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At least 595 records · Page 33
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Study of 3D Pores and Its Relationship with Crack Initiation Factors of Aluminum Alloy Die Castings

Observing different types of pores in aluminum alloy from A356 high-pressure die casting by X-ray computerized tomography and scanning electron microscopy, we found that equivalent spherical diameters of pores obeyed the 3-parameter lognormal distribution rather than the 2-parameter one. Statistically, the sphericity of most round gas pores with smooth inner surfaces consisting of oxide films was > 0.58, while the sphericity of shrinkage pores with unfractured dendrites was < 0.40. Sphericity range for the gas-shrinkage pores, composed of gas pores and shrinkage pores with long tails, was 0.40-0.58. Finite element analysis with simulation of the Von Mises stress distribution around the actual 3D pores among crack generation was performed. Tensile test simulation showed that cracks often originated from the shrinkage pores and the gas-shrinkage pores, rather than from the gas pores. This method also can be used to predict fracture strength of samples with pores. For our samples, results obtained using this method showed that simulated fracture strength was slightly higher than experimentally determined strength.

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

Characterization of Roughness, Porosity and Thermal Resistances of Continuous Casting Mold Slag Layers Devitrified and Crystallized in Laboratory

This paper presents an experimental investigation about the variation, with temperature, of surface roughness, porosity, degree of crystallization and microstructure, occurring in solid layers of a commercial mold powder slag used for casting medium carbon steel thin slabs. Characterization is done with samples devitrified and crystallized at 698 K, 823 K, 898 K and 973 K (425 °C, 550 °C, 625 °C and 700 °C) for 10,800 seconds, in the furnace of a high-temperature confocal laser scanning microscope. As well as, with slag disks devitrified non-isothermally in a heat flow apparatus based on the application of Fourier's law in steady state conditions, where the high temperature surface is maintained at selected values, between 927 K and 1241 K (654 °C and 968 °C). Surface roughness and porosity determinations are performed by image analysis of confocal laser scanning and scanning electron micrographs, respectively. For the time considered and temperatures ≥ 823 K (550 °C) the slag crystallizes completely, and variations of roughness and porosity with temperature are associated with changes in size and packing of the primary crystalline-phase grains. Crystallization induced porosity is significant and causes slag layer expansion. Hence crystallization does not lead to gap formation with a neighboring surface (e.g., mold wall) by shrinkage. Instead, surface separation arises from development of roughness, and measurements with the heat flow apparatus confirm that interfacial thermal resistance between a slag layer and a metallic wall can be estimated from the sum of the means of maximum peak to valley height of their surfaces. Furthermore, the results establish that slag layers roughness and porosity increase with temperature and reveal effective thermal conductivities in the range of ~ 0.3 to ~ 0.5 W/m K. Low effective thermal conductivities must be a consequence of porous bands, whose porosity depends on temperature and reaches values as high as ~ 0.20 and ~ 0.50.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Evolutions of the Micro- and Macrostructure and Tensile Property of Cu-15Ni-8Sn Alloy During Electromagnetic Stirring-Assisted Horizontal Continuous Casting

The present study investigates the evolution of the micro- and macrostructure and tensile property of the Cu-15Ni-8Sn (weight percent) alloy prepared by horizontal continuous casting and electromagnetic stirring (EMS). The results show that the application of EMS is beneficial for grain refinement and for microstructure transformation from the dendrite to the rosette structure and that it leads to a significant improvement in the tensile property. The forced flow induced by EMS homogenizes the temperature field ahead of the solid-liquid interface, disturbing the heat flow direction and resulting in the columnar to equiaxed transition. The grain refinement under different electromagnetic stirring frequencies is mainly derived from the homogenization of the temperature and the remelting of dendritic arms. In addition, the evolution of the tensile property with and without EMS is discussed from the perspective of fracture mode and fine-grain strengthening.

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↗
DOE OSTI2018

Effects of Nb on the Microstructure and Properties of Ti-Added Hypereutectic High-Cr Cast Iron

Effects of Nb on the microstructure and properties of Ti-added hypereutectic high-Cr cast iron were studied. With the addition of Nb, a new phase (Nb,Ti)C was formed. The microstructure analysis revealed that the amount of primary carbides was decreased from 18.6 to 8.8% and the primary and eutectic carbides were greatly refined. The decrease in the amount of primary carbides was attributed with the shrinking of primary M{sub 7}C{sub 3} phase zone in the phase diagram, while the refinement of primary carbides was attributed to the heterogeneous nucleus of (Nb,Ti)C phase for the primary M{sub 7}C{sub 3} carbides. The macrohardness of the alloy increased from 60.8 to 63.5HRC, and the impact toughness increased from 3.8 to 5.2 J cm{sup −2}. Furthermore, the wear resistance was enhanced with the addition of Nb due to the formation of hard (Nb,Ti)C carbides.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Mechanical Performance of Nodular Cast Irons After Prolonged High-Temperature Exposure

Ductile cast irons (DIs) are widely used in industrial applications. Their use is, however, often limited to components working at room temperature, since prolonged exposure at high temperature can lead to decomposition of both ausferrite and pearlite, with a consequent strength reduction. The present paper evaluated the effects of prolonged high-temperature exposure on microstructure and residual strength of DIs with different matrices, after an isothermal soaking at temperatures between 200 and 600 °C. Microstructural analyses highlighted that long-term exposure at temperatures higher than 500 °C leads to the complete decomposition of ausferritic and pearlitic matrix microstructures, while hardness tests showed that the hardness is stable up to 500 °C for the pearlitic ductile iron (PDI), up to 450-500 °C for the ausferritic ductile iron (ADI) and up to 400-450 °C for the perferritic isothermed ductile iron (IDI). Exposure at 500 °C for 240 h induces a reduction in tensile strength of IDI and ADI, respectively, of 10 and 25% (for both room temperature and 500 °C tensile testing), while it has no significant effects on PDI.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Modeling and Computation of Casting Process by Particle Method

Since particle-based computational methods, such as smoothed particle hydrodynamics (SPH) method, are suitable to treat free surfaces and moving boundaries, it is expected that the simulation with particle methods can represent more accurate molten metal flow. Hence, we apply the SPH method to some casting processes and validate the numerical results by comparing with experiments. While fluid behaviors of the transportation and the mold filling processes are expressed sufficiently, ladle pouring process of aluminum alloy is not reproduced by the existing scheme. So we developed a new numerical model of surface oxide film, and our numerical results show good agreement with the experimental data.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Effect of Nickel Content on Microstructural Evolution in Austempered Solution-Strengthened Ferritic Ductile Cast Iron

The effects of Ni content and austempering temperature on microstructural evolution during austempering in solution-strengthened ferritic ductile cast iron with Ni contents between 0 and 1.1 mass% were investigated. The microstructure observation for the samples austempered at temperatures between 375 and 325 °C using an infrared gold image furnace was carried out with optical microscopy, x-ray diffraction measurements, and electron back-scattered diffraction pattern (EBSP) analysis. In addition, the Vickers hardness of both the austempered and as-quenched samples was measured under a load of 0.9807 N. According to the microstructure observations, the matrix of the samples austempered at temperatures between 375 and 325 °C exhibited finer acicular ferrite microstructure with increasing Ni content. Optical microscopy and EBSP analysis revealed that the amount of high-carbon austenite phase for the austempered samples increased with increasing Ni content and austempering temperature. Although samples with higher Ni content were found to contain more high-carbon austenite phase in the matrix, the Vickers hardness of the samples tended to increase with increasing Ni content at the same austempering temperature. The reason for this may be the higher carbon content in the matrix of the samples with higher Ni contents.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Fabrication of a High Chromium Cast Iron/Low Carbon Steel Bimetal: Diffusion Behavior and Bonding Strength

In the present study, a high chromium cast iron (HCCI) alloyed with Mo (16 wt.% Cr-6 wt.% Mo-2.4 wt.% C) with excellent wear resistance was bonded to a low carbon steel (LCS) by surface liquid-phase sintering. The bimetal was also subjected to a quenching + tempering treatment. The diffusion behavior of the atoms between the HCCI and LCS was analyzed. The bonding strength of the bimetal was investigated before and after heat treatment. The results show that the bimetal had a good bonding quality due to the uphill diffusion of C atoms. A diffusion zone with a width of approximately 37 μm and a troostite structure formed on the HCCI side by the interface. With different bonding times, there was no obvious change in the width of the diffusion zone. The shear strength of the bimetal at all holding times was reduced from a high level after heat treatment and decreased with increasing tempering temperature. The impact toughness of the bimetal substantially increased compared with that of the HCCI. After a quenching treatment, the impact toughness of the bimetal decreased, and the microhardness of the diffusion zone improved. As the tempering temperature increased, the microhardness and impact toughness decreased and increased, respectively.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Tensile Properties of a Cast Al-Si-Mg Alloy with Reduced Si Content and Cr Addition at High Temperature

Tensile properties of an Al-Si-Mg casting alloy with reduced Si content and Cr addition were investigated at room and high temperatures. It was found that the studied alloy exhibits a remarkable performance up to 200 °C, with comparable or slightly higher strength than typical values for Al-Si-Mg-Cu alloys, commonly used for high-temperature applications, and good elongation. This is due to the choice of proper heat treatment and to the formation of dispersoids containing Cr during heat treatment, which are stable at the considered temperatures, as demonstrated by scanning and transmission electron microscopy (STEM) analysis. Interestingly, exposure to 300 °C during tensile tests enhanced an additional formation of dispersoids. It is believed that heating the material in T6 condition led to such observed dispersoids formation since precursors were already present in the Al matrix. This is not sufficient to avoid material softening at 300 °C, but it represents an interesting point in order to develop alternative heat treatment routes for dispersion-strengthened Al alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Microstructure and residual elastic strain at graphite nodules in ductile cast iron analyzed by synchrotron X-ray microdiffraction

The microstructure and residual elastic strain at graphite nodules (GNs) in ductile cast iron produced using either a fast or slow cooling rate have been characterized using synchrotron 3D X-ray Laue microdiffraction. The results demonstrate that thermal stress is introduced during cooling and that part of this stress is relaxed by plastic deformation of the polycrystalline ferrite matrix. It is observed that the plastic deformation is accommodated by the formation of dislocations and dislocation boundaries, which are organized in a cell structure. The dislocation density quantified based on the microstructure is most pronounced at the GN/matrix interface around small GNs in the fast cooled sample. Residual elastic strain is also present, which is mainly compressive with a maximum of 6.0–9.9 &times; 10 -4 near the GNs. Gradients of plastic deformation and elastic strain field around the GNs are observed. The results document for the first time that both the elastic strain field and the plastic strain field averaged over the grains around the GNs is approximately scaling with GN size and not affected by the cooling rate. The experimental data are compared with simulations by a finite element method, and agreement and disagreement are considered in detail.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Detecting Thermally-Induced Spinodal Decomposition with Picosecond Ultrasonics in Cast Austenitic Stainless Steels

Destructive techniques to monitor nuclear reactor component health may not always be available during service, as they are time-consuming and often require pre-installed inspection coupons. Non-destructive evaluation (NDE) techniques can bridge this gap by rapidly identifying the state of mission-critical reactor components, via inference between NDE-measurable material properties and those of ultimate interest, such as ductility and toughness. Here, we demonstrate one such inference about the health of thermally aged cast austenitic stainless steels. Observations of surface acoustic wave peak (SAW) splitting correlate with spinodal decomposition-induced embrittlement as destructively measured by Charpy impact energy. Elastodynamic calculations and molecular dynamics simulations of the effects of spinodal decomposition on elastic moduli support that the new acoustic modes present are due to stiffening in the δ-ferrite domains. Finally, this discovery enables one to probe structure-property relationships in materials in a greatly accelerated manner, suggesting that similar inference methods can be used to determine material fitness-for-service, or to quickly uncover new structure-property relationships.

304-type stainless steel↗
DOE OSTI2021

Unraveling compacted graphite evolution during solidification of cast iron using in-situ synchrotron X-ray tomography

In spite of many years of research, the physical phenomena leading to the evolution of compacted graphite (CG) during solidification is still not fully understood. In particular, it is unknown how highly branched CG aggregates form and evolve in the semi-solid, and how local microstructural variations at micrometer length scale affect this growth process. We present here the first time-resolved synchrotron tomography combined with a bespoke high-temperature environmental cell that allows direct observation of the evolution of CG and relates this dynamic process to the local surrounding microstructures in a cast iron sample during repeated melting and solidification. Distinct processes are identified for the formation of CG involving the nucleation, growth, development of branches and interconnection of graphite particles, ultimately evolving into highly branched graphite aggregates with large sizes and low sphericities. CG is found to nucleate with a spheroidal or a plate-like shape, developing branches induced by high carbon concentration, e.g. thin melt channels. Additionally, CG grows much faster than spheroidal graphite during subsequent cooling in solid state. The direct visualization of the dynamic solidification process provides unprecedented new insights into formation mechanisms of CG and correlating factors such as local microstructural variations, and guides the development of CG iron solidification models.

36 MATERIALS SCIENCE↗
DOE OSTI2020

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↗
DOE OSTI2017

Joining sheet aluminum AA6061-T4 to cast magnesium AM60B by vaporizing foil actuator welding: Input energy, interface, and strength

Dissimilar joining of sheet aluminum AA6061-T4 to cast magnesium AM60B was achieved by vaporizing foil actuator welding (VFAW). Three input energy levels were used (6, 8, and 10 kJ), and as a trend, higher input energies resulted in progressively higher flyer velocities, more pronounced interfacial wavy features, larger weld zones, higher peel strengths, and higher peel energies. In all cases, weld cross section revealed a soundly bonded interface characterized by well-developed wavy features and lack of voids and continuous layers of intermetallic compounds (IMCs). At 10 kJ input energy, flyer speed of 820 m/s, peel strength of 22.4 N/mm, and peel energy of 5.2 J were obtained. In lap-shear, failure occurred in AA6061- T4 flyer at 97% of the base material’s peak tensile load. Peel samples failed along the weld interface, and the AM60B-side of the fracture surface showed thin, evenly-spaced lines of Al residuals which had been torn out of the base AA6061-T4 in a ductile fashion and transferred over to the AM60B side, indicating very strong AA6061-T4/AM60B bond in these areas. Furthermore, this work demonstrates VFAW’s capability in joining dissimilar lightweight metals such as Al/Mg, which is expected to be a great enabler in the ongoing push for vehicle weight reduction.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Metal plasticity and ductile fracture modeling for cast aluminum alloy parts

Here in this study, plasticity and ductile fracture properties were characterized by performing various tension, shear, and compression tests. A series of 10 experiments were performed using notched round bars, flat-grooved plates, in-plane shear plates, and cylindrical bars. Two cast aluminum alloys used in automotive suspension systems were selected. Plasticity modelling was performed and the results were compared with experimental and corresponding simulation results; further, the relationships among the stress triaxiality, Lode angle parameter, and equivalent plastic strain at the onset of failure were determined to calibrate a ductile fracture model. Finally, the proposed ductile fracture model shows good agreement with experimental results.

36 MATERIALS SCIENCE↗
DOE OSTI2013

Separate effects identification via casting process modeling for experimental measurement of U–Pu–Zr alloys

Computational simulations of gravity casting processes for metallic U–Pu–Zr nuclear fuel rods have been performed using a design-of-experiments technique to determine the fluid flow, liquid heat transfer, and solid heat transfer parameters which most strongly influence the process solidification speed and fuel rod porosity. The results are used to make recommendations for the best investment of experimental time and effort to measure process parameters.

99 GENERAL AND MISCELLANEOUS↗