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Commercially supplied inoculation wires have a guaranteed chemical composition but not the size and distribution of individual phases, which are very important for nucleation. Therefore, two commercial alloys used for the inoculation of Al-Si alloys (AlTi3B1 and AlTi5B1) are investigated in this paper. The emphasis is placed on their structural analysis and the size and distribution of individual intermetallic phases. Furthermore, the grain refinement effect will be tested by adding these alloys to the AlSi7Mg0.3 alloy and testing the optimal amount of added inoculation wires. The results showed that the size and distribution of the individual phases in AlTi3B1 and AlTi5B1 meet the requirements for the successful inoculation of aluminum alloys, the intermetallic phases based on the TiAl3 phase are fine enough, and there is no agglomeration that would reduce the number of nuclei. This assumption was confirmed by adding these inoculants to the AlSi7Mg0.3 alloy, and it was found that the most ideal amount of inoculants added is 0.01 wt % when the structure was refined by approximately 32%. [ABSTRACT FROM AUTHOR]

Aluminothermic reduction without the separation of individual metals is currently considered as a possible method for processing ferromanganese sea nodules and creating new alloys. In this study, the product of their reduction—a manganese-based polymetallic mixture—was added to pure aluminum, as a mixture of alloying elements in their natural ratios. After extrusion, two new aluminum alloys with a total percentage of metallic additives ranging from 1 to 6 percent were prepared. The possibilities of the precipitation strengthening of these aluminum alloys, especially those containing Mn, Fe, Si, Ni, and Cu, were investigated under a wide range of heat treatment conditions. After each tested combination of annealing and artificial aging temperatures, the phase composition and the microstructure changes were recorded by X-ray diffraction, optical, and scanning electron microscopy with EDS analysis. Under none of the tested heat treatment conditions is a significant hardening effect observed, even though the precipitate phases are observed by TEM. However, the changes in the morphology of the present intermetallic phases caused by the heat treatment are revealed, which highlights the further possible development of these multicomponent alloys. [ABSTRACT FROM AUTHOR]

Ferromanganese nodules represent an industrially untapped source of valuable metals (Mn, Cu, Ni, Ti, Co) but are still just the object of scientific research. In comparison with already utilized rocks, deep-sea deposits are too hard to reach for their full-scale mining to be profitable. Despite of this, current marine engineering allows us to conduct complete exploration and obtain mineral samples. We can already now develop low-cost methods for subsequent processing in anticipation of improved and safer future mining technology. But in what form would be the final product the most applicable? In our study, we reduced the pyro metallurgical pretreatment of raw nodules to two simple steps: roasting and aluminothermic reduction. Then we added a product, manganese-based alloy, to pure aluminum as a new alloying additive. As a reference for experimental alloys, commercial cast AlMn10 master alloy was chosen. The tested samples were prepared using two advanced operations of powder metallurgy: melt-spinning and spark plasma sintering (SPS). Microstructure was described in detail, tribological and selected mechanical properties were measured, and a comparative analysis was conducted. New additive gradually improved properties of alloys to a level close to 3xxx industrial alloys with its increasing percentage in pure aluminum. Measured values did not surpass the referent AlMn10, but there was not recorded any adverse impact associated with the origin of alloying mixture. • New aluminum alloys with the natural additive – reduced deep-sea nodules – modified by rapid solidification. • Extremely fine-grained microstructure with the content of supersaturated matrix regions. • Improved mechanical and tribological properties comparable to commercial alloys of 3xxx group. • Uncommonly high plasticity. [ABSTRACT FROM AUTHOR]

Due to the lack of mineral resources, unconventional raw materials have to be considered. In this work, the use of reduced deep-sea nodules from Clarion-Clippertion Fracture Zone of Pacific Ocean was tested as the natural mixture of alloying elements for aluminum alloys. The nodules were reduced by aluminothermic process without the extraction of individual elements. As the technology for the manufacture of the alloys, the powder metallurgy comprising mechanical alloying and spark plasma sintering was applied. The produced Al-Mn based alloys are characterized by uncommon spherical morphology of Al-Mn intermetallics, which leads to a significant ductility even in the case of high total amount of additives (up to 20 wt%). The wear resistance of the alloys strongly increases with growing amount of the reduced deep-sea nodules. • New aluminum alloys with reduced deep-sea nodules prepared by powder metallurgy. • Unique rounded morphology of intermetallics was obtained. • Improved strength compared with common Al-Mn alloys. • Reduced deep sea nodules improve tribological properties of aluminum. [ABSTRACT FROM AUTHOR]

One of the current problems concerning the re-use of aluminium alloys is the recycling of aluminium alloys with increased content of iron. One of the recent trends is the processing by powder metallurgy, producing completely new grades of aluminium alloys. The aim of the present work was to test the properties of Al–Si–Fe alloy, which can be manufactured from the high-irony scrap, as a possible material for elevated temperature applications. Since chromium and nickel accompany the iron in the scrap when stainless steels are admixed, the effect of chromium and nickel on thermal stability and mechanical properties at room and elevated temperature was also studied. Al–Si–Fe–X alloys were rapidly solidified by using melt spinning technique. The rapidly solidified ribbons were pulverized by planetary ball mill and the obtained powders were used for compaction by means of Spark Plasma Sintering. It was found that nickel improves the thermal stability as well as the mechanical properties at the elevated temperature. On the other hand, the effect of chromium on the mechanical properties at elevated temperature was almost detrimental. [ABSTRACT FROM AUTHOR]

Abstract: This work is devoted to the preparation of ultrafine material based on Al–Cu–Fe quasicrystalline phase by powder metallurgy using mechanical alloying and Spark Plasma Sintering. The dependence of microstructure and phase composition of powders on the conditions of mechanical alloying was described. It was found that the Al60Cu30Fe10 quasicrystalline phase forms directly already after 2 h of milling under optimized conditions. The stability of this quasicrystalline phase was studied at various temperatures of Spark Plasma Sintering compaction process. [Copyright &y& Elsevier]

Quasicrystal-containing materials are usually prepared by rapid solidification of the melt (e.g. by melt spinning) or mechanical alloying. In this work, the method using exothermic reactions between compressed metallic powders called SHS (Self-propagating High-temperature Synthesis) was tested. The microstructure and phase composition of the product was described in dependence on cooling regime from the reaction temperature. Thermal stability of prepared Al-Cu-Fe quasicrystals was studied by annealing at the temperatures of 300 and 500 °C. [ABSTRACT FROM AUTHOR]

Abstract: In this work, Ti–Al–Si alloys were prepared by reactive sintering. The contents of silicon and aluminium ranged between 0–30wt.% and 0–36wt.%, respectively. Powders of titanium, aluminum, silicon and AlSi30 master alloy prepared by mechanical machining and/or milling were used for sintering. Powders were blended and pressed at room temperature. Sintering was carried out at 900°C for 30min. It was found that it is possible to produce compact materials with the structure corresponding to the as-cast materials when silicon is in the range of 15–20wt.% and aluminium content between 8 and 30wt.%. It was shown that these materials contain two phases—Ti5Si3 and TiAl. The central porosity can be reduced by induction heating. [Copyright &y& Elsevier]

Deep-sea manganese nodules are polymetallic oxidic ores that can be found on a seabed. Aluminothermic reduction is one of the possibilities of manganese nodules processing. This process obtains the polymetallic alloy with a high content of Mn and a varying content of Al, depending on the ratio between aluminum and nodules. The corrosion behaviors of three experimental Mn-based alloys produced by aluminothermic reduction with a content of Mn > 50 wt % were studied. The electrochemical testing in potable water and model seawater was used to explain the corrosion mechanism of Mn-based alloys. The results showed that the corrosion rate of experimental Mn-based alloy decreases with the increase in aluminum content in both potable water and model seawater. It was observed that the uniform corrosion of experimental Mn-based alloys is changed with an increase in aluminum content in alloy to localized corrosion, which was caused by microcells in an environment of model seawater. In contrast, the formation of a semi-protective layer of corrosion products was observed on the surface of Mn-based alloys with a higher content of aluminum in potable water. Moreover, the pitting corrosion of tested Mn-based alloys was observed neither in potable water nor in model seawater. [ABSTRACT FROM AUTHOR]

An innovative way to utilize deep-sea manganese nodules is described in this paper. The manganese nodules were reduced by aluminothermy and subsequently added into aluminum as a mixture of alloying elements in their natural ratio. The microstructure and properties of aluminum alloys containing 1.2, 7.7, and 9.7 wt % of reduced nodules were studied. The alloys were formed by Al matrix and minor amounts of Al6(Fe,Mn) and Al11Fe7 intermetallic phases. The alloys containing a higher amount of reduced nodules are characterized by very good thermal stability. The obtained alloys were studied by X-ray diffraction, their microstructure was observed by scanning electron microscopy, and their local chemical composition was analyzed by energy dispersive spectrometer. The hardness of the samples was measured on the initial materials and after long-term annealing. Based on the obtained results, the aluminum alloys, with the addition of reduced deep-sea nodules, can serve as precursors for processing, e.g., by rapid solidification or hot working methods. [ABSTRACT FROM AUTHOR]

Composite material prepared by spark plasma sintering (SPS) from a powder mixture of AlCrFeSi rapidly solidified alloy and 5 wt. % of Ni particles was studied in this work. It was proven that during SPS compaction at 500 °C, no intermetallic phases formed on the surface of Ni particles. The material exhibited sufficient mechanical properties obtained by tensile testing (ultimate tensile stress of 203 ± 4 MPa, ductility of 0.8% and 0.2% offset yield strength of 156 ± 2 MPa). Tensile samples were pre-stressed to 180 MPa and annealed at 450 and 550 °C for 1 h. Annealing at 450 °C did not lead to any recovery of the material. Annealing at 550 °C caused the full recovery of 0.2% offset yield strength, while the ductility was decreased. The self-healing behaviour originates from the growth of intermetallic phases between the Ni particle and the Al matrix. The sequence of NiAl, Ni2Al3 and NiAl3 intermetallic phases formation was observed. In particular, the morphology of the NiAl3 phase, growing in thin dendrites into the Al matrix, is suitable for the closing of cracks, which pass through the material. [ABSTRACT FROM AUTHOR]

Abstract: Rapidly solidified aluminum alloys are promising materials with very fine microstructure. The microscopy observation of these materials is complicated due to overlay of fcc-Al matrix and different intermetallic phases. A possible way to solve this problem is to dissolve the Al matrix. By this process powder formed by single intermetallic phase particles is obtained. In this paper a new aqueous based dissolving agent for Al-based alloy is presented. The influence of oxidation agent (FeCl3) concentration on quality of extraction process was studied. [Copyright &y& Elsevier]

Abstract: Positron annihilation spectroscopy was employed for the microstructure characterization of rapidly solidified Al–3wt.% Cr–3wt.% Fe–0.8wt.% Ce alloy prepared by melt spinning. Results of the positron annihilation study are analyzed within the diffusion trapping model and compared with results of X-ray diffraction, transmission electron microscopy and microhardness measurements. A good consistency among all experimental techniques was obtained. The rapidly solidified alloy exhibits ultra fine grained structure, consisting of cells separated by dislocation walls. Annealed samples showed no significant changes in structure up to 400°C which proves good thermal stability of ultra fine grained structure. Exposure of the sample to temperature of 500°C caused significant changes in the material. [ABSTRACT FROM AUTHOR]