Age Hardening of Copper-Aluminum Alloy Castings

Age hardening occurs in alloys of the solid solution type containing a hardening constituent, be it metal or metallic compound, which is more soluble in the solvent phase at higher temperatures than at lower ones.

Polymer-Derived In-Situ Metal Matrix Composites Created by Direct Injection of a Liquid Polymer into Molten Magnesium

We show that a liquid organic precursor can be injected directly into molten magnesium to produce nanoscale ceramic dispersions within the melt. The castings made in this way possess good resistance to tensile deformation at 673 K (400 degrees C), confirming the non-coarsening nature of these dispersions. Direct liquid injection into molten metals is a significant step toward inserting different chemistries of liquid precursors to generate a variety of polymer-derived metal matrix composites. (C) The Minerals, Metals & Materials Society and ASM International 2013

Initiation Reactions in Thermal Polymerization of Vinyl Monomers in the Molten State

Evidence of the initiation process during uncatalyzed thermal polymerization of vinyl monomers is presented. DSC studies reveal a prominent endothermic effect just before the polymerization exotherm, which is substantiated by the identification of the free radicals produced in the initiation by a quick quenching technique and subsequent detection by ESR at low temperatures.

Modeling growth of hydrogen bubbles in aluminum castings using the level-set method

A new approach is proposed to solve for the growth as well as the movement of hydrogen bubbles during solidification in aluminum castings. A level-set methodology has been adopted to handle this multiphase phenomenon. A microscale domain is considered and the growth and movement of hydrogen bubbles in this domain has been studied. The growth characteristics of hydrogen bubbles have been evaluated under free growth conditions in a melt having a hydrogen input caused b solidification occurring around the microdomain.

Self-Organization of n-Alkane Chains in Water: Length Dependent Crossover from Helix and Toroid to Molten Globule

We demonstrate a chain length dependent crossover in the structural properties of linear hydrocarbon (n-alkane) chains using detailed atomistic simulations in explicit water. We identify a number of exotic structures of the polymer chain through energy minimization of representative snapshots collected from molecular dynamics trajectory. While the collapsed state is ring-like (circular) for small chains (CnH2n+2; n <= 20) and spherical for very long ones (n = 100), we find the emergence of ordered helical structures at intermediate lengths (n similar to 40). We find different types of disordered helices and toroid-like structures at n = 60. We also report a sharp transition in the stability of the collapsed state as a function of the chain length through relevant free energy calculations. While the collapsed state is only marginally metastable for C20H42, a clear bistable free energy surface emerges only when the chain is about 30 monomers long. For n = 30, the polymer exhibits an intermittent oscillation between the collapsed and the coil structures, characteristic of two stable states separated by a small barrier.

Preparation of cast aluminium alloy-mica particle composites

The optimum conditions for producing cast aluminium alloy-mica particle composites, by stirring mica particles (40 to 120 mgrm) in molten aluminium alloys (above their liquidus temperatures), followed by casting in permanent moulds, are described. Addition of magnesium either as pieces along with mica particles on the surface of the melts or as a previously added alloying element was found to be necessary to disperse appreciable quantities (1.5 to 2 wt.%) of mica particles in the melts and retain them as uniform dispersions in castings under the conditions of present investigation. These castings can be remelted and degassed with nitrogen at least once with the retention of about 80% mica particles in the castings. Electron probe micro-analysis of these cast composites showed that magnesium added to the surface of the melt along with mica has a tendency to segregate around the mica particles, apparently improving the dispersability for mica particles in liquid aluminium alloys. The mechanical properties of the aluminium alloy-mica particle composite decrease with an increase in mica content, however, even at 2.2% the composite has a tensile strength of 14.22 kg mm–2 with 1.1% elongation, a compression strength of 42.61 kg mm–2, and an impact strength of 0.30 kgm cm–2. The properties are adequate for certain bearing applications, and the aluminium-mica composite bearings were found to run under boundary lubrication, semi-dry and dry friction conditions whereas the matrix alloy (without mica) bearings seized or showed stick slip under the same conditions.

Thermal Expansivities and Temperature Coefficients of Refractive Indices for Molten Salts

An empirical relation for temperature–independent molar polarization is suggested. When this relation was used, the thermal expansivity was estimated correctly from refractive index data.

Amide-based Room Temperature Molten Salt as Solvent cum Stabilizer for Metallic Nanochains

A simple and efficient method for spontaneous organization of long assemblies of gold nanoparticles is described. This is achieved in a molten solvent containing acetamide, urea and ammonium nitrate that acts as a solvent cum stabilizer. There is no external aggregating agent or stabilizing agent added to the system. Depending on the concentration of the metal salt in the ternary melt, either chain-like assemblies or individual nanoparticles could be obtained. The amine groups present in the components of the melt (acetamide and urea) help in the stabilization of nanoparticles. Ammonium ions present in the eutectic mixture are likely to assist in the organization of the particles. The method is simple, highly reproducible and does not require any templating agent for the formation of chain-like assemblies.

A semi-empirical theory of molten salts

A semi-empirical model is presented for describing the interionic interactions in molten salts using the experimentally available structure data. An extension of Bertaut's method of non-overlapping charges is used to estimate the electrostatic interaction energy in ionic melts. It is shown, in agreement with earlier computer simulation studies, that this energy increases when an ionic salt melts. The repulsion between ions is described using a compressible ion theory which uses structure-independent parameters. The van der Waals interactions and the thermal free energy are also included in the total energy, which is minimised with respect to isostructural volume variations to calculate the equilibrium density. Detailed results are presented for three molten systems, NaCl, CaCl2 and ZnCl2, and are shown to be in satisfactory agreement with experiments. With reliable structural data now being reported for several other molten salts, the present study gains relevance.

The UPAL process: a direct method of preparing cast aluminium alloy-graphite particle composites

A direct method of preparing cast aluminium alloy-graphite particle composites using uncoated graphite particles is reported. The method consists of introducing and dispersing uncoated but suitably pretreated graphite particles in aluminium alloy melts, and casting the resulting composite melts in suitable permanent moulds. The optical pretreatment required for the dispersion of the uncoated graphite particles in aluminium alloy melts consists of heating the graphite particles to 400° C in air for 1 h just prior to their dispersion in the melts. The effects of alloying elements such as Si, Cu and Mg on the dispersability of pretreated graphite in molten aluminium have also been reported. It was found that additions of about 0.5% Mg or 5% Si significantly improve the dispersability of graphite particles in aluminium alloy melts as indicated by the high recoveries of graphite in the castings of these composites. It was also possible to disperse upto 3% graphite in LM 13 alloy melts and retain the graphite particles in a well distributed fashion in the castings using the pre-heat-treated graphite particles. The observations in this study have been related to the information presently available on wetting between graphite and molten aluminium in the presence of different elements and our own thermogravimetric analysis studies on graphite particles. Physical and mechanical properties of LM 13-3% graphite composite made using pre-heat-treated graphite powder, were found to be adequate for many applications, including pistons which have been successfully used in internal combustion engines.

Effect of carbon equivalent and inoculation on residual stresses in grey iron castings

It is virtually impossible to produce castings free from internal stresses using conventional methods of founding. Castings with appreciable stresses distort during storage, transportation, machining and service. Though composition and melt treatment are known to affect the magnitude of residual stress in castings, the data on the effect of carbon equivalent and inoculation on the magnitude of residual stress in castings are limited. In the present investigation, an attempt is made to study (i) the effect of carbon equivalent on residual stress in cast iron castings, and (ii) the effect of inoculants such as calcium silicide and ferrosilicon on residual stress in iron castings in the carbon equivalent range 3.0–4.0%. The results of the investigation indicate the following: (i) the residual strains decrease linearly with increase in carbon equivalent in the uninoculated and inoculated irons; (ii) the tensile residual stresses decrease linearly with increase in carbon equivalent value of the uninoculated, calcium silicide-inoculated and ferrosilicon-inoculated cast iron castings; (iii) the ratio of UTS to residual stress increased on inoculating the grid castings. This increase is higher for calcium silicide-inoculated grids than for ferrosilicon-inoculated grid castings. This implies that from the residual stress point of view, inoculation of the iron with calcium silicide is beneficial.

Thermal decomposition of hydrazinium monoperchlorate in the molten state

The thermal decomposition of hydrazinium monoperchlorate (HP-1) in the molten state has been investigated using differential thermal analysis, thermogravimetric analysis, a constant volume manometric technique and mass-spectrometry. The stoichiometry of the reaction can be represented by the equation: 20 N2H5C1O4 13 NH4C1O4 + 3.5 Cl2 + 2 O2 + 13 N2 + 0.5 N2O + 0.5 H2 + + 23.5 H2O The data seem to indicate that the mechanism, which involves an associated complex, remains unchanged from 140 to 190°. Consequently, impurities capable of forming associated complexes with the hydrazinium or the perchlorate ion desensitize the thermal decomposition of HP-1, the extent of desensitization being determined by the size, the charge and the concentration of the impurity.

Physicochemical, Electrochemical, and Spectroscopic Characterization of Zinc-Based Room-Temperature Molten Electrolytes and Their Application in Rechargeable Batteries

Room-temperature zinc ion-conducting molten electrolytes based on acetamide, urea, and zinc perchlorate or zinc triflate have been prepared and characterized by various physicochemical, spectroscopic, and electrochemical techniques. The ternary molten electrolytes are easy to prepare and can be handled under ambient conditions. They show excellent stability, high ionic conductivity, relatively low viscosity, and other favorable physicochemical and electrochemical properties that make them good electrolytes for rechargeable zinc batteries. Specific conductivities of 3.4 and 0.5 mS cm(-1) at 25 degrees C are obtained for zinc-perchlorate-and zinc-triflate-containing melts, respectively. Vibrational spectroscopic data reveal that the free ion concentration is high in the optimized composition. Rechargeable Zn batteries have been assembled using the molten electrolytes, with gamma-MnO2 as the positive electrode and Zn as the negative electrode. They show excellent electrochemical characteristics with high discharge capacities. This study opens up the possibility of using acetamide-based molten electrolytes as alternate electrolytes in rechargeable zinc batteries. (C) 2009 The Electrochemical Society.

Magnesium ion conducting, room temperature molten electrolytes

Room temperature, magnesium ion conducting binary molten electrolyte consisting of acetamide and magnesium perchlorate has been prepared and characterized. The molten liquid is very stable and shows high ionic conductivity, of the order of several mS cm(-1) at 25 degrees C with other favourable physicochemical properties. Vibrational spectroscopic studies reveal that the free ion concentration is higher than that of ion pairs and aggregates in the melt. The electrochemical reversibility of magnesium deposition and dissolution is demonstrated using voltammetry and impedance studies. Preliminary studies on rechargeable batteries assembled using gamma-MnO2 and Mg metal as the electrodes together with the molten electrolyte show high discharge capacity.