Interaction of liquid copper with sintered iron compacts

Interaction of liquid copper with sintered iron is important in brazing, liquid phase sintering and infiltration. In brazing, the penetration of liquid copper into the pores is to be `avoided', whereas in infiltration processes it is `encouraged', and in liquid phase sintering it should be `controlled' so that optimum mechanical properties are achieved. The main objective of the research is to model the interaction by studying the effect of the process variables on the mechanisms of copper interaction in Fe-Cu and Fe-Cu-C systems. This involves both theoretical and experimental considerations. Dilatometric investigations at 950, 1125 and 1200oC, together with metallographic analyses were carried out to clarify the copper growth phenomenon. It is shown that penetration of liquid copper into the iron grain boundaries is the major cause of dimensional changes. Infiltration profiles revealed that copper penetration between the iron interparticle contact points and along iron grain boundaries is a rapid process. The extent of copper penetration depends on the dihedral angle. Large dihedral angles hinder, and small angles promote copper penetration into the grain boundaries. Dihedral angle analysis shows that the addition of 0.6wt.% graphite reduces the number of zero dihedral angle from 27 to 3o and increases the mean dihedral angle from 9.8 to 41.5o. The dihedral angle was lowest at 1125oC and then increased to higher values as the system approached its equilibrium condition. Elementally mixed (E.M.) Fe-Cu compacts showed a rapid expansion at the copper melting point. However, graphite additions reduced compact growth by increasing the mean dihedral angle. In order to reduce the copper growth phenomenon, iron powder was coated with a thin layer of copper by an immersion coating (I.C.) technique. The dilatometric curves revealed an overall shrinkage in the I.C. compacts compared to their corresponding E.M. compacts. Multiple regression models showed that temperature had the most effect on dimensional changes and density had the most contributing effect upon the copper penetration area in the infiltrated powder metallurgy compacts.

The compressive creep and load relaxation properties of a series of high aluminium zinc-based alloys

A new family of commercial zinc alloys designated as ZA8, ZA12, and ZA27 and high damping capacity alloys including Cosmal and Supercosmal and aluminium alloy LM25 were investigated for compressive creep and load relaxation behaviour under a series of temperatures and stresses. A compressive creep machine was designed to test the sand cast hollow cylindrical test specimens of these alloys. For each compressive creep experiment the variation of creep strain was presented in the form of graphs plotted as percentage of creep strain () versus time in seconds (s). In all cases, the curves showed the same general form of the creep curve, i.e. a primary creep stage, followed by a linear steady-state region (secondary creep). In general, it was observed that alloy ZA8 had the least primary creep among the commercial zinc-based alloys and ZA27 the greatest. The extent of primary creep increased with aluminium content to that of ZA27 then declined to Supercosmal. The overall creep strength of ZA27 was generally less than ZA8 and ZA12 but it showed better creep strength than ZA8 and ZA12 at high temperature and high stress. In high damping capacity alloys, Supercosmal had less primary creep and longer secondary creep regions and also had the lowest minimum creep rate among all the tested alloys. LM25 exhibited almost no creep at maximum temperature and stress used in this research work. Total creep elongation was shown to be well correlated using an empirical equation. Stress exponent and activation energies were calculated and found to be consistent with the creep mechanism of dislocation climb. The primary α and β phases in the as-cast structures decomposed to lamellar phases on cooling, with some particulates at dendrite edges and grain boundaries. Further breakdown into particulate bodies occurred during creep testing, and zinc bands developed at the highest test temperature of 160°C. The results of load relaxation testing showed that initially load loss proceeded rapidly and then deminished gradually with time. Load loss increased with temperature and almost all the curves approximated to a logarithmic decay of preload with time. ZA alloys exhibited almost the same load loss at lower temperature, but at 120°C ZA27 improved its relative performance with the passage of time. High damping capacity alloys and LM25 had much better resistance to load loss than ZA alloys and LM25 was found to be the best against load loss among these alloys. A preliminary equation was derived to correlate the retained load with time and temperature.

The breakdown of stainless steels in strong acids

A study was made of the corrosion behaviour in the ASTM standard Nitric acid and Oxalic acid tests, of two commercial AISI type 304L steels in the as received condition and after various heat treatments. Optical microscopy and SEM, TEM and STEM in conjunction with energy dispersive x-ray analysis, were used to correlate the corrosion behaviour of these steels with their microstructure. Some evidence of phosphorus segregation at grain boundaries was found. The corrosion behaviour at microstructural level was studied by examining on the TEM thin foils of steel that had been exposed to boiling nitric acid. Banding attack in the nitric acid and oxalic acid tests was studied using SEM and EPNA and found to be due to the micro-segregation of chromium and nickel. Using two experimental series of 304L, one a 17% Cr, 91 Ni, steel with phosphorus additions from 0.006% to 0.028%, the other a 20% Cr, 121 Ni steel with boron additions from 0.0011 to 0.00B51. The effect of these elements on corrosion in the nitric acid test was studied. The effect of different cooling rates and different solution treatment temperature on the behaviour of these steels was examined. TEM and STEM in conjunction with energy-dispersive x-ray analysis were again used to study the microstructure of the steels. Phosphorus was found to affect the corrosion behaviour but no effect was found with boron.

Ion plating

Under ideal conditions ion plating produces finely grained dense coatings with excellent adhesion. The ion bombardment induced damage initiates a large number of small nuclei. Simultaneous coating and sputtering stimulates high rates of diffusion and forms an interfacial region of graded composition responsible for good adhesion. To obtain such coatings on components far industrial applications, the design and construction Of an ion plater with a 24" (O.6rn) diameter chamber were investigated and modifications of the electron beam gun were proposed. A 12" (O.3m) diameter ion plater was designed and constructed. The equipment was used to develop surfaces for solar energy applications. The conditions to give extended surfaces by sputter etching were studied. Austenitic stainless steel was sputter etched at 20 and 30 mTorr working pressure and at 3, 4 and 5 kV. Uniform etching was achieved by redesigning the specimen holder to give a uniform electrostatic field over the surfaces of the specimens. Surface protrusions were observed after sputter etching. They were caused by the sputter process and were independent of grain boundaries, surface contaminants and inclusions. The sputtering rate of stainless steel was highly dependent on the background pressure which should be kept below 10-5 Torr. Sputter etching improved the performance of stainless steel used as a solar selective surface. A twofold improvement was achieved on sputter etching bright annealed stainless steel. However, there was only slight improvement after sputter etching stainless steel which had been mechanically polished to a mirror finish. Cooling curves Were used to measure the thermal emittance of specimens.The deposition rate of copper was measured at different levels of power input and was found to be a maximum at 9.5 kW. The diameter of the copper feed rod was found to be critical for the maintenance of a uniform evaporation rate.

Effect of solute segregation on the strength of nanocrystalline alloys:Inverse Hall-Petch relation

We have used a high-energy ball mill to prepare single-phased nanocrystalline Fe, Fe90Ni10, Fe85Al4Si11, Ni99Fe1 and Ni90Fe10 powders. We then increased their grain sizes by annealing. We found that a low-temperature anneal (T < 0.4 Tm) softens the elemental nanocrystalline Fe but hardens both the body-centered cubic iron- and face-centered cubic nickel-based solid solutions, leading in these alloys to an inverse Hall–Petch relationship. We explain this abnormal Hall–Petch effect in terms of solute segregation to the grain boundaries of the nanocrystalline alloys. Our analysis can also explain the inverse Hall–Petch relationship found in previous studies during the thermal anneal of ball-milled nanocrystalline Fe (containing ∼1.5 at.% impurities) and electrodeposited nanocrystalline Ni (containing ∼1.0 at.% impurities).

Effect of cooling rate on intercritically reheated microstructure and toughness in high strength low alloy steel

High strength low alloy steels have been shown to be adversely affected by the existence of regions of poor impact toughness within the heat affected zone (HAZ) produced during multipass welding. One of these regions is the intercritically reheated coarse grained HAZ or intercritical zone. Since this region is generally narrow and discontinuous, of the order of 0.5 mm in width, weld simulators are often employed to produce a larger volume of uniform microstructure suitable for toughness assessment. The steel usedfor this study was a commercial quenched and tempered steel of 450 MN m -2 yield strength. Specimen blanks were subjected to a simulated welding cycle to produce a coarse grained structure of upper bainite during the first thermal cycle, followed by a second thermal cycle where the peak temperature T p2 was controlled. Charpy tests carried out for T p2 values in the range 650-850°C showed low toughness for T p2 values between 760 and 790°C, in the intercritical regime. Microstructural investigation of the development of grain boundary martensite-retained austenite (MA) phase has been coupled with image analysis to measure the volume fraction of MAformed. Most of the MA constituent appears at the prior austenite grain boundaries during intercritical heating, resulting in a 'necklace' appearance. For values of T p2 greater than 790°C the necklace appearance is lost and the second phase areas are observed throughout the structure. Concurrent with this is the development of the fine grained, predominantly ferritic structure that is associated with the improvement in toughness. At this stage the microstructure is transforming from the intercritical regime structure to the supercritically reheated coarse grained HAZ structure. The toughness improvement occurs even though the MA phase is still present, suggesting that the embrittlement is associated with the presence of a connected grain boundary network of the MA phase. The nature of the second phase particles can be controlled by the cooling rate during the second cycle and variesfrom MA phase at high cooling rates to a pearlitic structure at low cooling rates. The lowest toughness of the intercritical zone is observed only when MA phase is present. The reason suggested for this is that only the MA particles debond readily, a number of debonded particles in close proximity providing sufficient stress concentration to initiate local cleavage. © 1993 The Institute of Materials.

Microstructural and environmental effects on fatigue crack propagation in duplex stainless steels

Fatigue crack initiation and propagation in duplex stainless steels are strongly affected by microstructure in both inert and aggressive environments. Fatigue crack growth rates in wrought Zeron 100 duplex stainless steel in air were found to vary with orientation depending on the frequency of crack tip retardation at ferrite/austenite grain boundaries. Fatigue crack propagation rates in 3.5% NaCl solution and high purity water are increased by hydrogen assisted transgranular cyclic cleavage of the ferrite. The corrosion fatigue results are interpreted using a model for the cyclic cleavage mechanism.

Comparison of crack growth behaviour between spray-formed and commercial plate Al-Zn-Mg-Cu alloy 7150

This paper compares the crack growth resistance of an experimental spray-formed extrusion with that of a commercial aluminium alloy, the two alloys having similar compositions but markedly different grain structures. Tensile and fracture behaviour is similar in both materials and is influenced by inclusion content. The two materials differ in their crack growth resistance, which is shown to be dependent upon grain size and shape. Environmentally-induced crack growth is favoured by aligned grain boundaries and small grain size.