The cooling rate of the center and edge of vacuum induction melting(VIM)or vacuum arc remelting(VAR)ingots exhibit substantial difference,leading to markedly distinct dendritic structures and precipitates.The current ...The cooling rate of the center and edge of vacuum induction melting(VIM)or vacuum arc remelting(VAR)ingots exhibit substantial difference,leading to markedly distinct dendritic structures and precipitates.The current lack of precise predictions for dendritic segregation and the distribution of precipitates in ingot makes it difficult to determine the annealing and homogenization heat treatment process.Thus,clarifying the impact of cooling rate on the solidification behavior of alloy is significantly important.The dendritic structure and precipitation characteristics of as-cast C-HRA-3 Ni–Cr–Co–Mo-based heat-resistant alloy were investigated using Thermo-Calc thermodynamic calculations,scanning electron microscopy observations,and electron probe microanalyzer.Based on high temperature observation system,the effects of cooling rate on the dendritic structure,dendritic segregation,and precipitation in this alloy were explored.The results showed that the precipitates in the as-cast C-HRA-3 alloy primarily consist of blocky Ti(C,N)phases,large-sized Ti(C,N)–M_(6)C–M_(23)C_(6) symbiotic phases and M_(6)C–M_(23)C_(6) carbides,and small-sized dispersed M_(6)C and M_(23)C_(6) carbides surronding these symbiotic phases.The primary constituent elements of these precipitates are Mo,Cr,C,and Ti,which predominantly concentrate in the interdendritic regions of the as-cast alloy.There is a clear power-law relationship between the secondary dendrite arm spacing and the cooling rate.The dendritic segregation ratio of Mo,Cr,and Ti exhibits a piecewise functional relationship with the cooling rate,under equiaxed dendritic solidification condition.These predictive models and theoretical analyses were validated using numerical simulations and experimental results from the 200 kg grade VIM electrode.展开更多
The effects of cooling rate on the solidification parameters and microstructure of Al-7Si-0.3Mg-0.15 Fe alloy during solidification process were studied.To obtain different cooling rates,the step casting with five dif...The effects of cooling rate on the solidification parameters and microstructure of Al-7Si-0.3Mg-0.15 Fe alloy during solidification process were studied.To obtain different cooling rates,the step casting with five different thicknesses was used and the cooling rates and solidification parameters were determined by computer-aided thermal analysis method.The results show that at higher cooling rates,the primary α（Al） dendrite nucleation temperature,eutectic reaction temperature and solidus temperature shift to lower temperatures.Besides,with increasing cooling rate from 0.19 ℃/s up to 6.25 ℃/s,the secondary dendritic arm spacing decreases from 68 μm to 20 μm,and the primary dendritic volume fraction declines by approximately 5%.In addition,it reduces the length of Fe-bearing phase from 28 μm to 18 μm with a better uniform distribution.It is also found that high cooling rates make for modifying eutectic silicon into fibrous branched morphology,and decreasing block or lamella shape eutectic silicon.展开更多
The effect of the cooling rate ranging from 1.4 °C/s to 3.5 °C/s on the solidification behavior of the sand-cast Mg?10Gd?3Y?0.4Zr alloy was studied by computer aided cooling curve analysis (CA-CCA). With the...The effect of the cooling rate ranging from 1.4 °C/s to 3.5 °C/s on the solidification behavior of the sand-cast Mg?10Gd?3Y?0.4Zr alloy was studied by computer aided cooling curve analysis (CA-CCA). With the increase in cooling rate, the nucleation temperature (Tα,N) increases from 634.8 °C to 636.3 °C, the minimum temperature (Tα,Min) decreases from 631.9 °C to 630.7 °C, the nucleation undercooling (ΔTN) increases from 2.9 °C to 5.6 °C, the beginning temperature of the eutectic reaction (Teut,N) increases, the time of the eutectic reaction shortens, solidus temperature decreases from 546.0 °C to 541.4 °C, and solidification temperature range (ΔTS) increases by 6.1 °C. The increased nucleation rate (N&) is supposed to be the main reason for the increased?TN. Increased value (Teut,N?Teut,G) and shortened time of the eutectic reaction cause the change in the volume fraction and morphology of the second phase.展开更多
An overview of the development and current status of the directional solidification process assisted by liquid metal cooling （LMC） has been presented in this paper. The driving force of the rapid development of the ...An overview of the development and current status of the directional solidification process assisted by liquid metal cooling （LMC） has been presented in this paper. The driving force of the rapid development of the LMC process has been analyzed by considering the demands of （1） newer technologies that can provide higher thermal gradients for alleviated segregation in advanced alloy systems, and （2） better production yield of the large directionally solidified superalloy components. The brief history of the industrialization of the LMC process has been reviewed, followed by the discussion on the LMC parameters including selection of the cooling media, using of the dynamic baffle, and the influence of withdrawal rates and so on. The microstructure and mechanical properties of the traditional superalloys processed by LMC, as well as the new alloys particularly developed for LMC process were then described. Finally, future aspects concerning the LMC process have been summarized.展开更多
The quality of wrought magnesium(Mg)alloys is closely linked to the quality of the cast ingots.Conventionally casting(CC)Mg-2Y ingots exhibit relatively coarse grain sizes.When CC ingots undergo rolling processing(CC-...The quality of wrought magnesium(Mg)alloys is closely linked to the quality of the cast ingots.Conventionally casting(CC)Mg-2Y ingots exhibit relatively coarse grain sizes.When CC ingots undergo rolling processing(CC-10-R),the resulting Mg-2Y sheets retain coarse grain sizes(~11.87μm),while precipitating a small number of Mg_(24)Y_(5) nanoparticles(~0.26%),as well as forming a strong C-type texture(~10.91).The implementation of controlled diffusion solidification(CDS)effectively refines the grain size of Mg-2Y ingots and increases the content of Mg_(24)Y_(5) particles.When CDS is combined with rolling(CDS-10-R),the grain size is refined to~5.57μm,the precipitation of Mg_(24)Y_(5) nanoparticles is increased to~1.79%,and the C-type texture was weakened to~7.74.The CDS-10-R shows an increase in strength of~51.8% and an enhancement in plasticity of~32.6% compared to CC-10-R.The enhancement in strength is primarily due to fine-grain strengthening(~42.1% contributions)and precipitating strengthening(~39.6% contributions).The improvement in plasticity is attributed to the weakening of the{0001}basal texture,which facilitates the activation of<c+a>slips.Compared to other wrought Mg-Y alloys,Mg-2Y sheets produced by combining CDS with rolling possess exceptional strength-plasticity combinations.This finding presents a novel route to achieving high strength and plasticity in low-alloyed rare-earth Mg alloys.展开更多
In this work, some important factors such as ceramic shell strength, heat preservation temperature, standing time and withdrawal rate, which influence the formability of directionally solidified large-size blades of h...In this work, some important factors such as ceramic shell strength, heat preservation temperature, standing time and withdrawal rate, which influence the formability of directionally solidified large-size blades of heavy-duty gas turbine with the liquid metal cooling(LMC) process, were studied through the method of microstructure analysis combining. The results show that the ceramic shell with medium strength(the high temperature flexural strength is 8 MPa, the flexural strength after thermal shock resistance is 12 MPa and the residual flexural strength is 20 MPa) can prevent the rupture and runout of the blade. The appropriate temperature(1,520 ℃ for upper region and 1,500 ℃ for lower region) of the heating furnace can eliminate the wide-angle grain boundary, the deviation of grain and the run-out caused by the shell crack. The holding time after pouring(3-5 min) can promote the growth of competitive grains and avoid a great deviation of columnar grains along the crystal orientation <001>, resulting in a straight and uniform grain structure. In addition, to avoid the formation of wrinkles and to ensure a smooth blade surface, the withdrawal rate should be no greater than the growth rate of grain. It is also found that the dendritic space of the blade decreases with the rise of solidification rate, and increases with the enlarging distance between the solidification position and the chill plate.展开更多
Scanning electron microscopy（SEM） and energy dispersive X-ray analysis（EDAX） were used to study the microstructure,microsegregation, and fluid flow tendency of the superalloy Waspaloy in the mushy zone,which had b...Scanning electron microscopy（SEM） and energy dispersive X-ray analysis（EDAX） were used to study the microstructure,microsegregation, and fluid flow tendency of the superalloy Waspaloy in the mushy zone,which had been solidified at different cooling rates. The investigation was accompanied with the calculation of Rayleigh numbers.It is found that Ti is the main segregating element and the content of Ti is the highest in the final liquid at the cooling rates of 3-6℃/min.The eta phase（η） precipitate presented in the residual liquid at the cooling rates higher than 6℃/min is responsible for the fluctuations in the curves of Ti content.The dendrite arm spacing is found to markedly decrease with the increase of cooling rate.The maximum relative Rayleigh number occurs at 10-20℃below the liquidus temperature at a cooling rate of 1℃/min,where the mushy zone is most unstable and fluid flow is most prone to occur.展开更多
The transformation mechanism of （γ ＋γ′） was studied by analyzing the microstructure and elemental distri- bution of the U720Li samples heated at 1250℃ and cooled at the rates in the range of 1-100℃/s. Although...The transformation mechanism of （γ ＋γ′） was studied by analyzing the microstructure and elemental distri- bution of the U720Li samples heated at 1250℃ and cooled at the rates in the range of 1-100℃/s. Although the （γ ＋γ′） is deemed to be formed by a eutectic reaction and has been called eutectic （γ ＋γ′）, it was found in the present study that the （γ ＋γ′） precipitation begins with a peritectic reaction of （L ＋ γ）γ′, and develops by the eutectic reaction of L （γ ＋γ′）. The energy for the γ′ nucleation is low because the interfacial energy for the γ /γ′ interface is about one-tenth of the solid/liquid interface, and hence, the nucleation rate is high and the fine structure of （γ ＋ γ′） is formed at the initial precipitation stage. The γ and γ′ in （γ ＋ γ′） tend to grow into a lamellar structure because it is difficult for them to nucleate directly from the residual liquids, and hence, the γ′ precipitates naturally tend to grow divergently direction of the regions rich in AI and Ti, forming a fan-like structure of the （γ ＋γ′）. As a result, the γ′ precipitates will coarsen finally because the space between them is enlarged. The solidification of the final residual liquids is a diffusion dependent process. When cooled at a higher rate, a higher degree of super cooling is reached and finally the solidification is finished by the pseudo- eutectic reaction of L → （γ ＋ boride） and L→ （γ ＋γ′）, which can absorb Zr and B. When cooled at a rate low enough, most of the residual liquids are consumed by the （γ ＋γ′） growth due to the sufficient diffusion, and the boride and Zr- bearing phase are precipitated at a quasi-equilibrium state. Under this condition, Ti is depleted at the （γ ＋γ′） growth front. However, the η-Ni3Ti phase is formed there occasionally due to the boride precipitation, because the compositions of the two phases are complementary.展开更多
Solidification process of 231 t 30Cr2Ni4MoV ingot manufactured by slow cooling process was studied using experimental and numerical simulations, which tackled the problems of high cost and long period in large ingot s...Solidification process of 231 t 30Cr2Ni4MoV ingot manufactured by slow cooling process was studied using experimental and numerical simulations, which tackled the problems of high cost and long period in large ingot studying. Based on the numerical results of large ingot, five characteristic locations under different temperature gradients and cooling rates chosen from the large ingot were simulated. The experiments were performed under the same temperature conditions as in numerical simulations with specialized instrument. The influences of temperature gradient in the solid-liquid interface and solidification rate on the size and morphology of solidification structure were analyzed at cooling rate ranging from 10-3 to 10 2℃ s-1. Solidification macrostructure and microstructure showed that no columnar dendrite was found in any specimen. The grain size and secondary dendrite arm spacing decreased at larger cooling rate, and the relationship between secondary dendrite arm spacing and local solidification time or cooling rate was determined.展开更多
Beta-solidifying TiAl alloy has great potential in the field of aero-industry as a cast alloy.In the present work,the influence of cooling rate during mushy zone on solidification behavior of Ti-44Al-4Nb-2Cr-0.1B allo...Beta-solidifying TiAl alloy has great potential in the field of aero-industry as a cast alloy.In the present work,the influence of cooling rate during mushy zone on solidification behavior of Ti-44Al-4Nb-2Cr-0.1B alloy was investigated.A vacuum induction heating device combining with temperature control system was used.The Ti-44Al-4Nb-2Cr-0.1B alloy solidified from superheated was melted to β phase with the cooling rates of 10,50,100,200,400 and 700 K·min^（-1）,respectively.Results show that with the increase in cooling rate from 10 to 700 K·min^（-1）,the colony size of α_2/γ lamella decreases from 1513 to48 urn and the solidification segregation significantly decreases.Also the content of residual B2 phase within α_2/γlamellar colony decreases with the increase in cooling rate.In addition,the alloy in local interdendritic regions would solidify in a hypo-peritectic way,which can be attributed to the solute redistribution and enrichment of Al element in solidification.展开更多
In order to investigate the relationship between microstructure and MnS inclusion in non-quenched and tempered steel, and cooling rate during horizontal directional solidification, 49MnVS steel was used to conduct the...In order to investigate the relationship between microstructure and MnS inclusion in non-quenched and tempered steel, and cooling rate during horizontal directional solidification, 49MnVS steel was used to conduct the experiments with a selfdesigned device. The mathematical effect of cooling rate on dendritic arm spacing and mean diameter of MnS particles (dMnS) were determined by using linear regression method. The results show that the length of dendrite from solid–liquid interface to end-solidification decreased with increasing the withdrawal velocity (#). dMnS has a similar value in the area of the steady directional solidification;the value of dMnS was 4.1, 3.6, 3.3, 2.8 and 2.3 lm at withdrawal velocity of 50, 75, 100, 150 and 200 lm/s, respectively. dMnS increased with reducing # or RC (interface cooling rate). MnS precipitated in the gaps between dendrites and was influenced by secondary dendritic arm spacing. Besides, a new concept of the ‘Precipitation Unit Space’(PUS) was proposed and the relationships between dMnS, VPUS (volume of PUS) and RC were obtained.展开更多
This study aims to investigate the primary carbides precipitation in H13 steel solidified at relatively high cooling rates,ranging from 300 to 6,000℃·min^-1,based on in situ observations with a high temperature ...This study aims to investigate the primary carbides precipitation in H13 steel solidified at relatively high cooling rates,ranging from 300 to 6,000℃·min^-1,based on in situ observations with a high temperature confocal laser scanning microscope.In the cooling rate range investigated,the solidification microstructure becomes more refined as cooling rate increases and the relationship between the secondary dendrite arm spacing(SDAS),λ2,and cooling rate,.T,can be expressed asλ2=128.45.T-0.124.Regardless of cooling rates,two kinds of primary carbides,i.e.,the Mo-Cr-rich and V-rich carbides,are precipitated along the interdendritic region and most of them are the Mo-Cr-rich carbides.The morphology of Mo-Cr-rich carbide is not obviously influenced by the cooling rate,but that of V-rich carbide is obviously affected.The increasing cooling rate markedly refines the primary carbides and reduces their volume fractions,but their precipitations cannot be inhibited even when the cooling rate is increased to 6,000℃·min^-1.Besides,the segregation ratios(SRs)of the carbides forming elements are not obviously affected by the cooling rate.However,compared with the conventionally cast ingot,the SDAS and primary carbides in the steel solidified at the investigated cooling rates are much finer,morphologies of the carbides have changed significantly,and SRs of the carbides forming elements are markedly greater.The variation of primary carbide characteristics with cooling rate is mainly due to the change in SDAS.展开更多
Cooling rate is a key factor that can drastically affect the phase transformation and thermal stress of duplex stainless steels. Therefore, in this research, different sand moulds were used to explore the influence of...Cooling rate is a key factor that can drastically affect the phase transformation and thermal stress of duplex stainless steels. Therefore, in this research, different sand moulds were used to explore the influence of cooling rate on the solidification of the 2304 duplex stainless steel (DSS). The macro and micro structures of the 2304 DSS were investigated. Small equiaxed grains are obtained in chromite sand mould sample with a lower pouring temperature and a higher cooling rate, whereas coarse columnar and equiaxed grains are found in silica sand and refractory powder mould samples. The size of austenite phase is significantly increased with decreasing cooling rate, while the ferrite phase content ranging from 51.6% to 53.9% does not change obviously. In addition, the linear contraction of the 2304 DSS decreases from 2.34% to 1.09% when the mean cooling rate above 1,173 K increases from 0.99 K·s-1 to 3.66 K·s-1.展开更多
Advancements in metallurgical technology have led to the emergence of high-performance requirements for metal materials,like high uniformity,high purity,and superfine crystallinity.This has resulted in the development...Advancements in metallurgical technology have led to the emergence of high-performance requirements for metal materials,like high uniformity,high purity,and superfine crystallinity.This has resulted in the development and application of internal cooling source(ICS),vibrational,and vibrational internal cooling source methods in metal solidification processes to afford products with refined crystal grains and large proportions of equiaxed crystals.These methods have gradually been introduced into laboratories and some steel mills over the past few decades.However,there are few successful industrial applications of these methods,as there is no comprehensive understanding of their control theories and principles.Accordingly,the development,basic principles,and classifications of the three types of methods are summarized,and their impact on the solidification of molten metals and the morphology of solid products is discussed.In addition,experimental and numerical simulation-based researches on each type of method are reviewed and their prospects for applications are briefly discussed to control metal solidification.Finally,detailed future perspectives are provided on vibratory strip feeding,ICS,and pulsed magneto-oscillation methods.Hopefully,it will serve as a reference for future studies of the application of these and related methods in metal solidification processes.展开更多
Preparation of semisolid slurry using a cooling slope is increasingly becoming popular,primarily because of the simplicity in design and ease control of the process.In this process,liquid alloy is poured down an incli...Preparation of semisolid slurry using a cooling slope is increasingly becoming popular,primarily because of the simplicity in design and ease control of the process.In this process,liquid alloy is poured down an inclined surface which is cooled from underneath.The cooling enables partial solidification and the incline provides the necessary shear for producing semisolid slurry.However,the final microstructure of the ingot depends on several process parameters such as cooling rate,incline angle of the cooling slope,length of the slope and initial melt superheat.In this work,a CFD model using volume of fluid(VOF) method for simulating flow along the cooling slope was presented.Equations for conservation of mass,momentum,energy and species were solved to predict hydrodynamic and thermal behavior,in addition to predicting solid fraction distribution and macrosegregation.Solidification was modeled using an enthalpy approach and a volume averaged technique for the different phases.The mushy region was modeled as a multi-layered porous medium consisting of fixed columnar dendrites and mobile equiaxed/fragmented grains.The alloy chosen for the study was aluminum alloy A356,for which adequate experimental data were available in the literature.The effects of two key process parameters,namely the slope angle and the pouring temperature,on temperature distribution,velocity distribution and macrosegregation were also studied.展开更多
Effect of cooling rate on the 3 D morphology and the growth mechanism of the proeutectic Al3Ni intermetallic compound(IMC) that forms at the Al/Ni interface after solidification was investigated by synchrotron X-ray m...Effect of cooling rate on the 3 D morphology and the growth mechanism of the proeutectic Al3Ni intermetallic compound(IMC) that forms at the Al/Ni interface after solidification was investigated by synchrotron X-ray microtomography in combination with EBSD analysis. The proeutectic Al3Ni phase that forms under an average cooling rate of 0.1 Ks^(-1) shows a characteristic faceted growth behavior and presents a typical 3 D morphology as partially hollow quadrangular prisms. On the contrary, that forms under an average cooling rate of 10 Ks^(-1) shows complicated dendritic morphology with asymmetrically distributed arms and faceted V-shape groove at the distal end, indicating a gradual transition of the growth behavior from non-faceted to faceted during the solidification process. These results reveal that the morphology of the proeutectic Al3Ni is highly sensitive to the solidification condition so that fine control of the desired morphology may be achieved by carefully manipulating the cooling profile.展开更多
The effect of different cooling rates(2.7,5.5,17.1,and 57.5℃/s)on the solidification parameters,microstructure,and mechanical properties of Al-15Mg_(2)Si composites was studied.The results showed that a high cooling ...The effect of different cooling rates(2.7,5.5,17.1,and 57.5℃/s)on the solidification parameters,microstructure,and mechanical properties of Al-15Mg_(2)Si composites was studied.The results showed that a high cooling rate refined the Mg_(2)Si particles and changed their morphology to more compacted forms with less microcracking tendency.The average radius and fraction of primary Mg_(2)Si particles decreased from 20μm and 13.5%to about 10μm and 7.3%,respectively,as the cooling rate increased from 2.7 to 57.5℃/s.Increasing the cooling rate also improved the distribution of microconstituents and decreased the grain size and volume fraction of micropores.The mechanical properties results revealed that augmenting the cooling rate from 2.7 to about 57.5℃/s increased the hardness and quality index by 25%and245%,respectively.The high cooling rate also changed the fracture mechanism from a brittle-dominated mode to a high-energy ductile mode comprising extensive dimpled zones.展开更多
Biodegradable Zn-based alloys, particularly Zn-Mg alloys with the addition of alloying elements, have been intensively investigated aiming to improve both mechanical properties and corrosion behavior. Since such prope...Biodegradable Zn-based alloys, particularly Zn-Mg alloys with the addition of alloying elements, have been intensively investigated aiming to improve both mechanical properties and corrosion behavior. Since such properties are strongly dependent on the alloy microstructure, any evaluation should commence on understanding the conditions influencing its formation. In this study, the effect of the solidification cooling rate on the microstructural evolution of Zn-1 wt.%Mg-(0.5 wt.%Ca, 0.5 wt.%Mn) alloys during transient solidification was investigated. The results show that the microstructures of both alloys have three phases in common: η-Zn dendritic matrix, intermetallic compounds(IMCs) Zn11Mg2, and Zn2 Mg in the eutectic mixture. MnZn9 and two Ca-bearing phases(CaZn11 and CaZn13) are associated with Mn and Ca additions, respectively. These additions are shown to refine the dendritic matrix and the eutectic mixture as compared to the Zn-1 wt.%Mg alloy. A correlation between cooling rate, dendritic or eutectic spacings was developed, thus permitting experimental growth laws to be proposed. Additionally, hardness tests were performed to evaluate the effects of additions of Ca and Mn. Experimental correlations between Vickers microhardness and secondary dendritic spacings were proposed, showing that the microstructural refinement and characteristic Ca and Mn based IMCs induce an increase in hardness as compared to the binary alloy.展开更多
Six alloys with different compositions of Al 0.1%Sc, Al 0.3%Sc, Al 0.3%Zr, Al 0.1% Sc 0.1%Zr, Al 0.3%Sc 0.1%Zr and Al 0.3%Sc 0.3%Zr were prepared by casting in a wedge shaped copper mould. The hardness test, microstru...Six alloys with different compositions of Al 0.1%Sc, Al 0.3%Sc, Al 0.3%Zr, Al 0.1% Sc 0.1%Zr, Al 0.3%Sc 0.1%Zr and Al 0.3%Sc 0.3%Zr were prepared by casting in a wedge shaped copper mould. The hardness test, microstructure observation, and DSC thermal analysis were applied to fully investigate the solidification behavior of the wedge tip (whose cooling rate is 1 000 K/s) and the top surface (cooling rate 100 K/s) of each casting. The results show that the cast structures in the hypoeutectic region of Al Sc alloys are slightly affected by cooling rates during the solidification. In the case of hypereutectic alloy of Al 0.3%Sc 0.3%Zr , the cast grains were remarkably refined under the condition of a 100 K/s cooling rate, however, under a 1 000 K/s cooling rate condition, solute atoms contribute nothing to the grain refinement, due to the eutectic concentration becomes higher. The hardness can be improved to a greater degree by Sc single addition, compared to single Zr addition, but it can be improved even greater when Sc added together with Zr. It is sensitive to cooling rate, the higher the cooling rate, the greater the hardness. By combining the results of TEM examination and DSC analysis, it can be seen that a supersaturated Al solid solution forms during the solidification, and the solubility of Sc in Al solution can be improved by increasing the cooling rate.展开更多
Al-18Si alloy reinforced with 15%,20% and 25%(volume fraction) SiC whiskers were prepared by squeeze casting technique and the solidification behavior and microstructure of as-prepared composites at different cooling ...Al-18Si alloy reinforced with 15%,20% and 25%(volume fraction) SiC whiskers were prepared by squeeze casting technique and the solidification behavior and microstructure of as-prepared composites at different cooling rates were studied by DSC,optical microscope,SEM and TEM.The results show that silicon phase is nucleated on SiC whiskers.With the increase of cooling rate,the degree of undercooling increases in the composites as well as in the alloys.The increase of cooling rate leads to a reduction in the size of eutectic Al-Si and also changes its morphology from short stick to equiaxed.However,the change of primary Si is complex.The primary Si size is refined,and then coarsened with increasing cooling rate.The primary Si morphology of composites changes from agglomerate to stick.展开更多
基金funded by the National Key R&D Program Funded Projects(No.2021YFB3704102).
文摘The cooling rate of the center and edge of vacuum induction melting(VIM)or vacuum arc remelting(VAR)ingots exhibit substantial difference,leading to markedly distinct dendritic structures and precipitates.The current lack of precise predictions for dendritic segregation and the distribution of precipitates in ingot makes it difficult to determine the annealing and homogenization heat treatment process.Thus,clarifying the impact of cooling rate on the solidification behavior of alloy is significantly important.The dendritic structure and precipitation characteristics of as-cast C-HRA-3 Ni–Cr–Co–Mo-based heat-resistant alloy were investigated using Thermo-Calc thermodynamic calculations,scanning electron microscopy observations,and electron probe microanalyzer.Based on high temperature observation system,the effects of cooling rate on the dendritic structure,dendritic segregation,and precipitation in this alloy were explored.The results showed that the precipitates in the as-cast C-HRA-3 alloy primarily consist of blocky Ti(C,N)phases,large-sized Ti(C,N)–M_(6)C–M_(23)C_(6) symbiotic phases and M_(6)C–M_(23)C_(6) carbides,and small-sized dispersed M_(6)C and M_(23)C_(6) carbides surronding these symbiotic phases.The primary constituent elements of these precipitates are Mo,Cr,C,and Ti,which predominantly concentrate in the interdendritic regions of the as-cast alloy.There is a clear power-law relationship between the secondary dendrite arm spacing and the cooling rate.The dendritic segregation ratio of Mo,Cr,and Ti exhibits a piecewise functional relationship with the cooling rate,under equiaxed dendritic solidification condition.These predictive models and theoretical analyses were validated using numerical simulations and experimental results from the 200 kg grade VIM electrode.
基金Projects (2005CB724105,2011CB706801) supported by the National Basic Research Program of ChinaProjects (10477010,51171089) supported by the National Natural Science Foundation of ChinaProjects (2009ZX04006-041-04,2011ZX04014-052) supported by the Important National Science&Technology Specific,China
文摘The effects of cooling rate on the solidification parameters and microstructure of Al-7Si-0.3Mg-0.15 Fe alloy during solidification process were studied.To obtain different cooling rates,the step casting with five different thicknesses was used and the cooling rates and solidification parameters were determined by computer-aided thermal analysis method.The results show that at higher cooling rates,the primary α（Al） dendrite nucleation temperature,eutectic reaction temperature and solidus temperature shift to lower temperatures.Besides,with increasing cooling rate from 0.19 ℃/s up to 6.25 ℃/s,the secondary dendritic arm spacing decreases from 68 μm to 20 μm,and the primary dendritic volume fraction declines by approximately 5%.In addition,it reduces the length of Fe-bearing phase from 28 μm to 18 μm with a better uniform distribution.It is also found that high cooling rates make for modifying eutectic silicon into fibrous branched morphology,and decreasing block or lamella shape eutectic silicon.
基金Project(51275295)supported by the National Natural Science Foundation of ChinaProject(USCAST2012-15)supported by the SAST-SJTU Joint Research Centre of Advanced Aerospace Technology,ChinaProjects(20120073120011,20130073110052)supported by the Research Fund for the Doctoral Program of Higher Education of China
文摘The effect of the cooling rate ranging from 1.4 °C/s to 3.5 °C/s on the solidification behavior of the sand-cast Mg?10Gd?3Y?0.4Zr alloy was studied by computer aided cooling curve analysis (CA-CCA). With the increase in cooling rate, the nucleation temperature (Tα,N) increases from 634.8 °C to 636.3 °C, the minimum temperature (Tα,Min) decreases from 631.9 °C to 630.7 °C, the nucleation undercooling (ΔTN) increases from 2.9 °C to 5.6 °C, the beginning temperature of the eutectic reaction (Teut,N) increases, the time of the eutectic reaction shortens, solidus temperature decreases from 546.0 °C to 541.4 °C, and solidification temperature range (ΔTS) increases by 6.1 °C. The increased nucleation rate (N&) is supposed to be the main reason for the increased?TN. Increased value (Teut,N?Teut,G) and shortened time of the eutectic reaction cause the change in the volume fraction and morphology of the second phase.
文摘An overview of the development and current status of the directional solidification process assisted by liquid metal cooling （LMC） has been presented in this paper. The driving force of the rapid development of the LMC process has been analyzed by considering the demands of （1） newer technologies that can provide higher thermal gradients for alleviated segregation in advanced alloy systems, and （2） better production yield of the large directionally solidified superalloy components. The brief history of the industrialization of the LMC process has been reviewed, followed by the discussion on the LMC parameters including selection of the cooling media, using of the dynamic baffle, and the influence of withdrawal rates and so on. The microstructure and mechanical properties of the traditional superalloys processed by LMC, as well as the new alloys particularly developed for LMC process were then described. Finally, future aspects concerning the LMC process have been summarized.
基金supported by the National Natural Science Foundation of China(No.52474437).
文摘The quality of wrought magnesium(Mg)alloys is closely linked to the quality of the cast ingots.Conventionally casting(CC)Mg-2Y ingots exhibit relatively coarse grain sizes.When CC ingots undergo rolling processing(CC-10-R),the resulting Mg-2Y sheets retain coarse grain sizes(~11.87μm),while precipitating a small number of Mg_(24)Y_(5) nanoparticles(~0.26%),as well as forming a strong C-type texture(~10.91).The implementation of controlled diffusion solidification(CDS)effectively refines the grain size of Mg-2Y ingots and increases the content of Mg_(24)Y_(5) particles.When CDS is combined with rolling(CDS-10-R),the grain size is refined to~5.57μm,the precipitation of Mg_(24)Y_(5) nanoparticles is increased to~1.79%,and the C-type texture was weakened to~7.74.The CDS-10-R shows an increase in strength of~51.8% and an enhancement in plasticity of~32.6% compared to CC-10-R.The enhancement in strength is primarily due to fine-grain strengthening(~42.1% contributions)and precipitating strengthening(~39.6% contributions).The improvement in plasticity is attributed to the weakening of the{0001}basal texture,which facilitates the activation of<c+a>slips.Compared to other wrought Mg-Y alloys,Mg-2Y sheets produced by combining CDS with rolling possess exceptional strength-plasticity combinations.This finding presents a novel route to achieving high strength and plasticity in low-alloyed rare-earth Mg alloys.
基金financially supported by the National Science and Technology Major Project of High-end CNC Machine Tools and Basic Manufacturing Equipment(No.2017ZX04014001)
文摘In this work, some important factors such as ceramic shell strength, heat preservation temperature, standing time and withdrawal rate, which influence the formability of directionally solidified large-size blades of heavy-duty gas turbine with the liquid metal cooling(LMC) process, were studied through the method of microstructure analysis combining. The results show that the ceramic shell with medium strength(the high temperature flexural strength is 8 MPa, the flexural strength after thermal shock resistance is 12 MPa and the residual flexural strength is 20 MPa) can prevent the rupture and runout of the blade. The appropriate temperature(1,520 ℃ for upper region and 1,500 ℃ for lower region) of the heating furnace can eliminate the wide-angle grain boundary, the deviation of grain and the run-out caused by the shell crack. The holding time after pouring(3-5 min) can promote the growth of competitive grains and avoid a great deviation of columnar grains along the crystal orientation <001>, resulting in a straight and uniform grain structure. In addition, to avoid the formation of wrinkles and to ensure a smooth blade surface, the withdrawal rate should be no greater than the growth rate of grain. It is also found that the dendritic space of the blade decreases with the rise of solidification rate, and increases with the enlarging distance between the solidification position and the chill plate.
基金supported by the school fund of Nanjing University of Information Science and Technol ogy
文摘Scanning electron microscopy（SEM） and energy dispersive X-ray analysis（EDAX） were used to study the microstructure,microsegregation, and fluid flow tendency of the superalloy Waspaloy in the mushy zone,which had been solidified at different cooling rates. The investigation was accompanied with the calculation of Rayleigh numbers.It is found that Ti is the main segregating element and the content of Ti is the highest in the final liquid at the cooling rates of 3-6℃/min.The eta phase（η） precipitate presented in the residual liquid at the cooling rates higher than 6℃/min is responsible for the fluctuations in the curves of Ti content.The dendrite arm spacing is found to markedly decrease with the increase of cooling rate.The maximum relative Rayleigh number occurs at 10-20℃below the liquidus temperature at a cooling rate of 1℃/min,where the mushy zone is most unstable and fluid flow is most prone to occur.
文摘The transformation mechanism of （γ ＋γ′） was studied by analyzing the microstructure and elemental distri- bution of the U720Li samples heated at 1250℃ and cooled at the rates in the range of 1-100℃/s. Although the （γ ＋γ′） is deemed to be formed by a eutectic reaction and has been called eutectic （γ ＋γ′）, it was found in the present study that the （γ ＋γ′） precipitation begins with a peritectic reaction of （L ＋ γ）γ′, and develops by the eutectic reaction of L （γ ＋γ′）. The energy for the γ′ nucleation is low because the interfacial energy for the γ /γ′ interface is about one-tenth of the solid/liquid interface, and hence, the nucleation rate is high and the fine structure of （γ ＋ γ′） is formed at the initial precipitation stage. The γ and γ′ in （γ ＋ γ′） tend to grow into a lamellar structure because it is difficult for them to nucleate directly from the residual liquids, and hence, the γ′ precipitates naturally tend to grow divergently direction of the regions rich in AI and Ti, forming a fan-like structure of the （γ ＋γ′）. As a result, the γ′ precipitates will coarsen finally because the space between them is enlarged. The solidification of the final residual liquids is a diffusion dependent process. When cooled at a higher rate, a higher degree of super cooling is reached and finally the solidification is finished by the pseudo- eutectic reaction of L → （γ ＋ boride） and L→ （γ ＋γ′）, which can absorb Zr and B. When cooled at a rate low enough, most of the residual liquids are consumed by the （γ ＋γ′） growth due to the sufficient diffusion, and the boride and Zr- bearing phase are precipitated at a quasi-equilibrium state. Under this condition, Ti is depleted at the （γ ＋γ′） growth front. However, the η-Ni3Ti phase is formed there occasionally due to the boride precipitation, because the compositions of the two phases are complementary.
基金Acknowledgements This work was financially supported by the National Natural Science Foundation of China （51704210）, the National Key Research and Development Program of China （No. 2017YFB0701802） and Natural Science Foundation of Hebei Province （E2017105016）.
文摘Solidification process of 231 t 30Cr2Ni4MoV ingot manufactured by slow cooling process was studied using experimental and numerical simulations, which tackled the problems of high cost and long period in large ingot studying. Based on the numerical results of large ingot, five characteristic locations under different temperature gradients and cooling rates chosen from the large ingot were simulated. The experiments were performed under the same temperature conditions as in numerical simulations with specialized instrument. The influences of temperature gradient in the solid-liquid interface and solidification rate on the size and morphology of solidification structure were analyzed at cooling rate ranging from 10-3 to 10 2℃ s-1. Solidification macrostructure and microstructure showed that no columnar dendrite was found in any specimen. The grain size and secondary dendrite arm spacing decreased at larger cooling rate, and the relationship between secondary dendrite arm spacing and local solidification time or cooling rate was determined.
基金financially supported by the National Natural Science Foundation of China(No.51401168)the Fundamental Research Funds for the Central Universities(No.3102014JCQ01026)
文摘Beta-solidifying TiAl alloy has great potential in the field of aero-industry as a cast alloy.In the present work,the influence of cooling rate during mushy zone on solidification behavior of Ti-44Al-4Nb-2Cr-0.1B alloy was investigated.A vacuum induction heating device combining with temperature control system was used.The Ti-44Al-4Nb-2Cr-0.1B alloy solidified from superheated was melted to β phase with the cooling rates of 10,50,100,200,400 and 700 K·min^（-1）,respectively.Results show that with the increase in cooling rate from 10 to 700 K·min^（-1）,the colony size of α_2/γ lamella decreases from 1513 to48 urn and the solidification segregation significantly decreases.Also the content of residual B2 phase within α_2/γlamellar colony decreases with the increase in cooling rate.In addition,the alloy in local interdendritic regions would solidify in a hypo-peritectic way,which can be attributed to the solute redistribution and enrichment of Al element in solidification.
基金This work is supported by National Key Research and Development Program of China (2018YFB0704400)the National Natural Science Foundation of China (Grant Nos. 51671124 and 51474142)the support of State Key Laboratory of Development and Application Technology of Automotive Steels (Baosteel Group).
文摘In order to investigate the relationship between microstructure and MnS inclusion in non-quenched and tempered steel, and cooling rate during horizontal directional solidification, 49MnVS steel was used to conduct the experiments with a selfdesigned device. The mathematical effect of cooling rate on dendritic arm spacing and mean diameter of MnS particles (dMnS) were determined by using linear regression method. The results show that the length of dendrite from solid–liquid interface to end-solidification decreased with increasing the withdrawal velocity (#). dMnS has a similar value in the area of the steady directional solidification;the value of dMnS was 4.1, 3.6, 3.3, 2.8 and 2.3 lm at withdrawal velocity of 50, 75, 100, 150 and 200 lm/s, respectively. dMnS increased with reducing # or RC (interface cooling rate). MnS precipitated in the gaps between dendrites and was influenced by secondary dendritic arm spacing. Besides, a new concept of the ‘Precipitation Unit Space’(PUS) was proposed and the relationships between dMnS, VPUS (volume of PUS) and RC were obtained.
基金the National Natural Science Foundation of China(Grant No.51904146)the Doctor Start-up Fund of Liaoning Province(Grant No.2019-BS-125)the National Key Laboratory of Marine Engineering of China(Grant No.SKLMEA-USTL-201707)。
文摘This study aims to investigate the primary carbides precipitation in H13 steel solidified at relatively high cooling rates,ranging from 300 to 6,000℃·min^-1,based on in situ observations with a high temperature confocal laser scanning microscope.In the cooling rate range investigated,the solidification microstructure becomes more refined as cooling rate increases and the relationship between the secondary dendrite arm spacing(SDAS),λ2,and cooling rate,.T,can be expressed asλ2=128.45.T-0.124.Regardless of cooling rates,two kinds of primary carbides,i.e.,the Mo-Cr-rich and V-rich carbides,are precipitated along the interdendritic region and most of them are the Mo-Cr-rich carbides.The morphology of Mo-Cr-rich carbide is not obviously influenced by the cooling rate,but that of V-rich carbide is obviously affected.The increasing cooling rate markedly refines the primary carbides and reduces their volume fractions,but their precipitations cannot be inhibited even when the cooling rate is increased to 6,000℃·min^-1.Besides,the segregation ratios(SRs)of the carbides forming elements are not obviously affected by the cooling rate.However,compared with the conventionally cast ingot,the SDAS and primary carbides in the steel solidified at the investigated cooling rates are much finer,morphologies of the carbides have changed significantly,and SRs of the carbides forming elements are markedly greater.The variation of primary carbide characteristics with cooling rate is mainly due to the change in SDAS.
基金supported by the National Natural Science Foundation of China (Grant No. 50904044)
文摘Cooling rate is a key factor that can drastically affect the phase transformation and thermal stress of duplex stainless steels. Therefore, in this research, different sand moulds were used to explore the influence of cooling rate on the solidification of the 2304 duplex stainless steel (DSS). The macro and micro structures of the 2304 DSS were investigated. Small equiaxed grains are obtained in chromite sand mould sample with a lower pouring temperature and a higher cooling rate, whereas coarse columnar and equiaxed grains are found in silica sand and refractory powder mould samples. The size of austenite phase is significantly increased with decreasing cooling rate, while the ferrite phase content ranging from 51.6% to 53.9% does not change obviously. In addition, the linear contraction of the 2304 DSS decreases from 2.34% to 1.09% when the mean cooling rate above 1,173 K increases from 0.99 K·s-1 to 3.66 K·s-1.
基金supported by the National Natural Science Foundation of China(No.51974071)National Key Research and Development Program of China(No.2022YFB3705101)the Opening Project Fund of Materials Service Safety Assessment Facilities(No.MSAF-2021-009).
文摘Advancements in metallurgical technology have led to the emergence of high-performance requirements for metal materials,like high uniformity,high purity,and superfine crystallinity.This has resulted in the development and application of internal cooling source(ICS),vibrational,and vibrational internal cooling source methods in metal solidification processes to afford products with refined crystal grains and large proportions of equiaxed crystals.These methods have gradually been introduced into laboratories and some steel mills over the past few decades.However,there are few successful industrial applications of these methods,as there is no comprehensive understanding of their control theories and principles.Accordingly,the development,basic principles,and classifications of the three types of methods are summarized,and their impact on the solidification of molten metals and the morphology of solid products is discussed.In addition,experimental and numerical simulation-based researches on each type of method are reviewed and their prospects for applications are briefly discussed to control metal solidification.Finally,detailed future perspectives are provided on vibratory strip feeding,ICS,and pulsed magneto-oscillation methods.Hopefully,it will serve as a reference for future studies of the application of these and related methods in metal solidification processes.
文摘Preparation of semisolid slurry using a cooling slope is increasingly becoming popular,primarily because of the simplicity in design and ease control of the process.In this process,liquid alloy is poured down an inclined surface which is cooled from underneath.The cooling enables partial solidification and the incline provides the necessary shear for producing semisolid slurry.However,the final microstructure of the ingot depends on several process parameters such as cooling rate,incline angle of the cooling slope,length of the slope and initial melt superheat.In this work,a CFD model using volume of fluid(VOF) method for simulating flow along the cooling slope was presented.Equations for conservation of mass,momentum,energy and species were solved to predict hydrodynamic and thermal behavior,in addition to predicting solid fraction distribution and macrosegregation.Solidification was modeled using an enthalpy approach and a volume averaged technique for the different phases.The mushy region was modeled as a multi-layered porous medium consisting of fixed columnar dendrites and mobile equiaxed/fragmented grains.The alloy chosen for the study was aluminum alloy A356,for which adequate experimental data were available in the literature.The effects of two key process parameters,namely the slope angle and the pouring temperature,on temperature distribution,velocity distribution and macrosegregation were also studied.
基金the National Natural Science Foundation of China-Excellent Young Scholars(No.51922068)the National Natural Science Foundation of China(Nos.51727802,51821001 and 51904187)The support of synchrotron radiation phase-contrast imaging by the BL13W1 beam line of Shanghai Synchrotron Radiation Facility(SSRF),China,is gratefully acknowledged。
文摘Effect of cooling rate on the 3 D morphology and the growth mechanism of the proeutectic Al3Ni intermetallic compound(IMC) that forms at the Al/Ni interface after solidification was investigated by synchrotron X-ray microtomography in combination with EBSD analysis. The proeutectic Al3Ni phase that forms under an average cooling rate of 0.1 Ks^(-1) shows a characteristic faceted growth behavior and presents a typical 3 D morphology as partially hollow quadrangular prisms. On the contrary, that forms under an average cooling rate of 10 Ks^(-1) shows complicated dendritic morphology with asymmetrically distributed arms and faceted V-shape groove at the distal end, indicating a gradual transition of the growth behavior from non-faceted to faceted during the solidification process. These results reveal that the morphology of the proeutectic Al3Ni is highly sensitive to the solidification condition so that fine control of the desired morphology may be achieved by carefully manipulating the cooling profile.
文摘The effect of different cooling rates(2.7,5.5,17.1,and 57.5℃/s)on the solidification parameters,microstructure,and mechanical properties of Al-15Mg_(2)Si composites was studied.The results showed that a high cooling rate refined the Mg_(2)Si particles and changed their morphology to more compacted forms with less microcracking tendency.The average radius and fraction of primary Mg_(2)Si particles decreased from 20μm and 13.5%to about 10μm and 7.3%,respectively,as the cooling rate increased from 2.7 to 57.5℃/s.Increasing the cooling rate also improved the distribution of microconstituents and decreased the grain size and volume fraction of micropores.The mechanical properties results revealed that augmenting the cooling rate from 2.7 to about 57.5℃/s increased the hardness and quality index by 25%and245%,respectively.The high cooling rate also changed the fracture mechanism from a brittle-dominated mode to a high-energy ductile mode comprising extensive dimpled zones.
基金The authors are grateful to FAPESP-São Paulo Research Foundation,Brazil(2014/50502-5 and 2017/16058-9)Capes-Coordenação de Aperfeiçoamento de Pessoal de Nível Superior,Brazil(Funding code 001)and CNPq-National Council for Scientific and Technological Development(406239/2018-5)for their financial supportThe authors would like to thank the Brazilian Nanotechnology National Laboratory–LNNano for allowing us to use its facilities.
文摘Biodegradable Zn-based alloys, particularly Zn-Mg alloys with the addition of alloying elements, have been intensively investigated aiming to improve both mechanical properties and corrosion behavior. Since such properties are strongly dependent on the alloy microstructure, any evaluation should commence on understanding the conditions influencing its formation. In this study, the effect of the solidification cooling rate on the microstructural evolution of Zn-1 wt.%Mg-(0.5 wt.%Ca, 0.5 wt.%Mn) alloys during transient solidification was investigated. The results show that the microstructures of both alloys have three phases in common: η-Zn dendritic matrix, intermetallic compounds(IMCs) Zn11Mg2, and Zn2 Mg in the eutectic mixture. MnZn9 and two Ca-bearing phases(CaZn11 and CaZn13) are associated with Mn and Ca additions, respectively. These additions are shown to refine the dendritic matrix and the eutectic mixture as compared to the Zn-1 wt.%Mg alloy. A correlation between cooling rate, dendritic or eutectic spacings was developed, thus permitting experimental growth laws to be proposed. Additionally, hardness tests were performed to evaluate the effects of additions of Ca and Mn. Experimental correlations between Vickers microhardness and secondary dendritic spacings were proposed, showing that the microstructural refinement and characteristic Ca and Mn based IMCs induce an increase in hardness as compared to the binary alloy.
文摘Six alloys with different compositions of Al 0.1%Sc, Al 0.3%Sc, Al 0.3%Zr, Al 0.1% Sc 0.1%Zr, Al 0.3%Sc 0.1%Zr and Al 0.3%Sc 0.3%Zr were prepared by casting in a wedge shaped copper mould. The hardness test, microstructure observation, and DSC thermal analysis were applied to fully investigate the solidification behavior of the wedge tip (whose cooling rate is 1 000 K/s) and the top surface (cooling rate 100 K/s) of each casting. The results show that the cast structures in the hypoeutectic region of Al Sc alloys are slightly affected by cooling rates during the solidification. In the case of hypereutectic alloy of Al 0.3%Sc 0.3%Zr , the cast grains were remarkably refined under the condition of a 100 K/s cooling rate, however, under a 1 000 K/s cooling rate condition, solute atoms contribute nothing to the grain refinement, due to the eutectic concentration becomes higher. The hardness can be improved to a greater degree by Sc single addition, compared to single Zr addition, but it can be improved even greater when Sc added together with Zr. It is sensitive to cooling rate, the higher the cooling rate, the greater the hardness. By combining the results of TEM examination and DSC analysis, it can be seen that a supersaturated Al solid solution forms during the solidification, and the solubility of Sc in Al solution can be improved by increasing the cooling rate.
文摘Al-18Si alloy reinforced with 15%,20% and 25%(volume fraction) SiC whiskers were prepared by squeeze casting technique and the solidification behavior and microstructure of as-prepared composites at different cooling rates were studied by DSC,optical microscope,SEM and TEM.The results show that silicon phase is nucleated on SiC whiskers.With the increase of cooling rate,the degree of undercooling increases in the composites as well as in the alloys.The increase of cooling rate leads to a reduction in the size of eutectic Al-Si and also changes its morphology from short stick to equiaxed.However,the change of primary Si is complex.The primary Si size is refined,and then coarsened with increasing cooling rate.The primary Si morphology of composites changes from agglomerate to stick.
