Effect of solidification grain refinement on the development of wrought Mg alloys

A recent trial investigated the effect of solidification grain refinement of billet on the grain refinement and properties of alloy ZM20. It was found that even at levels of 0.4Mn, significant grain refinement could be obtained when 0.7Zr was added. At 0.2Mn grain sizes as low as 60μm were
obtained. Billets of Mg-2Zn-0.2Mn with four different grain sizes, due to different Zr and cooling rates were then cast via vertical direct chill casting and extruded conventionally. Benefits of grain refinement of the billet on extrusion were found to be a slight increase in the size of the operating
window, and a reduction of the grain size in the extrudate. However, the effect of the reduction in extrudate grain size due to refinement of the billet was small compared with the amount of grain refinement obtained due to recrystallisation on extrusion.

Solidification of cast magnesium alloys

A description of the key solidification steps in the formation of the as-cast microstructure of magnesium alloys is presented. The focus is on the two common magnesium alloy groups: Mg-Al alloys and Mg-Zn-rare earth alloys. The key elements described are: nucleation (including grain refinement), growth of the primary phase and the formation of the eutectic phases. In addition the effect of casting process (e.g. high-pressure diecasting and sand casting) on the outcomes from solidification are discussed. This includes consideration of the formation of banded defects during solidification in the dynamic environment of high pressure die casting.

High-temperature laser-scanning confocal microscopy as a tool to study the interface instability during unsteady-state solidification of low-carbon steel

Solidification microstructure is a defining link between production techniques and the mechanical properties of metals and in particular steel. Due to the difficulty of conducting solidification studies at high temperature, knowledge of the development of solidification microstructure in steel is scarce. In this study, a laser-scanning confocal microscopy (LSCM) has been used to observe in situ and in real-time the planar to cellular to dendritic transition of the progressing solid/liquid interface in low carbon steel. Because the in situ observations in the laser-scanning confocal microscopy are restricted to the surface, the effect of sample thickness on surface observations was determined. Moreover, the effect of cooling rate and alloy composition on the planar to cellular interface transition was investigated. In the low-alloyed, low-carbon steel studied, the cooling rate does not seem to have an effect on the spacing of the cellular microstructure. However, in the presence of copper and manganese, the cell spacing decreased at higher cooling rates. Higher concentrations of copper in steel resulted on an increased cell spacing at the same cooling rates.

Solidification behaviour and microstructural development of ironbased alloys under conditions pertinent to strip casting - 200 series stainless steels

The castability and microstructures produced from strip casting simulations of three compositions in the 200 series stainless steels have been examined. The nucleation density was similar for all three compositions.The as-cast microstructure showed very fine austenite grains of 10–20 μm in width. Retained delta ferrite was observed in the inter-dendritic regions, and was likely to be stabilised by the segregation of Cr into these regions. An analysis of the crystallography expected of different solidification sequences is presented, but a strict adherence to the Kurdjumov-Sachs orientation relationship was not found in these samples.

A survey on mechanisms and critical parameters on solidification of selective laser melting during fabrication of Ti-6Al-4V prosthetic acetabular cup

Additive Manufacturing (AM) includes a range of approaches that correlate with computer aided design (CAD) and manufacturing by fabrication via precise layers and is a promising method for the production of medical tools. In this study, different aspects and mechanisms of solidification for curved surfaces based on equilibrium at curved interfaces, Monge patch, interfacial and Gibbs energy will be discussed. Also, the effect of capillarity, geometry, substrate temperature, cooling rate and scanning parameters in the solidification of a prosthetic acetabular cup (PAC) using selective laser melting (SLM) is analysed. The contributions of this work are analysing solidification and effective factors in this process to produce parts with a higher quality and mechanical properties such as strength, strain, porosity, relative density and hardness. Results indicate that due to the surface to volume (S/V) ratio, and the increasing effect of the radius on Monge patch, thermal stresses and surface forces are more prevalent on outer surfaces. Moreover, solidification and mechanical properties are related to capillarity, geometry, substrate temperature, cooling rate, scanning power and speed. The results also indicate the interaction of solute diffusion and heat transfer with interatomic forces in large S/V ratio and at small scales tend to improve solidification.

Method for determining reaction rate of mild steel containers during melting of magnesium-aluminium alloys and effect of aluminium content on directionally solidified microstructures

A magnesium alloy of eutectic composition (33 wt-'%Al) was directionally solidified in mild steel tubes at two growth rates, 32 and 580 mum s(-1,) in a temperature gradient between 10 and 20 K mm(-1). After directional solidification, the composition of each specimen varied dramatically, from 32'%Al in the region that had remained solid to 18%Al (32 mum s(-1) specimen) and 13%Al (580 mum s(-1) specimen) at the plane that had been quenched from the eutectic temperature. As the aluminium content decreased, the microstructure contained an increasing volume fraction of primary magnesium dendrites and the eutectic morphology gradually changed from lamellar to partially divorced. The reduction in aluminium content was caused by the growth of an Al-Fe phase ahead of the Mg-Al growth front. Most of the growth of the Al-Fe phase occurred during the remelting period before directional solidification. The thickness of the Al-Fe phase increased with increased temperature and time of contact with the molten Mg-Al alloy. (C) 2003 Maney Publishing.

Seeding of single crystal superalloys--Role of seed melt-back on casting defects

Single crystal seeds of the nickel-base superalloy CMSX-4 have been partially melted in a temperature gradient and then quenched. Small islands of random orientation are observed throughout the melted-back semi-solid. These random orientations appear to be pinched-off secondary dendrite arms, but there is no evidence that they are transported ahead of the dendrite tips to nucleate stray grains during directional solidification.

Squeeze pin implementation in a high pressure die casting

This paper discusses the implementation of hydraulically operated squeeze pins to reduce porosity formation in cast aluminium bearing caps. Two complete sets are cast in an eight-cavity die with a 2000t cold chamber high pressure die casting machine. The initial die configuration used a sliding core assembly with stationary pins to core a through hole in a thick section of the front cam caps. This configuration resulted in high post machining scrap rates, primarily due to porosity associated with solidification shrinkage. Replacement of the sliding core assembly with a squeeze pin unit substantially reduced shrinkage porosity in the critical region, with consequent reductions in the scrap rate. The squeeze pins are actuated 1.5s after the piston reaches the high shot changeover position, but can be successfully engaged between I and 3.5 seconds after high shot changeover. Density measurements and visual inspection confirmed the substantial improvement in porosity levels in the critical region of the castings.

Casting yield improvement in graphite iron castings

A well designed runner and feeding system should produce castings with minimal defects and low pour weight. This thesis investigates how the filling regime and solidification of the mould influences defects in the castings produced from that mould. Design guidelines to reduce such defects are proposed and tested. An existing shrinkage fault in a Grey Iron disc brake casting is simulated using a commercial finite-difference computer program. Three criteria are used to predict the defect and the effect of changes to the feeder geometry. Critical Fraction Solidification analysis is used to determine whether the feeder remains in liquid contact with the casting during solidification and this approach is shown to correctly predict the presence or absence of porosity* The feeder block is extended below the ingate of the casting to improve liquid contact between the casting and feeder without significantly increasing the feeder mass. Plant trials confirm the change to the feeder eliminates the porosity defect. The runner system and mould venting for a thin walled Ductile Iron casting are investigated. Trials show that by setting the total mould vent area to be greater than the net ingate area of the castings, the cold-shut frequency is halved. A method for runner system design based on peak linear flow velocity in the runner during mould filling is proposed. A new pressurised runner system produces castings with significantly fewer defects and reduced pour weight when runner areas are designed to maintain peak velocity below 1 m/s. Peak velocity and magnesium levels are demonstrated to be critical factors in the elimination of cold-shut defects. A pressurised runner system is also shown to isolate inclusion defects from castings more effectively than an unpressurised system. From this work, a technique is proposed which allows the yield of an existing runner and feeder system for iron castings to be improved with confidence in the results.

Solid state ion transport and phase behaviour in composites of N,N-methyl propylpyrrolidinium tetrafluoroborate and amorphous polyethylene oxide

The binary and ternary addition of 2 wt.% LiBF₄ and 2 wt.% amorphous polyethylene oxide (aPEO) respectively to the plastic crystal forming salt P₁₃BF₄ (where P₁₃⁺=methylpropyl pyrrolidinium cation) was investigated with specific focus on the phase behaviour and evaluation of transport characteristics. Differential scanning calorimetry (DSC), optical thermomicroscopy, solid state nuclear magnetic resonance (NMR), and AC impedance spectroscopy were used to develop an understanding of the conduction process in the pure and mixed systems. The morphology of the ternary compound appeared as hexagonal spherulites upon solidification. Multinuclear NMR Pulsed Field Gradient measurements (¹H,¹⁹F,⁷Li) to probe both cation and anion diffusion coefficients are reported. The anion is shown to be the most diffusive (at 320 K:¹⁹F=2.5×10⁻¹¹ m² s⁻¹; 1H: 1.8×10⁻¹¹ m² s⁻¹; ⁷Li: 1.1×10⁻¹¹ m² s⁻¹) in the ternary compound, with enhanced conductivity (2.7×10⁻⁵ S cm⁻¹ at 310 K) just below the melt.

Electrospinning of nanofibres with parallel line surface texture for improvement of nerve cell growth

Nanofibres having a parallel line surface texture were electrospun from cellulose acetate butyrate solutions using a solvent mixture of acetone and N,N'-dimethylacetamide. The formation mechanism of the unusual surface feature was explored and attributed to the formation of voids on the jet surface at the early stage of electrospinning and subsequent elongation and solidification of the voids into a line surface structure. The fast evaporation of a highly volatile solvent, acetone, from the polymer solution was found to play a key role in the formation of surface voids, while the high viscosity of the residual solution after the solvent evaporation ensured the line surface to be maintained after the solidification. Based on this principle, nanofibres having a similar surface texture were also electrospun successfully from other polymers, such as cellulose acetate, polyvinylidene fluoride, poly(methyl methacrylate), polystyrene and poly(vinylidene fluoride-co-hexafluoropropene), either from the same or from different solvent systems. Polarized Fourier transform infrared spectroscopy was used to measure the polymer molecular orientation within nanofibres. Schwann cells were grown on both aligned and randomly oriented nanofibre mats. The parallel line surface texture assisted in the growth of Schwann cells especially at the early stage of cell culture regardless of the fibre orientation. In contrast, the molecular orientation within nanofibres showed little impact on the cell growth.

Needleless eletrospinning of polystyrene fibers with an oriented surface line texture

We have demonstrated that polystyrene (PS) nanofibers having an ordered surface line texture can be produced on a large scale from a PS solution of acetone and N,N′-dimethylformamide (2/1, vol/vol) by a needleless electrospinning technique using a disc as fiber generator. The formation of the unusual surface feature was investigated and attributed to the voids formed on the surface of jets due to the fast evaporation of acetone at the early stage of electrospinning, and subsequent elongation and solidification turning the voids into ordered lines on fiber surface. In comparison with the nanofibers electrospun by a conventional needle electrospinning using the same solution, the disc electrospun fibers were finer with similar diameter distribution. The fiber production rate for the disc electrospinning was 62 times higher than that of the conventional electrospinning. Fourier transform infrared spectroscopy and X-ray diffraction measurements indicated that the PS nanofibers produced from the two electrospinning techniques showed no significant difference in chemical component, albeit slightly higher crystallinity in the disc spun nanofibers.