The evolution of microstructure and mechanical properties during high-speed direct-chill casting in different Al-Mg2Si in situ composites

The effect of high-speed direct-chill (DC) casting on the microstructure and mechanical properties of Al-Mg₂Si in situ composites and AA6061 alloy was investigated. The microstructural evolution of the Al-Mg₂Si composites and AA6061 alloy was examined by optical microscopy, field-emission scanning electron microscopy (FE-SEM) and transmission electron microscopy (TEM). The results revealed that an increase of the casting speed substantially refined the primary Mg₂Si particles (from 28 to 12 μm), the spacing of eutectic Mg₂Si (from 3 to 0.5 μm), and the grains of AA6061 alloy (from 102 to 22 μm). The morphology of the eutectic Mg₂Si transformed from lamellar to rod-like and fibrous with increasing casting speed. The tensile tests showed that the yield strength, tensile strength, and elongation improved at higher casting speeds because of refinement of the Mg₂Si phase and the grains in the Al-Mg₂Si composites and the AA6061 alloy. High-speed DC casting is demonstrated to be an effective method to improve the mechanical properties of Al-Mg₂Si composites and AA6061 alloy billets.     

Preparation of Al<Subscript>72</Subscript>Ni<Subscript>8</Subscript>Ti<Subscript>8</Subscript>Zr<Subscript>6</Subscript>Nb<Subscript>3</Subscript>Y<Subscript>3</Subscript> amorphous powders and bulk materials

Amorphous Al₇₂Ni₈Ti₈Zr₆Nb₃Y₃ powders were successfully fabricated by mechanical alloying. The microstructure, glass-forming ability, and crystallization behavior of amorphous Al₇₂Ni₈Ti₈Zr₆Nb₃Y₃ powders were investigated by X-ray diffraction (XRD), transmission electron microscopy (TEM), and differential scanning calorimetry (DSC). The isothermal crystallization kinetics was analyzed by the Johnson–Mehl–Avrami equation. In the results, the supercooled liquid region of the amorphous alloy is as high as 81 K, as determined by non-isothermal DSC curves. The activation energy for crystallization is as high as 312.6 kJ·mol?1 obtained by Kissinger and Ozawa analyses. The values of Avrami exponent (n) imply that the crystallization is dominated by interface-controlled three-dimensional growth in the early stage and the end stage and by diffusion-controlled two- or three-dimensional growth in the middle stage. In addition, the amorphous Al₇₂Ni₈Ti₈Zr₆Nb₃Y₃ powders were sintered under 2 GPa at temperatures of 673 K and 723 K. The results show that the Vickers hardness of the compacted powders is as high as Hv 1215.     

Effects of metal binder on the microstructure and mechanical properties of Al<Subscript>2</Subscript>O<Subscript>3</Subscript>-based micro-nanocomposite ceramic tool material

The Al₂O₃-(W,Ti)C composites with Ni and Mo additions varying from 0vol% to 12vol% were prepared via hot pressing sintering under 30 MPa. The microstructure was investigated via X-ray diffraction (XRD) and scanning electron microscopy (SEM) equipped with energy dispersive spectrometry (EDS). Mechanical properties such as flexural strength, fracture toughness, and Vickers hardness were also measured. Results show that the main phases Al₂O₃ and (W,Ti)C were detected by XRD. Compound MoNi also existed in sintered nanocomposites. The fracture modes of the nanocomposites were both intergranular and transgranular fractures. The plastic deformation of metal particles and crack bridging were the main toughening mechanisms. The maximum flexural strength and fracture toughness were obtained for 9vol% and 12vol% additions of Ni and Mo, respectively. The hardness of the composites reduced gradually with increasing content of metals Ni and Mo.     

CuCrW(Al<Subscript>2</Subscript>O<Subscript>3</Subscript>) nanocomposite: mechanical alloying,microstructure, and tribological properties

The effect of alumina nanoparticle addition on the microstructure and tribological properties of a CuCrW alloy was investigated in this work. Mechanical alloying was carried out in a satellite ball mill. The tribological properties of the samples were evaluated using pin-on-disk wear tests with different pins (alumina, tungsten carbide, and steel pins). The results indicated that the tungsten carbide pin had a lower coefficient of friction than the alumina and steel pins because of its high hardness and low surface roughness. In addition, when the sliding rate was decreased, the weight-loss rate increased. The existence of alumina nanoparticles in the nanocomposite led to a lower weight-loss rate and to a change in the wear mechanism from adhesive to abrasive.     

Fabrication of wear-resistant layers with lamellar eutectic structure by laser surface alloying using the <Emphasis Type="Italic">in situ</Emphasis> reaction between Cr and B<Subscript>4</Subscript>C

To improve the wear resistance of Cr5 steel, wear-resistant layers with lamellar eutectic microstructure were fabricated by laser surface alloying (LSA), which is dependent on the in situ reaction between Cr and B₄C. Our results indicated that the hypoeutectic structures of the LSA layers were divided into interdendritic eutectic structures and dendrites. The area fraction of the eutectic structures increased with increasing laser scanning speed, which improved the hardness and wear resistance of the LSA layers. The average hardness of the LSA layer prepared at a scanning speed of 8 mm/s was HV_0.2 883.9, which was 1.8 times greater than that of the traditional quenched layer (approximately HV 480). After sliding for 659.4 m, the specimen prepared at a scanning speed of 8 mm/s exhibited a volume loss of 0.0323 mm3, which was only 29.5% of the volume loss of the traditional quenched specimen.     

Growth characteristics of directionally solidified Al<Subscript>2</Subscript>O<Subscript>3</Subscript>/YAG/ZrO<Subscript>2</Subscript> ternary hypereutectic <Emphasis Type="Italic">in situ</Emphasis> composites under ultra-high temperature gradient

Oxide eutectic ceramic in situ composites have attracted significant interest in the application of high-temperature structural materials because of their excellent high-temperature strength, oxidation and creep resistance, as well as outstanding microstructural stability. The directionally solidified ternary Al₂O₃/YAG/ZrO₂ hypereutectic in situ composite was successfully prepared by a laser zone remelting method, aiming to investigate the growth characteristic under ultra-high temperature gradient. The microstructures and phase composition of the as-solidified hypereutectic were characterized by using scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), and X-ray diffraction (XRD). The results show that the composite presents a typical hypereutectic lamellar microstructure consisting of fine Al₂O₃ and YAG phases, and the enriched ZrO₂ phases with smaller sizes are randomly distributed at the Al₂O₃/YAG interface and in Al₂O₃ phases. Laser power and scanning rate strongly affect the sample quality and microstructure characteristic. Additionally, coarse colony microstructures were also observed, and their formation and the effect of temperature gradient on the microstructure were discussed.     

Reinforcing effect of graphene on the mechanical properties of Al<Subscript>2</Subscript>O<Subscript>3</Subscript>/TiC ceramics

Multilayer graphene (MLG)-reinforced Al₂O₃/TiC ceramics were fabricated through hot pressing sintering, and the reinforcing effect of MLG on the microstructure and mechanical properties of the composites was investigated by experiment and simulation. The simulation of dynamic crack initiation and propagation was investigated based on the cohesive zone method. The results show that the composite added with 0.2wt% MLG has excellent flexural strength and high fracture toughness. The major reinforcing mechanisms are the synergistic effect by strong and weak bonding interfaces, MLG pull-out, and grain refinement resulting from the addition of MLG. In addition, the aggravating of crack deflection, branching, blunting, and bridging have indispensable contribution to the improvement of the as-designed materials.     

Corrosion-wear behavior of nanocrystalline Fe88Si12 alloy in acid and alkaline solutions

The corrosion-wear behavior of a nanocrystalline Fe₈₈Si₁₂ alloy disc coupled with a Si₃N₄ ball was investigated in acid (pH 3) and alkaline (pH 9) aqueous solutions. The dry wear was also measured for reference. The average friction coefficient of Fe₈₈Si₁₂ alloy in the pH 9 solution was approximately 0.2, which was lower than those observed for Fe₈₈Si₁₂ alloy in the pH 3 solution and in the case of dry wear. The fluctuation of the friction coefficient of samples subjected to the pH 9 solution also showed similar characteristics. The wear rate in the pH 9 solution slightly increased with increasing applied load. The wear rate was approximately one order of magnitude less than that in the pH 3 solution and was far lower than that in the case of dry wear, especially at high applied load. The wear traces of Fe₈₈Si₁₂ alloy under different wear conditions were examined and analyzed by scanning electron microscopy, energy-dispersive X-ray spectroscopy, and X-ray photoelectron spectroscopy. The results indicated that the tribo-chemical reactions that involve oxidation of the worn surface and hydrolysis of the Si₃N₄ ball in the acid solution were restricted in the pH 9 aqueous solution. Thus, water lubrication can effectively improve the wear resistance of nanocrystalline Fe₈₈Si₁₂ alloy in the pH 9 aqueous solution.     

Fabrication and properties of aluminum silicate fibrous materials with <Emphasis Type="Italic">in situ</Emphasis> synthesized K<Subscript>2</Subscript>Ti<Subscript>6</Subscript>O<Subscript>13</Subscript> whiskers

To improve their mechanical and thermal insulation properties, aluminum silicate fibrous materials with in situ synthesized K₂Ti₆O₁₃ whiskers were prepared by firing a mixture of short aluminum silicate fibers and gel powders obtained from a sol-gel process. During the preparation process, the fiber surface was coated with K₂Ti₆O₁₃ whiskers after the fibers were subjected to a heat treatment carried out at various temperatures. The effects of process parameters on the microstructure, compressive strength, and thermal conductivity were analyzed systematically. The results show that higher treatment temperatures and longer treatment durations promoted the development of K₂Ti₆O₁₃ whiskers on the surface of aluminum silicate fibers; in addition, the intersection structure between whiskers modulated the morphology and volume of the multi-aperture structure among fibers, substantially increasing the fibers' compressive strength and reducing their heat conduction and convective heat transfer at high temperatures.     

Microstructure,mechanical properties,and wear resistance of VC<Subscript>p</Subscript>-reinforced Fe-matrix composites treated by Q&amp;P process

A quenching and partitioning (Q&P) process was applied to vanadium carbide particle (VCp)-reinforced Fe-matrix composites (VC-Fe-MCs) to obtain a multiphase microstructure comprising VC, V₈C₇, M₃C, α-Fe, and γ-Fe. The effects of the austenitizing temperature and the quenching temperature on the microstructure, mechanical properties, and wear resistance of the VC-Fe-MCs were studied. The results show that the size of the carbide became coarse and that the shape of some particles began to transform from diffused graininess into a chrysanthemum-shaped structure with increasing austenitizing temperature. The microhardness decreased with increasing austenitizing temperature but substantially increased after wear testing compared with the microhardness before wear testing; the microhardness values improved by 20.0% ±2.5%. Retained austenite enhanced the impact toughness and promoted the transformation-induced plasticity (TRIP) effect to improve wear resistance under certain load conditions.     

Microwave sintering of Ca<Subscript>0.6</Subscript>La<Subscript>0.2667</Subscript>TiO<Subscript>3</Subscript> microwave dielectric ceramics

Ca_0.6La_0.2667TiO₃ ceramics were prepared by conventional and microwave sintering techniques and their sinterability, microstructure, and microwave dielectric properties were investigated in detail for comparison. Densified Ca_0.6La_0.2667TiO₃ ceramics were obtained by microwave sintering at 1350°C for 30 min and by conventional sintering at 1450°C for 4 h. An unusual phenomenon was found that some larger grains (grain size range: 8–10 μm) inclined to assemble in one area but some smaller ones (grain size range: 2–4 μm) inclined to gather in another area in the microwave sintered ceramics. The microwave dielectric properties of Ca_0.6La_0.2667TiO₃ ceramics prepared by microwave sintering at 1350°C were as follows: dielectric constant (ɛ _r) = 119.6, quality factor (Qf) = 17858.5 GHz, and temperature coefficient of resonant frequency (τ _f) = 155.5 ppm/°C. In contrast, the microwave dielectric properties of the ceramics prepared by conventional sintering at 1450°C were ɛ _r = 117.4, Qf = 13375 GHz, and τ _f = 217.2 ppm/°C.     

Electrodeposition and characterization of thermoelectric Bi<Subscript>2</Subscript>Se<Subscript>3</Subscript> thin films

Bi₂Se₃ thin films were electrochemically deposited on Ti and indium tin oxide-coated glass substrates, respectively, at room temperature, using Bi(NO₃)₃·5H₂O and SeO₂ as starting materials in diluted HNO₃ solution. A conventional three-electrode cell was used with a platinum sheet as a counter electrode, and a saturated calomel electrode was used as a reference electrode. The films were annealed in argon atmosphere. The influence of cold isostatic pressing before annealing on the microstructure and thermoelectric properties of the films was investigated. X-ray diffraction analysis indicates that the film grown on the indium tin oxide-coated glass substrate is pure rhombohedral Bi₂Se₃, and the film grown on the Ti substrate consists of both rhombohedral and orthorhombic Bi₂Se₃.     

Mechanical properties and friction behaviors of CNT/AlSi<Subscript>10</Subscript>Mg composites produced by spark plasma sintering

The mechanical properties and friction behaviors of CNT/AlSi₁₀Mg composites produced by spark plasma sintering (SPS) were investigated. The results showed that the densities of the sintered composites gradually increased with increasing sintering temperature and that the highest microhardness and compressive strength were achieved in the specimen sintered at 450℃. CNTs dispersed uniformly in the AlSi₁₀Mg matrix when the addition of CNTs was less than 1.5wt%. However, when the addition of CNTs exceeded 1.5wt%, the aggregation of CNTs was clearly observed. Moreover, the mechanical properties (including the densities, compressive strength, and microhardness) of the composites changed with CNT content and reached a maximum value when the CNT content was 1.5wt%. Meanwhile, the minimum average friction coefficient and wear rate of the CNT/AlSi₁₀Mg composites were obtained with 1.0wt% CNTs.     

Glass-forming ability,microhardness, corrosion resistance,and dealloying treatment of Mg60-xCu40Ndx alloy ribbons

The influence of Nd addition on the glass-forming ability (GFA), microhardness, and corrosion resistance of Mg_60-xCu₄₀Nd_x (x=5, 10, 15, 20, and 25, at%) alloys were investigated by differential scanning calorimetry, Vickers-type hardness tests, and electrochemical methods. The results suggest that the GFA and microhardness of the amorphous alloys increase until the Nd content reaches 20at%. The corrosion potential and corrosion current density obtained from the Tafel curves indicate that the Mg₃₅Cu₄₀Nd₂₅ ternary alloy exhibits the best corrosion resistance among the investigated alloys. Notably, nanoporous copper (NPC) was synthesized through a single-step dealloying of Mg_60-xCu₄₀Nd_x (x=5, 10, 15, 20, and 25) ternary alloys in 0.04 mol·L-1 H₂SO₄ solution under free corrosion conditions. The influence of dealloying process parameters, such as dealloying time and temperature, on the microstructure of the ribbons was also studied using the surface diffusivity theory. The formation mechanism of dealloyed samples with a multilayered structure was also discussed.     

Microstructure and properties of mullite-based porous ceramics produced from coal fly ash with added Al<Subscript>2</Subscript>O<Subscript>3</Subscript>

Using coal fly ash slurry samples supplemented with different amounts of Al₂O₃, we fabricated mullite-based porous ceramics via a dipping-polymer-replica approach, which is a popular method suitable for industrial application. The microstructure, phase composition, and compressive strength of the sintered samples were investigated. Mullite was identified in all of the prepared materials by X-ray diffraction analysis. The microstructure and compressive strength were strongly influenced by the content of Al₂O₃. As the Al/Si mole ratio in the starting materials was increased from 0.84 to 2.40, the amount of amorphous phases in the sintered microstructure decreased and the compressive strength of the sintered samples increased. A further increase in the Al₂O₃ content resulted in a decrease in the compressive strength of the sintered samples. The mullite-based porous ceramic with an Al/Si molar ratio of 2.40 exhibited the highest compressive strength and the greatest shrinkage among the investigated samples prepared using coal fly ash as the main starting material.     

Effect of scanning speed during PTA remelting treatment on the microstructure and wear resistance of nodular cast iron

The surface of nodular cast iron (NCI) with a ferrite substrate was rapidly remelted and solidified by plasma transferred arc (PTA) to induce a chilled structure with high hardness and favorable wear resistance. The effect of scanning speed on the microstructure, microhardness distribution, and wear properties of PTA-remelted specimens was systematically investigated. Microstructural characterization indicated that the PTA remelting treatment could dissolve most graphite nodules and that the crystallized primary austenite dendrites were transformed into cementite, martensite, an interdendritic network of ledeburite eutectic, and certain residual austenite during rapid solidification. The dimensions of the remelted zone and its dendrites increase with decreased scanning speed. The microhardness of the remelted zone varied in the range of 650 HV_0.2 to 820 HV_0.2, which is approximately 2.3–3.1 times higher than the hardness of the substrate. The wear resistance of NCI was also significantly improved after the PTA remelting treatment.     

Influence of nano-Al<Subscript>2</Subscript>O<Subscript>3</Subscript>-reinforced oxide-dispersion-strengthened Cu on the mechanical and tribological properties of Cu-based composites

The mechanical and tribological properties of Cu-based powder metallurgy (P/M) friction composites containing 10wt%–50wt% oxide-dispersion-strengthened (ODS) Cu reinforced with nano-Al₂O₃ were investigated. Additionally, the friction and wear behaviors as well as the wear mechanism of the Cu-based composites were characterized by scanning electron microscopy (SEM) in conjunction with energy-dispersive X-ray spectroscopy (EDS) elemental mapping. The results indicated that the Cu-based friction composite containing 30wt% ODS Cu exhibited the highest hardness and shear strength. The average and instantaneous friction coefficient curves of this sample, when operated in a high-speed train at a speed of 300 km/h, were similar to those of a commercial disc brake pad produced by Knorr-Bremse AG (Germany). Additionally, the lowest linear wear loss of the obtained samples was (0.008 ± 0.001) mm per time per face, which is much lower than that of the Knorr-Bremse pad ((0.01 ± 0.001) mm). The excellent performance of the developed pad is a consequence of the formation of a dense oxide composite layer and its close combination with the pad body.     

Y含量对汽车变速箱AK30镁合金显微组织及 力学性能的影响

采用光学显微镜(OM)、扫描电镜(SEM)、X射线衍射(XRD)、维氏硬度和拉伸-压缩试验机等手段,评价Y含量对AK30镁合金微观组织和力学性能的影响。研究结果发现,Y含量能够显著影响AK30镁合金凝固组织和力学性能。当合金中没有添加Y元素时,AK30镁合金的晶粒粗大,晶界处有大量的Mg_3Zn相分布,力学性能最差。当合金中添加1%的Y元素时,AK30镁合金的晶粒尺寸没有发生变化,依然较大;但晶界处的Mg_3Zn相却在减少,而合金的晶内却出现了少量的Mg_3Y相,合金的力学性能增加。当合金中的Y含量增加到2%时,晶粒细化,晶体内析出了大量的Mg_3Zn相与α-Mg相组成的共晶组织,力学性能达到最大值。当合金的Y含量增加到4%时,晶粒粗化,且大量的Mg_3Zn脆性相在晶界处析出,合金的力学性能下降。为了提高AK30镁合金的力学性能,应该向AK30镁合金中添加2%的Y元素。     

Hydrogen storage properties of MgH<Subscript>2</Subscript> co-catalyzed by LaH<Subscript>3</Subscript> and NbH

To improve the hydrogen storage properties of Mg-based alloys, a composite material of MgH₂ + 10wt%LaH₃ + 10wt%NbH was prepared by a mechanical milling method. The composite exhibited favorable hydrogen desorption properties, releasing 0.67wt% H₂ within 20 min at 548 K, which was ascribed to the co-catalytic effect of LaH₃ and NbH upon dehydriding of MgH₂. By contrast, pure MgH₂, an MgH₂ + 20wt%LaH₃ composite, and an MgH₂ + 20wt%NbH composite only released 0.1wt%, 0.28wt%, and 0.57wt% H₂, respectively, under the same conditions. Analyses by X-ray diffraction and scanning electron microscopy showed that the composite particle size was small. Energy-dispersive X-ray spectroscopic mapping demonstrated that La and Nb were distributed homogeneously in the matrix. Differential thermal analysis revealed that the dehydriding peak temperature of the MgH₂ + 10wt%LaH₃ + 10wt%NbH composite was 595.03 K, which was 94.26 K lower than that of pure MgH₂. The introduction of LaH₃ and NbH was beneficial to the hydrogen storage performance of MgH₂.     

Tribological properties of La2O3 and CeO2 doped CoCrW coatings deposited by supersonic plasma spraying

A novel supersonic plasma spraying was used to prepare rare earth oxides doped CoCrW coatings. X-ray diffractometer, contact surface profiler, hardness tester, micro-friction and -wear tester and en- vironmental scanning electron microscope equipped with energy dispersive X-ray spectroscopy were employed to investigate the phase structure, surface morphology, microhardness, friction and wear properties of the sprayed coatings. The results show that rare earth oxide doped coatings have high microhardness and excellent tribological properties. Furthermore, the friction and wear mechanisms of sprayed coatings are also discussed.