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Materials Science and Engineering, Mechanical, Maritime and Materials Engineering

Coarsening within the mushy zone during continuous directional solidification experiments was studied on an Al-30 wt pct Cu alloy. High brilliance synchrotron X-radiation microscopy allowed images to be taken in-situ during solidification. Transient conditions were present during directional solidification. Under these conditions, solute-rich settling liquid flow affects the dendritic array and thus coarsening. Coarsening was studied by following the secondary dendrite arm spacing (SDAS) of a developing dendrite at different local solidification times according to the mush depth and instant interface velocity. Solute enrichment and liquid flow cause deceleration and acceleration of the solidification front, which in turn influences both the mush depth and local growth and coarsening due to variations in solutal gradients and thus local undercooling. In addition, spacing between neighboring dendrites (i.e., primary dendrite arm spacing), which determines permeability within the mushy zone, affects the development of high-order branches., Materials Science and Engineering, Mechanical, Maritime and Materials Engineering

Thermally induced strains and stresses developed during direct-chill (DC) semicontinuous casting of high strength aluminum alloys can result in formation of micro-cracks in different locations of the billet. Rapid propagation of such micro-cracks in tensile thermal stress fields can lead to catastrophic failure of ingots in the solid state called cold cracking. Numerical models can simulate the thermomechanical behavior of an ingot during casting and after solidification and reveal the critical cooling conditions that result in catastrophic failure, provided that the constitutive parameters of the material represent genuine as-cast properties. Application of fracture mechanics, on the other hand, can help to derive the critical crack length leading to failure. In the present research work, the state of residual thermal stresses was determined in an AA7050 billet during DC casting by means of ALSIM5. Simulation results showed that in the steady-state conditions, large compressive stresses form near the surface of the billet in the circumferential direction, whereas in the center, the stresses are tensile in all directions. Magnitudes of von Mises effective stresses, the largest component of principal stresses and the fracture mechanics concepts, were then applied to investigate the crack susceptibility of the billet., Materials Science and Engineering, Mechanical, Maritime and Materials Engineering

Shrinkage, imposed strain rate, and (lack of) feeding are considered the main factors that determine cavity formation or the formation of hot tears. A hot-tearing model is proposed that will combine a macroscopic description of the casting process and a microscopic model. The micromodel predicts whether porosity will form or a hot tear will develop. Results for an Al-4.5 pct Cu alloy are presented as a function of the constant strain rate and cooling rate. Also, incorporation of the model in a finite element method (FEM) simulation of the direct-chill (DC) casting process is reported. The model shows features well known from literature such as increasing hot-tearing sensitivity with increasing deformation rate, cooling rate, and grain size. Similar trends are found for the porosity formation as well. The model also predicts a beneficial effect of applying a ramping procedure during the start-up phase, which is an improvement in comparison with earlier findings obtained with alternative models. In principle, the model does not contain adjustable parameters, but several parameters are not well known. A full quantitative validation not only requires detailed casting trials but also independent determination of some thermophysical parameters of the semisolid mush., Materials Science and Engineering, Mechanical, Maritime and Materials Engineering

The commonly used hyperbolic sine constitutive equation for metal forming at elevated temperatures, with no strain incorporated, is in principle applicable only to deformation in the steady state. However, the actual deformation processes applied to magnesium alloys are mostly in the non-steady state. In the present research, the results of hot uniaxial compression tests of three wrought magnesium alloys covering wide ranges of temperatures and strain rates were used for a strain-dependent constitutive analysis. A strain-dependent constitutive relationship for these alloys was established. It appeared that the apparent activation energy for deformation decreased with increasing the alloying content in these alloys. The constitutive parameters obtained were used to predict flow stresses at given strains and the results were in good agreement with experimental measurements., Materials Science and Engineering, Mechanical, Maritime and Materials Engineering

An existing constitutive model for creep, developed by Dorn and Harmathy, is modified in order to be used for fire-exposed aluminum alloys. Two alloys, 5083-O/H111 and 6060-T66, are selected for the development of this constitutive model because of their different behavior at elevated temperature and their frequent application in structures for which fire design is relevant. The material parameters in the model are calibrated with the experimental results of creep tests, carried out with constant load and temperature in time. The model is validated with so-called transient state tests, with a constant load in time (stresses ranging from 20 to 150 N/mm2) and with an increasing temperature (with heating rates ranging from 1.6 °C/min to 11 °C/min and critical temperatures ranging from 170 °C to 380 °C). These tests are considered as representative for fire-exposed, insulated aluminum members. The existing constitutive model of Dorn and Harmathy provides good agreement with the transient state tests carried out for the 5xxx series alloy, but appeared to be not suited for the 6xxx series alloy. This is attributed to the early development of tertiary creep in case of 6xxx series alloys. The existing model was modified to incorporate this first stage of tertiary creep, to arrive at a good agreement between the tests and the modified model for 6xxx series alloys., Materials Science and Engineering, Mechanical, Maritime and Materials Engineering

The purification of gaseous and liquid media by means of a cyclone concept is well known and has been successfully applied in different industries. While the impurities removal from molten metal has been an important issue for many years, to the best of our knowledge, the application of a cyclone concept has rarely been considered for molten metal applications. The presence of impurities in cast products is detrimental to their quality. In this article, computer simulations are used to evaluate the possibilities of cyclone application in molten aluminum processing by determining the following: the fluid flow for flow velocities of 0.01, 0.1, and 1 m/s; the particle behavior for discrete particle sizes in the range of 20 to 100 ?m; and the collection efficiency of the cyclone. The geometrical features are discussed. The results show that the cyclone concept can be effectively used as an alternative method to remove the impurities from a stream of molten aluminum in a wide range of flow regimes., Department of Materials Science and Engineering, Mechanical, Maritime and Materials Engineering

Hot tearing remains a major problem of casting technology despite decades-long efforts to develop working hot tearing criteria and to implement those into casting process computer simulation. Existing models allow one to calculate the stress-strain and temperature situation in a casting (ingot, billet) and to compare those with the chosen hot tearing criterion. In most successful cases, the simulation shows the relative probability of hot tearing and the sensitivity of this probability to such process parameters as casting speed, casting dimensions, and casting recipe. None of the existing criteria, however, can give the answer on whether the hot crack will appear or not and what will be the extent of hot cracking (position, length, shape). This article outlines the requirements for a modern hot tearing model and a criterion based on this model as well as the future development of hot tearing research in terms of mechanisms of hot crack nucleation and propagation. It is suggested that the new model and criterion should take into account different mechanisms of hot tearing that are operational at different stages of solidification and be based on fracture mechanics, i.e., include the mechanisms of nucleation and propagation of a crack., Materials Science and Engineering, Mechanical, Maritime and Materials Engineering

Direct-chill (DC) cast billets 192 mm in diameter of an Al-Cu-Mg alloy were examined in detail with the aim to reveal the effects of grain refining (GR) and casting speed on structure, “floating” grains, and centerline macrosegregation. Experimental results show that grain size and dendrite arm spacing (DAS) tend to coarsen toward the billet center with a local refinement DAS in the center. In GR billets, grain size does not change much with the cooling rate, casting speed, and grain refiner amount. Coarse-DAS (floating) grains are observed around the billet axis regardless of GR and the amount of Ti, though their amount is significantly higher in GR billets. Macrosegregation profiles show a negligible influence of GR, while the effect of casting speed is large. The concept of solute-depleted floating grains contributing to the centerline macrosegregation is substantiated by microsegregation measurements, which show that, independent of GR, coarse dendrite branches have a depleted concentration plateau in contrast to the fine dendrite arms., Materials Science and Engineering, Mechanical, Maritime and Materials Engineering

It is well known that ultrasonic melt treatment (UST) promotes grain refinement in aluminum alloys. Cavitation-aided grain refinement has been studied for many years; however, it is still not being applied commercially. The current article summarizes the results of experimental work performed on various alloying systems at different stages of solidification. The influence of UST parameters and solidification conditions on the final grain structure is analyzed. It was found that small additions of zirconium and titanium can significantly increase the efficiency of UST, under the stipulation that grain refinement is performed in the temperature range of primary solidification of Al3Zr. The possible mechanisms for this effect are discussed., Materials Science and Engineering, Mechanical, Maritime and Materials Engineering