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DOE OSTI2018

Processing Parameter Control of Lifetime-Limiting Failure Mechanisms in Al-Si Cast Alloys at Room and Elevated Temperatures

Aluminum-silicon cast alloys widely used throughout the transportation sector, A356, 319, and A390, have been studied with respect to chemical compositions and processing parameters that control the resultant mechanical behavior. First, the development of strengthening mechanisms is discussed in terms of the role that alloying elements, solidification behavior, and thermal treatments play. Based on this understanding, an extensive matrix of material conditions was developed and characterized in order to provide practical guidelines for alloy development. In order to provide an understanding of lifetime-limiting failure mechanisms, fatigue crack growth and hot compressive dwell behaviors were further investigated. Fatigue crack growth tests were conducted for all alloys at R = 0.1 and room temperature, and creep–fatigue of 319 was studied at R = − 1.5 and 250 °C. The role of processing parameters in controlling the mechanical properties is identified and discussed, and recommendations for optimized design are made.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Effects of Copper Content and Mold Temperature on the Hot Tearing Susceptibility of Mg-7Zn-xCu-0.6Zr Alloys

The effects of copper (Cu) content and mold temperature on the hot tearing susceptibility (HTS) of Mg-7Zn-xCu-0.6Zr (x = 0, 1, 2) alloys were investigated experimentally using a T-type hot tearing mold. The crack volumes were measured by paraffin permeation method, and the solidification process was analyzed by thermal analysis and by using the Clyne and Davies model. The microstructure and morphology of the crack zone of Mg-7Zn-xCu-0.6Zr alloys were characterized by scanning electron microscopy, and the composition of alloys was analyzed by X-ray diffraction. The results showed the formation of a new phase of MgZnCu in the alloys with Cu addition. Moreover, addition of Cu also led to the refinement of microstructures of Mg-7Zn-xCu-0.6Zr alloys. The HTS of Mg-7Zn-xCu-0.6Zr alloys decreased with the increase in both the content of Cu and the mold temperature.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Engulfment Behavior of Inclusions in High-Carbon Steel: Theoretical and Experimental Investigation

Previous studies on inclusions behavior at the front of the solidifying steel shell have mainly focused on low-carbon steels. However, with the increasing applications of high-carbon steel in recent years because of its superior properties, it is crucial to understand this behavior in high-carbon steel. Most of the high-carbon steels are deoxidized by silicon, calcium treated, and contain higher sulfur percentage. Also, higher carbon content has a determining influence on the viscosity and surface tension, which will affect the inclusion behavior. In this study, we have investigated the engulfment behaviors of inclusions in front of the solidifying interface in high-carbon steels using concentric solidification method. The critical velocity of the growing shell, at which the particle is engulfed in the solidifying shell, instead of being pushed by this shell, was determined. The inclusion identified in this study is a bi-component form of CaO-SiO{sub 2}-based oxide and CaS. It was revealed that engulfment behavior is strongly affected by convection of liquid steel that originates from carbon push out in high-carbon steels. This study provides new crucial information to produce high-carbon steel with fewer inclusions, which opens new application pathways for this emerging grade of steel.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Influence of Growth Rate on Eutectic Spacing, Microhardness, and Ultimate Tensile Strength in the Directionally Solidified Al-Cu-Ni Eutectic Alloy

In this work, the mechanical properties of the Al-Cu-Ni eutectic alloy, Al-32.5 wt pct Cu-1 wt pct Ni, were investigated in terms of the dependency on growth rates. The Al-Cu-Ni eutectic alloy was directionally solidified at a constant temperature gradient, G = 4.93 K mm{sup −1}, with a wide range of growth rates (V = 9.25 to 2056.68 µm s{sup −1}) using a Bridgman-type directional solidification furnace. The eutectic spacing (λ), microhardness (HV{sub T}), and ultimate tensile strength (σ{sub UTS}) were measured with standard techniques. The dependences of λ, HV{sub T}, and σ{sub UTS} on V for directionally solidified Al-Cu-Ni eutectic alloy were experimentally obtained using regression analysis. The results obtained in the present work were compared with the similar experimental results in the literature. Finally, the elastic energy dependence on growth rates for Al-32.5 wt pct Cu-1 wt pct N alloy was determined from their nominal stress–strain plots.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Transient Behavior and Thermodynamics of Inclusions in Al-Ti-Deoxidized and Ca-Treated Steel

Ti-alloyed steels have severe nozzle clogging problems, which are detrimental to the steel production process. However, little research on the Al-Ti-Ca-O complex inclusion in molten steel has been carried out. Based on that, experiments with different calcium additions were carried out in an Al{sub 2}O{sub 3} crucible at 1873 K to investigate the variation of inclusions in Ti-bearing Al-killed steel in the current article. It was found that calcium treatment significantly influenced the morphology, composition distribution, and size of oxides in Ti-bearing Al-killed steel. Inclusions with a higher CaO or TiO{sub x} content were liquid at 1873 K (1600 °C), indicating that the inclusions in Ti-contained steel can be modified to liquid ones through the proper calcium treatment process. The appropriate amount of calcium should be added to the steel depending upon the aluminum and titanium contents. Thermodynamics of the inclusions in the Al-Ti-Ca-O molten steel system at high temperature and during the solidification process were comprehensively calculated, including all types of inclusions such as calcium oxide, aluminum oxide, titanium oxide, calcium aluminate, calcium titanate, and liquid inclusion. The thermodynamic calculations agree well with the experimental results and can precisely predict the formation of the inclusions in Al-Ti-Ca deoxidized steel.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Simultaneous Removal of Silicon and Iron-Rich Phases from Coarse Al-Si Alloys Using Manganese Under Electromagnetic Field

Coarse Al-Si alloy is produced from bauxite via carbon electro-thermal reduction method. Silicon and iron-rich phases are two main detrimental impurities in coarse Al-Si alloy, and they can be simultaneously removed by adding Mn under the electromagnetic field. We focus on the influence of different Mn additions, dropping rates, and current intensity on the simultaneous removal efficiency of Si and Fe. Experimental results show that as mole ratio of Mn/Fe reaches more than 0.8, the morphology of iron-rich phases together with silicon changed from harmful acicular-like to the contributing bulks, concentrated at the bottom of Al-Si alloy as intermetallic compounds. Furthermore, when Mn/Fe reaches 1.2 and a lower dropping rate (5 to 25 μm/s) is adopted, both Si and Fe contents in the Al-Si alloy decreased drastically after electromagnetic directional solidification process, reaching 11.42 and 0.4 pct, respectively, with a desirable Fe removal efficiency of 91 pct. Finally, the principle of simultaneously separating Si and removing iron-rich phases from Al-Si alloy is studied deeply.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Feasibility Study of Continuous Casting of Steel Billets in Twin-Belt Caster

Integrated casting and rolling in a series production line is well established for the non-ferrous metals through the use of twin-belt casting technology. However, this twin-belt casting with high mass flow is not yet commercialized in the continuous production of steel alloys. A novel steel casting for the in-line rolling (named LUUP method) is presented and one main focus of this work is to design a casting machine: twin-belt caster. Influence of mass flow rate and dimensional ratio on the solidification, compensation, and total process length is addressed. A gap-dependent belt and dam block side heat transfer is modeled. The admissible casting speed due to the limitations of caster length and shell strength is addressed. The total process length only depends on the mass flow rate. A 2D traveling slice numerical model is presented with realistic boundary conditions for the entire process starting from the meniscus to roll mill entry.

36 MATERIALS SCIENCE↗
DOE OSTI2019

High-Temperature Properties and Microstructural Stability of the AISI H13 Hot-Work Tool Steel Processed by Selective Laser Melting

The microstructural stabilities, softening resistance, and high-temperature tensile properties of the H13 hot-work tool steel by selective laser melting (SLM) were systematically studied. A series of tempering procedures were performed on the as-SLMed specimens. Afterwards, the mechanism of softening resistance behavior was discussed based on the XRD, SEM, EBSD observations, hardness measurements, and high-temperature tensile tests. It was found that the as-SLMed H13 consisted of α-iron and γ-iron. The carbide-stabilizing elements aggregated as the cell-like substructures for the rapid solidification of the SLM process. After the softening resistance treatment, the retained austenite transformed to ferrite and carbide mixtures. The cell-like substructures dissolved slowly into the matrix when the temperature was below 550 °C. These factors increased the hardness and retarded the softening of the material. When the temperature was 600 °C, the microstructural constituents transformed to soft ferrite and globular carbides, which lead to a considerable decrease of the hardness. Due to the grain refinement, solid solution strengthening, and residual stress, the as-SLMed H13 exhibited better mechanical properties than that of the wrought counterparts.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Evaluation of Experimental Studies in the U-Rich Region of the U-Pu Phase Diagram

Upon the re-examination of two experimental studies, additional thermophysical data pertaining to the uranium-rich portion of the uranium-plutonium binary phase diagram have been elucidated. The first study involved the analysis of solidification cooling curves following the processing of U-Pu alloys. Two phase transitions (liquidus and bcc) were evaluated and the results agreed very well with the established boundaries. The second study was actually performed over sixty years ago but still warrants recognition due to the paucity of thermodynamic data on the U-Pu system to date. From the investigation, the activity coefficients of plutonium in liquid uranium from 1813 K to 2042 K were derived assuming Henry’s law from which the partial molar excess Gibbs energy change of plutonium was obtained: Δ G-bar {sup ex}=R∗T∗ln γ{sub Pu}{sup o}=− 76694+39.2∗T(J/mol).

36 MATERIALS SCIENCE↗
DOE OSTI2019

Dendritic Growth Under Natural and Forced Convection in Al-Cu Alloys: From Equiaxed to Columnar Dendrites and from 2D to 3D Phase-Field Simulations

The interaction between convection and solute transport during solidification has significant influence on the dendritic evolution. By employing the phase-field lattice-Boltzmann approach together with the parallel and adaptive-mesh-refinement algorithm, the dendritic evolution under convection is simulated in both 2D and 3D cases. The flow-induced redistribution of the solute alters both tip velocity and the development of dendritic arms. The effect of both convection and undercooling is quantified and compared using the length ratio of the dendritic arms. The effect of convection behavior (i.e., natural and forced) and domain dimension (i.e., 2D and 3D) on dendritic growth is discussed. Results show that the convection effect is mainly dominated by the convection mode, and the melt flow in 2D can produce biased results comparing with those in 3D.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Characterization, Mechanism and Control Measures of V Segregation in Continuous Casting Billet of C-Mn Steel

To eliminate V segregation, which significantly deteriorates the homogeneity of continuous casting steel billets, V segregation in the C-Mn steel billet was observed by microscope, SEM and EDS. The formation mechanism and control measures for V segregation were proposed. Results show that many slim V segregation strips are distributed on an inverted conical surface and that most segregation strips start from the vertex of the inverted conical surface. A series of inverted conical surfaces containing V segregation strips periodically appears along the longitudinal direction of the billet. The microstructures in the V segregation strip are fine granular structures, while the microstructures outside the V segregation strip are coarse Widmanstätten. The V segregation strip also contains many inclusions and porosities. The formation mechanism for V segregation, which is illuminated by a physical simulation of Al-5wt pctCu alloy, is attributed to the fissure in the equiaxed dendritic network torn by solidification contraction. By controlling the percentage and distribution of equiaxed grains, the V segregation in the billet of C-Mn steel is completely eliminated.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Precipitation Mechanism and Reduction of Amount of Primary Carbides During Electroslag Remelting of 8Cr13MoV Stainless Steel

The precipitation and growth of primary carbides in 8Cr13MoV steel during electroslag remelting (ESR) were studied. The effects of melting rate and fill ratio of ESR on the reduction of primary carbides were clarified. Primary carbides M{sub 7}C{sub 3} precipitated from liquid steel at the final stage of solidification, which is attributed to an enrichment of carbon and chromium in liquid steel. The carbon content in the residual liquid steel was the determining factor for the formation of primary carbides. The growth of primary carbides was affected mainly by the chromium-concentration and temperature-field gradients. An appropriate melting rate facilitated the nucleation and growth of dendrites, which caused dendrite closure and prevented the further enrichment of carbon atoms. Primary carbides were refined and their amount was reduced when using a lower ESR melting rate. The fill ratio can affect the uniformity of the temperature field in the liquid metal pool and heat transfer from the slag pool to the liquid metal pool, and an optimal fill ratio resulted in a minimum mushy zone and less primary carbides. The volume fraction of primary carbides was reduced by 23 pct when the melting rate decreased from 150 to 133 kg/h and the fill ratio increased from 0.23 to 0.33.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Mg-Bearing Oxide(+TiN) Inclusion on Microstructure of Fe-16 Mass Pct Cr Ferritic Alloy and Its Evolution During Heating at 1573 K (1300 °C)

Both the effects of Mg-bearing oxide and Mg-bearing oxide +TiN inclusions on the microstructures of Fe-16 mass pct Cr alloy should be clarified. In this paper, the effects of Mg-bearing oxide(+TiN) inclusions on the microstructures of Fe-16 mass pct Cr ferritic alloy and changes due to the inclusions during heating at 1573 K (1300 °C) were studied by manual and automatic SEM-EDS analyses. Three alloys were used as specimens. The inclusions were Al{sub 2}TiO{sub 4} +TiN with a small amount of TiN in alloy #1, Al{sub 2}(Mg, Ti)O{sub 4} in alloy #2 and Al{sub 2}(Mg, Ti)O{sub 4} +TiN in alloy #3. The average grain size was smaller, and the ratio of columnar grains was lower in the as-cast alloy #2 and as-cast alloy #3 than that in the as-cast alloy #1. This is attributed to the heterogeneous nucleation of delta ferrite on Al{sub 2}(Mg, Ti)O{sub 4} during solidification. Refinement of the microstructures of ferritic steel by Mg-bearing oxide + multi-TiN inclusions is proposed. Changes in composition, aspect ratio, and size distribution of inclusions in each alloy during heating were investigated systematically. Mg-bearing oxide(+TiN) was dispersed in both the as-cast alloys and heated alloys, which contributed to microstructural refinement of the heated alloys through the pinning effect.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Modeling and Simulation of Porosity in Spray Deposition

Numerical models, consisting of interstitial porosity model and gas porosity model, have been developed to predict the porosity in the spray deposition process. The interstitial porosity model is based on the assumption of liquid feeding in the porous mushy layer of the deposit. The porosity fraction is related to the particle packing density and the amount of the feeding flow during solidification. The gas porosity model is based on the diffusion kinetics of gas pore formation. A numerical simulation of spray deposition for a billet was carried out by coupling the porosity model with the shape and heat-transfer models. The volume fraction and distribution of the porosity were investigated. As a result of the experimental verification, the simulation results showed good agreement with the experimental data. As applications, the models were used to investigate the influence of spray process parameters on porosity formation. The investigation demonstrated that the porosity is substantially influenced by the temperature of the impinging layer and the preheating of the substrate.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Understanding the Formation and Evolution of Oxide Inclusions in Si-Deoxidized Spring Steel

To illustrate the mechanism of the formation and evolution of inclusions in Si-deoxidized spring steel, pilot trials and systematic samplings were conducted, and detailed information about the inclusion density, morphology and composition was elucidated by electron probe X-ray microanalysis. The steel samples were collected from the vacuum degassing furnace, tundish furnace and spring rods after hot rolling. Based on the relationship between the mass ratio of X{sub (CaO)}/X{sub (SiO{sub 2)}} and diameters of inclusions, CaO-SiO{sub 2} inclusions were found to be formed by the coalescence between SiO{sub 2} and CaO-SiO{sub 2} inclusions. Most CaO-SiO{sub 2} inclusions > 10 μm were located in the melilite areas with liquidus temperatures < 1400 °C. The Al{sub 2}O{sub 3}-SiO{sub 2}-CaO inclusions in the steel samples from the vacuum degassing and tundish furnaces were considered to be formed by reduction of CaO-SiO{sub 2} inclusions by Al dissolved in steel. The increased number density of Al{sub 2}O{sub 3}-SiO{sub 2}-CaO inclusions in spring rods was primarily attributed to the entrapment of Na{sub 2}O-contained mould flux particles and inclusions crushed after hot rolling. Many Al{sub 2}O{sub 3}-SiO{sub 2}-MnO and SiO{sub 2}-MnO inclusions were observed in tundish furnace samples, which originated from inherent reactions between [Al], [Si], [Mn] and [O] in the molten steel. The SiO{sub 2} precipitation of Al{sub 2}O{sub 3}-SiO{sub 2}-MnO inclusions was attributed to the solubility decrease during the solidification process with temperature drop.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Porosity Prediction in A356 Wheel Casting

A FLUENT™-based thermal-fluid-compositional model has been developed and applied to a low-pressure, die-cast, A356 aluminum alloy wheel to explore the effects of macro-segregation of hydrogen and late-stage liquid encapsulation on pore formation during solidification. Based on the evolution of temperature, pressure, and hydrogen concentration in the liquid output from FLUENT, the porosity size distribution has been predicted at a number of locations in a commercially produced wheel using an in-house micro-porosity model. The porosity model incorporates pore nucleation kinetics based on hydrogen supersaturation, and two modes of pore growth: the first, occurring at low solid fractions is based on hydrogen diffusion; and the second, occurring at high solid fractions is based on conservation of volume. Samples from a commercially cast wheel have been analyzed using X-ray micro-tomography to provide basic validation of the micro-porosity model. The predicted results showed that the evolution in pressure has the dominant effect on pore growth, but only under conditions where pores have nucleated prior to late-stage liquid encapsulation. Otherwise, the cooling rate appears to have the dominant effect. The accuracy of the model is discussed in terms of the predicted pore size distribution and number density of pores. Areas for continued development are presented.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Numerical Simulation and Experimental Validation of Nondendritic Structure Formation in Magnesium Alloy Under Oscillation and Ultrasonic Vibration

In this study, the formation of nondendritic structures in the primary phase of magnesium alloy solidified under oscillation and ultrasonic vibration was investigated by numerical simulation and experimentally. The growth and motion of a dendrite during solidification was simulated by a combination of the lattice Boltzmann method and the phase-field method. The simulation and experimental results indicated that higher oscillation amplitudes and acoustic streaming made the microstructures change from dendritic to nondendritic in the α-Mg primary phases. A sufficient shear stress and an appropriate flow time in the barrel should be satisfied when a given inclined angle is selected. The effects of the flow and the thermal field on the nucleation behavior, the constitutional undercooling, and the growth morphology are also discussed. It was found that a high shear rate and high turbulence can help homogenize the temperature and the concentration fields and collide and rotate the α-Mg primary phases.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Formation Mechanisms and Microstructure Characterization of Al/Al{sub 3}Ni In-situ Composite by Compound Casting

The Compound casting method was used to produce an Al/Ni bimetal composite. The mechanisms of formation of the reinforcing intermetallic phases were studied and the produced bimetal composite’s microstructure was then characterized. The results showed that the Al/Ni interface consisted of two intermetallic layers including Al{sub 3}Ni{sub 2} and Al{sub 3}Ni. It is suggested that the Al{sub 3}Ni reinforcing particles of the composite originated from two sources. (1) Some Al{sub 3}Ni particles detached from the Al{sub 3}Ni layer formed at the interface between the Ni core and the Al melt and dispersed in the liquid Al and (2) Al-Al{sub 3}Ni eutectic phase, which formed during the solidification process. The increase in the temperature led to the formation of more reinforcing particles and extended the depth of dispersion of the particles in the Al matrix.

36 MATERIALS SCIENCE↗