. (C) 2002 Published by Elsevier Science B.V.

Effect of Si additions and heat treatment on the mechanical behaviour of an Al-5Mg casting alloy

Adding 1%Si to binary Al-5Mg alloy slightly increases the yield stress in comparison with the Si free alloy but dramatically reduces the ductility and tensile strength due to the formation of brittle eutectic Mg2Si and pi-Al8FeMg3Si6 particles. Adding 3%Si slightly reduces the yield stress, presumably due to some of the Mg being tied up in the Mg2Si, and further reduces the ductility due to the increased volume fraction of intermetallics. Solution heat treatment at 436degreesC decreases the yield stress of both Si containing alloys, and slightly increases the ductility in the alloy with 3%Si. Subsequent ageing at 180degreesC has no further effects on the strength or ductility. The loss in strength of the heat treated alloys seems to be due to overageing Of Mg2Si precipitates dispersed in the bulk of the alloy. (C) 2004 W. S. Maney Son Ltd.

The effect of the reduction of carbon content on the toughness of high chromium white irons in the as-cast state

Three high chromium white cast irons were examined in the as-cast state to determine the effect of the carbon content on the fracture toughness. The plane strain fracture toughness K-Ic and the fracture strength were measured for each alloy. X-ray mapping was used to identify the phases on the fracture surfaces. Scanning electron fractography and optical microscopy were used to determine the volume fraction of each phase on the fracture surfaces. It was found that most fracture occurred in the eutectic carbides, but that for the alloys with a reduced volume fraction of eutectic carbides, a small amount of crack propagation occurred in the austenitic dendrites. This change in crack path correlated with an increase in fracture toughness. The Ritchie-Knott-Rice model of brittle fracture was applied. It was found to sensibly predict the critical length for fracture for each alloy. Deep etching was employed to examine the distribution of eutectic carbides. It was found that the eutectic carbides formed a continuous network in each case. (C) 2004 Kluwer Academic Publishers.

On the role of magnesium and nitrogen in the infiltration of aluminium by aluminium for rapid prototyping applications

Selective laser sintering has been used to fabricate an aluminium alloy powder preform which is subsequently debound and infiltrated with a second aluminium alloy. This represents a new rapid manufacturing system for aluminium that can be used to fabricate large, intricate parts. The base powder is an alloy such as AA6061. The infiltrant is a binary or higher-order eutectic based on either Al-Cu or At-Si. To ensure that infiltration occurs without loss of dimensional precision, it is important that a rigid skeleton forms prior to infiltration. This can be achieved by the partial transformation of the aluminium to aluminium nitride. In order for this to occur throughout the component, magnesium powder must be added to the alumina support powder which surrounds the part in the furnace. The magnesium scavenges the oxygen and thereby creates a microclimate in which aluminium nitride can form. The replacement of the ionocovalent Al2O3 with the covalent AlN on the surface of the aluminium powders also facilitates wetting and thus spontaneous and complete infiltration. (C) 2004 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Semisolid microstructural evolution of AlSi7Mg alloy during partial remelting

Different as-cast microstructures of an AlSi7Mg alloy were produced by controlling the solidification conditions. The as-cast grain size ranged from 1.4 mm to 160 mum and the morphology varied from dendritic to rosette-like to globular. The as-cast materials were then partially remelted and isothermally held at 580degreesC for microstructure evolution. The final microstructure depended on the initial as-cast microstructure and the isothermal holding time. After partial remelting and isothermal holding, coarse-grained dendritic structures were not able to evolve to a globular structure, while structures with medium sized dendritic grains evolved to a globular structure with a relatively large particle size after a long isothermal holding time. Fine-grained structures evolved to well-rounded globular grains within times ranging front 10 min to 5 min as the dendritic nature of the starting structure diminished. An empirical equation has been established to describe the relationship between the evolved microstructure and the as-cast microstructure. (C) 2003 Elsevier B.V. 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.

The igneous charnockite—high-K alkali-calcic I-type granite—incipient charnockite association in Trivandrum Block, southern India

The Pan-African (640 Ma) Chengannoor granite intrudes the NW margin of the Neoproterozoic high-grade metamorphic terrain of the Trivandrum Block (TB), southern India, and is spatially associated with the Cardamom hills igneous charnockite massif (CM). Geochemical features characterize the Chengannoor granite as high-K alkali-calcic I-type granite. Within the constraints imposed by the high temperature, anhydrous, K-rich nature of the magmas, comparison with recent experimental studies on various granitold source compositions, and trace- and rare-earth-element modelling, the distinctive features of the Chengannoor granite reflect a source rock of igneous charnockitic nature. A petrogenetic model is proposed whereby there was a period of basaltic underplating; the partial melting of this basaltic lower crust formed the CM charnockites. The Chengannoor granite was produced by the partial melting of the charnoenderbites from the CM, with subsequent fractionation dominated by feldspars. In a regional context, the Chengannoor I-type granite is considered as a possible heat source for the near-UHT nature of metamorphism in the northern part of the TB. This is different from previous studies, which favoured CM charnockite as the major heat source. The Occurrence of incipient charnockites (both large scale as well as small scale) adjacent to the granite as well as pegmatites (which contain CO2, CO2-H2O, F and other volatiles), suggests that the fluids expelled from the alkaline magma upon solidification generated incipient charnockites through fluid-induced lowering of water activity. Thus the granite and associated alkaline pegmatites acted as conduits for the transfer of heat and volatiles in the Achankovil Shear Zone area, causing pervasive as well as patchy charnockite formation. The transport Of CO2 by felsic melts through the southern Indian middle crust is suggested to be part of a crustal-scale fluid system that linked mantle heat and CO2 input with upward migration of crustally derived felsic melts and incipient charnockite formation, resulting in an igneous charnockite - I-type granite - incipient charnockite association.

Migration of crystals during the filling of semi-solid castings

In cold-chamber high-pressure die castings (HPDC), the microstructure consists of coarse externally solidified crystals (ESCs) that are commonly observed in the central region of cross sections. In the present work, controlled laboratory scale casting experiments have been conducted with particular emphasis on the flow and solidification conditions. An A356 aluminum alloy was used to produce castings by pouring semi-solid metal through a steel die. Microstructures similar to those encountered in HPDC have been produced and the resulting microstructure is found to depend on the melt and die temperature: (1) the fraction of ESCs determines the extent of migration to the central region; (2) a maximum packing determines the area fraction of ESCs in the center; and (3) the die temperature affects the position of the ESCs-a higher die temperature can induce a displaced ESC distribution. It is found that the n-figration of crystals to the central region requires a flow, which is constrained at all melt/die interfaces. Furthermore, potential lift mechanisms are discussed. An assessment of the Saffman lift force on individual particles shows it has no significant effect on the migration of ESCs.

An analysis of the relationship between grain size, solute content, and the potency and number density of nucleant particles

To be able to determine the grain size obtained from the addition of a grain refining master alloy, the relationship between grain size (d), solute content (defined by the growth restriction factor Q), and the potency and number density of nucleant particles needs to be understood. A study was undertaken on aluminium alloys where additions of TiB2 and Ti were made to eight wrought aluminum alloys covering a range of alloying elements and compositions. It was found from analysis of the data that d = a/(3)root pct TiB2 + b/Q. From consideration of the experimental data and from further analysis of previously published data, it is shown that the coefficients a and b relate to characteristics of the nucleant particles added by a grain refiner. The term a is related to the maximum density of active TiB2 nucleant particles within the melt, while b is related to their potency. By using the analysis methodology presented in this article, the performance characteristics of different master alloys were defined and the effects of Zr and Si on the poisoning of grain refinement were illustrated.

Manufacture of high pressure die-cast radio frequency filter bodies

The manufacture of a radio frequency filter box using high pressure die casting (HPDC) is compared to the traditional high speed machining route. This paper describes an industrial exercise that concluded HPDC to be an economical and appropriate method to produce larger volumes of thin-walled telecommunications components. Modifications to the component design were made to make the component suitable for the HPDC process. Development of the die design through simulation modelling is described. The wrought alloy was replaced by near-eutectic Al-Si die casting alloy that was found to give better temperature stability performance. Apart from the economic benefits, HPDC was found to give lower filter efficiency losses through better surface finish. The effects of HPDC process variables, such as intensification pressure and injection piston velocity, on component quality, particularly porosity levels, were investigated. The pressure was analysed in terms of HPDC machine set pressure and the pressure measured in the die cavity by pressure sensors. Porosity was found to decrease with increased pressure and slightly increase with higher casting velocities.

As-cast morphology of iron-intermetallics in Al-Si foundry alloys

The as-cast three-dimensional morphologies of alpha-Al-15(Fe,Mn)(3)Si-2 and beta-Al5FeSi intermetallics were investigated by serial sectioning. Large beta-Al5FeSi intermetallics were observed to grow around pre-existing dendrite arms. The alpha-Al-15(Fe,Mn)(3)Si-2 intermetallic particle was observed to have a central polyhedral particle and an external highly convoluted three-dimensional structure. (c) 2005 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.