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A β-solidifying TiAl alloy with a refined microstructure and ultra-fine yttrium-rich precipitates that was consolidated by spark plasma sintering was investigated by scanning and transmission electron microscopies. Two categories of yttrium-rich precipitates, Y2O3 and YAl2, with sizes ranging from tens to hundreds of nanometers were found to be dispersed within the matrix uniformly. The crystallographic relationship between the two precipitates and the γ-TiAl matrix was determined by the selected area electron diffraction and high-resolution transmission electron microscopy. This spark plasma sintered TiAl alloy was characterized by a uniform duplex microstructure, and it exhibited excellent tensile properties at room temperature. Typically, specimen sintered at 1150°C has an ultimate tensile strength of 1113.1 MPa, yield strength of 881MPa, and a moderate plastic elongation of 1.41%.

Bifilm defects have been proposed to be critical for the generation of various metallurgical defects in castings and have been reported to exist in various composition-based alloys. However, the geometry structure of bifilm defects has not yet been well understood. This present work reconstructed the bifilm defects in a nickel-aluminium bronze alloy casting in three-dimensional (3D) space through the use of computer tomography technology. It was shown that the shape of the bifilm defects is very complex and different from a spherical defect in 3D space. The bifilm defects were experimentally extracted successfully by an electrolysis method and were imaged, which confirmed the folded double-layer structure of the bifilm defects. These results will shed new light on the understanding of bifilm defects and improve the defect control engineering of castings.

Most of the metallurgical defects in castings can be initiated by oxide bifilms reported in various alloys. However, investigations of bifilm defects in nickel-aluminium bronze castings and their fracture behaviors were absent to date, which was explored in the present work. The results showed that there are two types of defects, i.e. smooth oxide film separating from the alloy matrix (old bifilm) and crinkled oxide film tightly adhering to the matrix (young bifilm). Thermodynamics and energy spectrum analysis proved that the bifilm was Al2O3. The inferred bifilm thickening speed curve also suggests that they come from different stages of the casting process. A fracture model was proposed to understand the fracture behaviors associated with the Young's modulus of the two types of bifilm defects. These results will shed new light on the understanding of bifilm defects failure and improve the defect control of castings.

In this paper, we report the results obtained from the hot compression behaviour of co-spray-formed Al-Si/7075 bimetallic gradient alloys by investigating the five selected layers divided evenly from top to bottom. It was found that with a decrease in the strain rate and an increase in temperature, the hot compression flow stress of deposited alloys decreases gradually, as expected. The relationship between flow stress, temperature and strain rate follows the Arrhenius relationship. The deformation activation energy of the co-spray formed gradient alloy gradually increases from bottom to top in the height direction, which are 100.15, 167.35, 185.54, 208.78 and 220.83 KJ/mol, indicating that the degree of difficulty in the deformation of the alloy is affected by changes in the silicon content of the alloy. Finally, the flow stress constitutive equation is calculated for each layer of alloy material, which is instructive for the subsequent study of the densification process of co-spray-formed gradient alloys.

Bimetallic gradient alloys have attracted research attention recently due to their potential applications in the aerospace and automobile industries. In this study, Al-20Si/7075 bimetallic gradient alloys were successfully manufactured by co-spray forming and the roll process. We investigated the thermal expansion behavior of the gradient alloy. It was found that the coefficients of thermal expansion increased with silicon content and increased temperature, reaching the highest point at 573 K, after which they decreased on account of the relaxation of residual thermal stress and the silicon desolvation from the supersaturated aluminum phase. The measured thermal expansion coefficient can be roughly predicted through the traditional theoretical models. Our results revealed the thermal expansion behavior of Al-20Si/7075 bimetallic gradient alloys and would improve the development of new type aluminum–silicon alloy for electronic packaging.

High-temperature oxidation behavior of molten Mg-Nd-Zr in the pyrolysis atmosphere of resin-bind sand mold was investigated. The results showed that pouring temperature higher than 1023 K would sharply increase the ignition risk of melt in mold. The oxide formed on Mg-Nd-Zr melt below 973 K consists of two layers: mainly MgO for outer layer; mixture of MgO and Nd2O3 for inner layer. The inner oxide mixture layer played an essential role in the protection of Mg-Nd-Zr matrix. Based on the experimental results and thermodynamic analysis, the oxidation process containing three stages was proposed. Nd- and Zn-enriched zone was found at the subsurface of oxide scale, without the enrichment of Zr. DICTRA calculation results indicated that this phenomenon was caused by the depletion of Mg and up-hill diffusion of Zr. Thus, Zr showed limited protection to the melt in long-term oxidation.

Mg-Gd-Y-Zr alloy has excellent mechanical properties at room and high temperatures, but its high oxidation properties can also result in a significant number of bifilm defects. However, its formation mechanism was not revealed so far, which was explored in the present work. The results showed that the surface oxide film folds into a grid-like double layer structure defect during solidification, due to the difference of thermal expansion coefficient between surface oxide film and matrix. In addition, the oxide film produces microcracks. As the magnesium alloy melt fills the crack, Zr precipitates into crystal nucleus with peritectic reaction and Y2O3 accumulates. These results would shed new lights on the understanding of shrinkage formation of bifilm defects and improving the defects control of magnesium alloy castings.

Bifilm defects are proposed to be critical among the metallurgical defects generated in castings. However, direct investigations of individual bifilm defects separated from the casting matrix were absent to date. In this study, separated bifilm defects in nickel-aluminium bronze were investigated systematically. The results showed that an electrolysis method can successfully separate the bifilms from the casting matrix. Al2O3 with an amorphous state, a γ-phase structure, and an α-phase structure were observed in the separated bifilms, respectively, violating the conventional prediction of only α-Al2O3 existing in the final casting. The thickness of the bifilm defects was not uniform and varied in a wide range from several nanometres to several hundred nanometres. Upon analysis, the thinner bifilm presented a much smaller Young’s modulus in comparison to the crystallised Al2O3. The thicker bifilm was intergrown with several single crystals and covered by smooth and faceted faces. These results suggest the complex bifilms form in cast nickel-aluminium bronze alloys and more investigations are therefore required in future.

This study deals with the densification of a pre-alloyed TiAl powder with excessive yttrium addition by spark plasma sintering (SPS) technique. The gas-atomized Ti–43Al–5Nb–2V–1Y (at. %) powders were sintered at various temperatures between 1100 and 1250 °C, applying a uniaxial pressure of 40 MPa. The microstructures of pre-alloyed powders and SPSed TiAl alloy samples were analyzed by scanning and transmission electron microscopies. In addition, the compression tests of SPSed alloys was carried out at room temperature (RT). Attention is focused on the existing form and distribution of excess yttrium in the initial powders and the SPSed samples. The initial powder exhibits a dendrite structure, and yttrium-rich phases (YAl2) are segregated along the interdendritic zone. After sintering, duplex, nearly lamellar (NL) and fully lamellar (FL) microstructures were obtained as a function of the sintering temperature. For duplex and NL microstructures, the YAl2 phases are fine granular precipitates in homogeneous dispersion state. Conversely, stripe-like YAl2 precipitates, which surround the α2/γ lamellar colonies, emerged in the FL microstructures. Excessive sintering temperature leads to grain growth and serious segregation of the YAl2 phases, and it deteriorates the mechanical properties of this alloy eventually.