Towards high-temperature applications of aluminium alloys enabled by additive manufacturing
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36 MATERIALS SCIENCE↗
Engineering topics
Shyam, Amit
Publications and source records attributed to Shyam, Amit.
The role of Si in determining the stability of the θ; precipitate in Al-Cu-Mn-Zr alloys
Precipitate-strengthened Al-Cu-Mn-Zr (ACMZ) alloys demonstrate improved microstructural stability compared to conventional Al-Cu alloys. Si is typically considered an impurity in these alloys, but a systematic analysis of ACMZ alloys with a range of Si levels revealed that there is a Si content range (~0.05 wt. % < Si < ~0.10 wt. %) for achieving optimal high temperature microstructural stability. A combination of hardness testing, scanning electron microscopy, and atom probe tomography has been used to understand the relationship between Si content, aging response, and thermal stability in ACMZ alloys. It is shown that the optimum Si content range corresponds to a reduced as-aged hardness, but a greater hardness value retained by the alloy after thermal exposure to 350 °C for 200 hours. A mechanism is proposed in which optimum Si levels reduce the number density of nucleation sites for θ' precipitates, resulting in larger precipitates that, on average, provide a reduced as-aged strength but are more coarsening resistant. This inherent θ' coarsening resistance allows more time for slow-diffusing Mn and Zr to reach the θ' interface and further stabilize the precipitates. Designing the optimal as-aged microstructure for improved thermal stability of the alloy by controlling impurity levels is a concept that has implications beyond the investigated Al-Cu alloy system.
36 MATERIALS SCIENCE↗
Atomic structures of interfacial solute gateways to θ' precipitates in Al-Cu alloys
Many materials employed in critical structural applications depend upon metastable strengthening precipitates that transform or dissolve at elevated temperatures. Herein, aberration-corrected scanning transmission electron microscopy and first-principles calculations are used to accurately determine the atomic structure of the highly mobile, semi-coherent precipitate interfaces that control this process in the classic θ' (Al 2 Cu) precipitate in the Al-Cu system. Semi-coherent {110} interfaces are found to be composed of an array of unexpected misfit dislocations that are arranged in two different structural units. Dislocations accommodate nearly all of the misfit between the Al matrix and strengthening phase. Cu is observed to segregate to the compressed edge of the dislocation cores at specific sites in this interface. First-principles calculations revealed the energetic landscape that facilitates these sites to become entry and exit gateways of Cu atoms in this semi-coherent interface. In conclusion, this investigation reveals critical features within semi-coherent interfaces that determine the thermal stability of precipitation-hardened alloys.
36 MATERIALS SCIENCE↗
Aging behavior and strengthening mechanisms of coarsening resistant metastable θ' precipitates in an Al–Cu alloy
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36 MATERIALS SCIENCE↗
Crystallographic orientation-dependent strain hardening in a precipitation-strengthened Al-Cu alloy
While the strengthening of Al-Cu alloys due to precipitation has been extensively studied, the effect of crystallographic orientation of the matrix and precipitates, as well as precipitate morphology, on the strain hardening behavior is not well understood. In this paper, we investigate this effect with in situ neutron diffraction during deformation of an Al-Cu alloy (206) after multiple aging treatments. Precipitate-dislocation interactions were found to change from precipitate shearing for microstructures predominantly containing GPI and θ" precipitates to Orowan looping for microstructures with primarily θ' and θ precipitates. Notably, significant anisotropy in strain hardening behavior was observed when θ' precipitates were present, which was attributed to crystallographic orientation dependent load transfer from the Al matrix to the θ' precipitates. The anisotropic load transfer is hypothesized to be caused by the extent of rotation of high aspect-ratio θ' precipitates, owing to dislocations looping around them during plastic deformation of the matrix. Predictions from an analytical model describing the anisotropic magnitude of load transfer from precipitate rotation agree well with experimental results, successfully validating the precipitate rotation hypothesis and explaining the anisotropic strain hardening behavior. This model allows for the prediction of stresses separately in the precipitate and matrix phases as a function of crystallographic orientation, only given the bulk mechanical properties.
36 MATERIALS SCIENCE↗
Deformation and failure of PrintCast A356/316 L composites: Digital image correlation and finite element modeling
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36 MATERIALS SCIENCE↗
Influence of copper content on the high temperature tensile and low cycle fatigue behavior of cast Al-Cu-Mn-Zr alloys
The relationship between low cycle fatigue (LCF) and monotonic tensile fracture strain was investigated for cast Al-Cu-Mn-Zr alloys containing 6 and 9 wt% Cu at 250 °C. The 9% Cu alloy consisted of larger size and volume fraction of brittle intermetallic grain boundary particles that fractured during tensile tests to reduce the fracture strain by 50% compared to the 6% Cu alloy. We found that LCF life was similar between the two alloys and weakly influenced by the particles. LCF life and fracture strain were poorly correlated due to the dominant influence of particles on monotonic tensile crack but not on fatigue crack.
36 MATERIALS SCIENCE↗
Microstructure and properties of a high temperature Al–Ce–Mn alloy produced by additive manufacturing
An Al–10Ce-8Mn (wt%) alloy was designed and fabricated by laser powder bed fusion additive manufacturing (AM). The rapid cooling rates of the AM process produced a refined microstructure with a large fraction of reinforcing intermetallic phases. The tensile properties of the alloy were characterized in the as-fabricated state and following thermal exposure. The properties of the as-fabricated microstructure showed exceptional high-temperature performance and strength retention at elevated temperatures up to 400 °C relative to benchmark wrought Al and AM Al alloy properties. Characterization of the microstructure and thermodynamic modeling of the ternary Al–Ce–Mn system rationalized the solidification and solid-state phase transformations. Finally, analysis of the relevant strengthening mechanisms for both the as-fabricated and thermally exposed conditions was performed.
36 MATERIALS SCIENCE↗
Solute-vacancy clustering in aluminum
In this study, we present an extensive first-principles database of solute-vacancy, homoatomic, heteroatomic solute-solute, and solute-solute-vacancy binding energies of relevant alloying elements in aluminum. We particularly focus on the systems with major alloying elements in aluminum, i.e., Cu, Mg, and Si. The computed binding energies of solute-vacancy, solute-solute pairs, and solute-solute-vacancy triplets agree with available experiments and theoretical results in literature. We consider physical factors such as solute size and formation energies of intermetallic compounds to correlate with binding energies. Systematic studies of the homoatomic solute-solute-vacancy and heteroatomic (Cu, Mg, or Si)-solute-vacancy complexes reveal the overarching effect of the vacancy in stabilizing solute-solute pairs. The binding energy database presented here elucidates the interaction between solute cluster and vacancy in aluminum, and it is expected to provide insight into the design of advanced Al alloys with tailored properties.
36 MATERIALS SCIENCE↗
Equilibrium solute segregation to matrix- θ' precipitate interfaces in Al-Cu alloys from first principles
Particular combinations of solute atoms segregated to the interface of the Al and θ ' - Al 2 Cu in Al-Cu alloys can help stabilize θ ' precipitates at high temperatures. Stabilization of such precipitates is determined by a combination of thermodynamics (including driving forces for coarsening and transformation and solute segregation tendencies) and kinetic effects (including solute diffusion and interfacial mobility in the presence of interfacial solute segregation). For some alloys such as recent Al-Cu-based alloys, multiple solutes segregate in significant quantities to interfaces, and solute-solute interactions at the interface are important, with multiple types of solutes competing for similar interfacial sites. To treat this situation, we develop and apply a statistical mechanics approach to calculate the temperature-dependent equilibrium solute atoms distribution near the coherent and semicoherent interfaces between the Al matrix and the θ ' - Al 2 Cu precipitates. The developed approach is applied to the investigation of Si, Mn, and Zr segregation at the interface, as particular combinations of these elements affect the thermal stability of the θ ' precipitates. We demonstrate that because Si and Mn atoms segregate on the same semicoherent interface, the presence of Si reduces the concentration of Mn solutes at the interface. Si atoms preferably occupy the first layer of the interface and compete with Mn atoms for one type of particular sites in the layer. Mn atoms preferably occupy the second layer of the semicoherent interface, and the Mn-Mn interaction plays an important role in their distribution. Zr atoms mostly segregate on one of the two nonequivalent sites of the second layer of the coherent interface. Due to symmetry properties of the coherent interface, the calculations show that the segregation Zr of atoms to this interface will likely lead to the formation of L 1 2 ordered Al 3 Zr layer.
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Primary solidification of ternary compounds in Al-rich Al–Ce–Mn alloys
Primary solidification of ternary compounds Al 20 Mn 2 Ce and Al 10 Mn 2 Ce were analyzed through the coupling of the thermodynamic modeling and classic nucleation theory. Thermodynamic models of Al 20 Mn 2 Ce and Al 10 Mn 2 Ce were developed using the CALPHAD approach based on first-principles calculated enthalpy of formation and experimental data obtained from this work and the literature. The analysis suggested that despite the larger thermodynamic driving force for nucleation of Al 10 Mn 2 Ce, nucleation is preferred for the Al 20 Mn 2 Ce phase in the highly undercooled liquid due to its smaller interfacial energy. Therefore, manufacturing methods with rapid cooling rates will favor primary solidification of Al 20 Mn 2 Ce for Al-rich Al–Ce–Mn alloys.
36 MATERIALS SCIENCE↗
An additively manufactured AlCuMnZr alloy microstructure and tensile mechanical properties
In this study, selective laser melting (SLM) was used to fabricate an AlCuMnZr alloy. The microstructural features that resulted from additive manufacturing (AM) were significantly refined compared to the corresponding cast alloy features. A combination of fine equiaxed and columnar grains along with in-situ formation of θ' precipitates during AM leads to enhanced yield strength (up to 300°C) in the as-fabricated AM alloy. The refinement of brittle intermetallics and a bimodal grain size distribution leads to improved tensile elongation in the AM alloy. The results illustrate the microstructural advantages that can result from additive processing over conventionally processed microstructures.
36 MATERIALS SCIENCE↗
The synergistic role of Mn and Zr/Ti in producing θ'/L12 co-precipitates in Al-Cu alloys
Microstructural stability is a critical factor to consider when designing new alloys for high-temperature applications. An Al-Cu alloy with Mn and Zr additions has recently been developed to withstand extended exposures of up to 350 °C. The addition of Mn in combination with Zr and their segregation to precipitate interfaces play a significant role in stabilizing the metastable θ ' precipitates responsible for the alloy's hardness; however, adding Zr and Mn separately only improves the stability to 200 °C and 300 °C, respectively. To this end, the effect of the synergistic additions on interfacial structure and chemistry was studied in detail using atom probe tomography (APT) and scanning transmission electron microscopy (STEM) for Al-Cu-Mn-Zr/Ti-containing alloys subjected to long-term annealing (up to 2,100 h) in the critical temperature range, 300 °C and 350 °C, to investigate the role of Zr/Ti in increasing the θ '-precipitate stability. The APT and STEM results reveal that Mn additions stabilize θ ' long enough for the slower diffusing Zr atoms to segregate to coherent θ ' interfaces that eventually create a θ '/ L1 2 -Al 3 (Zr x ,Ti 1-x ) co-precipitate structure. The co-precipitate is highly stable, as shown by density functional theory calculations, and is a key factor that governs microstructural stability beyond 300 °C. This study reveals how solute additions with different stabilization mechanisms can work in concert to stabilize a desired microstructure, and the results provide insights that can be applied to other high-temperature alloy systems.
36 MATERIALS SCIENCE↗
Grain Refinement Effect on the Hot-Tearing Resistance of Higher-Temperature Al–Cu–Mn–Zr Alloys
The hot-tearing resistance of Al-Cu-Mn-Zr (ACMZ) alloys was investigated as a step toward introducing these new cast alloys for severe duty, higher-temperature applications, such as cylinder heads for down-sized, turbocharged automotive engines. Alloy Cu compositions were varied from 5 to 8 wt.%. Targeted Ti levels were 0.02, 0.1, and 0.2 wt.% via additions of the Al–5Ti–1B master alloy. Hot-tearing resistance was assessed by visual examination and ranking of the cracking severity in a multi-arm permanent mold casting. It was found that at high impurity contents (Fe and Si of 0.2 wt.% each), the Al–Cu–Mn–Zr alloy with 4.95 wt.% Cu exhibited the poorest hot-tearing resistance, irrespective of the grain refining amount. Microstructural analysis indicated an effective reduction in the grain size, as the Ti additions were increased to 0.02 and 0.1 wt.% Ti via the Al–Ti–B grain refiner. The finest grain size was attained with a 0.1 wt.% Ti. Based on the hot-tearing evaluation, it was found that the additional grain refining via the Al–5Ti–1B master alloy at 0.1 wt.% Ti significantly reduces the hot-tearing susceptibility at Cu contents greater than 7.3 wt.% for ACMZ alloys with low Fe and Si. These findings indicate that the best hot-tearing resistance was observed at a grain refiner level of 0.1 wt.% Ti and high Cu content (greater than 7.3 wt.%). This study to indicates that these Al–Cu–Mn–Zr alloys, which possess excellent microstructural stability and mechanical properties at elevated temperatures, can also possess excellent hot-tearing resistance.
36 MATERIALS SCIENCE↗