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.

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.

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.

On the role of tin in the infiltration of aluminium by aluminium for rapid prototyping applications

The use of tin as an alloying element in the production of freeformed infiltrated aluminium components is explored. Tin slows the growth of the aluminium nitride skeleton which provides dimensional stability, as well as increasing the rate of infiltration of the aluminium liquid into the aluminium nitride skeleton. (C) 2004 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Experimental study of phase equilibria in the Al-Fe-Zn-O system in air

The phase equilibria in the Al-Fe-Zn-O system in the range 1250 °C to 1695 °C in air have been experimentally studied using equilibration and quenching techniques followed by electron probe X-ray microanalysis. The phase diagram of the binary Al2O3-ZnO system and isothermal sections of the Al2O3-“Fe2O3”-ZnO system at 1250 °C, 1400 °C, and 1550 °C have been constructed and reported for the first time. The extents of solid solutions in the corundum (Al,Fe)2O3, hematite (Fe,Al)2O3, Al2O3*Fe2O3 phase (Al,Fe)2O3, spinel (Al,Fe,Zn)O4, and zincite (Al,Zn,Fe)O primary phase fields have been measured. Corundum, hematite, and Al2O3*Fe2O3 phases dissolve less than 1 mol pct zinc oxide. The limiting compositions of Al2O3*Fe2O3 phase measured in this study at 1400 °C are slightly nonstoichiometric, containing more Al2O3 then previously reported. Spinel forms an extensive solid solution in the Al2O3-“Fe2O3”-ZnO system in air with increasing temperature. Zincite was found to dissolve up to 7 mole pct of aluminum in the presence of iron at 1550 °C in air. A meta-stable Al2O3-rich phase of the approximate composition Al8FeZnO14+x was observed at all of the conditions investigated. Aluminum dissolved in the zincite in the presence of iron appears to suppress the transformation from a round to platelike morphology.

Service performance of engineering materials

Corrosion research by Atrens and co-workers has made significant contributions to the understanding of the service performance of engineering materials. This includes: (1) elucidated corrosion mechanisms of Mg alloys, stainless steels and Cu alloys, (2) developed an improved understanding of passivity in stainless steels and binary alloys such as Fe-Cr, Ni-Cr, Co-Cr, Fe-Ti, and Fe-Si, (3) developed an improved understanding of the melt spinning of Cu alloys, and (4) elucidated mechanisms of environment assisted fracture (EAF) of steels and Zr alloys. This paper summarises contributions in the following: (1) intergranular stress corrosion cracking of pipeline steels, (2) atmospheric corrosion and patination of Cu, (3) corrosion of Mg alloys, and (4) transgranular stress corrosion cracking of rock bolts.

A reinvestigation of phase equilibria in the system Al2O3-SiO2-ZnO

The phase equilibria and liquidus temperatures in the binary SiO2-ZnO system and in the ternary Al2O3-SiO2-ZnO system at low Al2O3 concentrations have been experimentally determined using the equilibration and quenching technique followed by electron probe X-ray microanalysis. In the SiO2-ZnO system, two binary eutectics involving the congruently melting willemite (Zn2SiO4) were found at 1448 +/- 5 degrees C and 0.52 +/- 0.01 mole fraction ZnO and at 1502 +/- 5 degrees C and 0.71 +/- 0.01 mole fraction ZnO, respectively. The two ternary eutectics involving willemite previously reported in the Al2O3SiO2-ZnO system were found to be at 1315 +/- 5 degrees C and 1425 +/- 25 T, respectively. The compositions of the eutectics are 0.07, 0.52, and 0.41 and 0.05, 0.28, and 0.67 mole fraction Al2O3, SiO2, and ZnO, respectively. The results of the present investigation are significantly different from the results of previous studies.

Phase equilibria in the system Fe-Zn-O at intermediate conditions between metallic-iron saturation and air

The phase equilibria in the FeO-Fe2O3-ZnO system have been experimentally investigated at oxygen partial pressures between metallic iron saturation and air using a specially developed quenching technique, followed by electron probe X-ray microanalysis (EPMA) and then wet chemistry for determination of ferrous and ferric iron concentrations. Gas mixtures of H-2, N-2, and CO2 or CO and CO2 controlled the atmosphere in the furnace. The determined metal cation ratios in phases at equilibrium were used for the construction of the 1200 degrees C isothermal section of the Fe-Zn-O system. The univariant equilibria between the gas phase, spinel, wustite, and zincite was found to be close to pO(2) = 1 center dot 10(-8) atm at 1200 degrees C. The ferric and ferrous iron concentrations in zincite and spinel at equilibrium were also determined at temperatures from 1200 degrees C to 1400 degrees C at pO(2) = 1 center dot 10(-6) atm and at 1200 degrees C at pO(2) values ranging from 1 center dot 10(-4) to 1 center dot 10(-8) atm. Implications of the phase equilibria in the Fe-Zn-O system for the formation of the platelike zincite, especially important for the Imperial Smelting Process (ISP), are discussed.

Kinetics of reduction of lead smelting slags with solid carbon

Research techniques and a methodology have been developed that enable the reduction kinetics of molten lead smelting slags with solid carbon to be studied. The rates of reduction of PbO-FeO-Fe2O3-CaO-SiO2 slags with carbon have been measured for a range of slag compositions for PbO concentrations between 3 and 100 weight percent, and temperatures between 1423 and 1573 K. The reduction rates were determined for both graphite and coke. Within the range of process conditions examined, it has been shown that the reaction rates are almost independent of carbon reactivity, SiO2/CaO and SiO2/Fe ratio in the range of compositions investigated and are not influenced by the presence of sulphur in the slag.The apparent first order rate constants for oxygen removal increase with increasing PbO concentration and oxygen activity in the slag. The data indicate that the rate limiting reaction step for the reduction of lead slags with solid carbon is the chemical reaction at the gas/slag interface.

Phase equilibria in the Fe-Zn-O system at conditions relevant to zinc sintering and smelting

Zincite and spinel phases are present in the complex slag systems encountered in zinc/lead sintering and zinc smelting processes. These phases form extensive solid solutions and are stable over a wide range of compositions, temperatures and oxygen partial pressures. Accurate information on the stability of these phases is required in order to develop thermodynamic models of these slag systems. Phase equilibria in the Fe–Zn–O system have been experimentally studied for a range of conditions, between 900°C and 1580°C and oxygen partial pressures (pO2) between air and metallic iron saturation, using equilibration and quenching techniques. The compositions of the phases were measured using Electron probe X-ray microanalysis (EPMA). The ferrous and ferric bulk iron concentrations were determined using a specially developed wet-chemical analysis procedure based on the use of ammonium metavanadate. XRD was used to confirm phase identification. A procedure was developed to overcome the problems associated with evaporation of zinc at low pO2 values and to ensure the achievement of equilibria. An isothermal section of the system FeO–Fe2O3–ZnO at high ZnO concentrations at 1200°C was constructed. The maximum solubilities of iron and zinc in zincite and spinel phases in equilibrium were determined at pO2 = 1 × 10-6 atm at 1200°C and 1300°C. The morphology of the zincite crystals sharply changes in air between 1200–1300°C from rounded to plate-like. This is shown to be associated with significant increase in total iron concentration, the additional iron being principally in the form of ferric iron. Calculations performed by FactSage with a thermodynamically optimised database have been compared with the experimental results.