A simple model for grain refinement during solidification

Quantifying the Effects of Grain Refiners Al-Ti-B and La on the Microstructure and Mechanical Properties of W319 Alloy

It is well known that the microstructure distribution in recycled Al-Si alloys has a large impact on the final mechanical properties. In this study, the microstructure, including Fe-rich intermetallics and microporosity, was quantitatively adjusted using multi-scale characterization with microalloying rare earth elements and traditional grain refiners as the objects of study. It was found that the addition of Al-Ti-B to W319 recycled aluminum alloy reduces the microstructure size and Fe-rich intermetallics, while the addition of La facilitates the transformation of harmful β-Fe into less harmful particles and the densification of coarse eutectic Si, promoting the refining effects on the microstructure additionally. Therefore, the RE and Al-Ti-B master alloy could be a potential new grain refining agent, especially for Al-cast alloys when the ductility is critical for designing. The improvement in elongation far exceeds the original level, up to 69.6%, while maintaining the same level of strength or even better. At the same time, the excessive addition of La may lead to the depletion of Cu and Ti elements during heat treatment, degrading ductility and strength.

Prediction of Grain Size in Cast Aluminum Alloys

Grain refinement of cast alloys, especially aluminum–silicon and magnesium-based alloys, is an effective approach to improve the strength of alloys. Grain size is the most representative parameter used to characterize grain refinement in the industry, thereby attracting increasing attention for developing accurate grain size prediction models. In this paper, several important grain size prediction models under different adaptation conditions are reviewed. These models are obtained either by regression of experimental data or by physical/mathematical inference under certain assumptions of specified cases, focusing on the effects of alloy composition, solidification temperature gradient, grain growth rate, and fining agent composition, among others. The trends of grain size prediction models were also discussed. The results revealed machine learning as an effective tool to establish a data-driven prediction model of grain size in cast aluminum alloys.

Investigating Metal Solidification with X-ray Imaging

In the last two decades, X-ray imaging techniques have been used increasingly to study metal solidification in real-time as, thanks to advances in X-ray sources (synchrotron and laboratory-based) and detector technology, images can now be obtained with spatio-temporal resolutions sufficient to record key phenomena and extract quantitative information, primarily relating to crystal growth. This paper presents an overview of the research conducted at the University of Oxford over the last 6 years as a partner in the UK’s Future Liquid Metal Engineering (LiME) Manufacturing Hub. The focus is on in situ X-ray radiography to investigate the solidification of Al alloys, including the formation of primary α-Al crystals, and the formation and growth of secondary intermetallic phases. Technologically, the thrust is to understand how to control as-cast phases, structures and element distributions, particularly elements associated with recycling, as a means to facilitate greater recirculation of aluminium alloys. We first present studies on refinement of primary α-Al, including extrinsic grain refinement using inoculation and intrinsic refinement based on dendrite fragmentation. Second, we describe studies on intermetallic phase formation and growth, because intermetallic fraction, morphology and distribution are frequently a limiting factor of alloy mechanical properties and recyclability. Then we present some of the latest progress in studying liquid flow during solidification and associated hot tear formation. Finally, future research directions are described.

X-ray Imaging of Alloy Solidification: Crystal Formation, Growth, Instability and Defects

Synchrotron and laboratory-based X-ray imaging techniques have been increasingly used for in situ investigations of alloy solidification and other metal processes. Several reviews have been published in recent years that have focused on the development of in situ X-ray imaging techniques for metal solidification studies. Instead, this work provides a comprehensive review of knowledge provided by in situ X-ray imaging for improved understanding of solidification theories and emerging metal processing technologies. We first review insights related to crystal nucleation and growth mechanisms gained by in situ X-ray imaging, including solute suppressed nucleation theory of α-Al and intermetallic compound crystals, dendritic growth of α-Al and the twin plane re-entrant growth mechanism of faceted Fe-rich intermetallics. Second, we discuss the contribution of in situ X-ray studies in understanding microstructural instability, including dendrite fragmentation induced by solute-driven, dendrite root re-melting, instability of a planar solid/liquid interface, the cellular-to-dendritic transition and the columnar-to-equiaxed transition. Third, we review investigations of defect formation mechanisms during near-equilibrium solidification, including porosity and hot tear formation, and the associated liquid metal flow. Then, we discuss how X-ray imaging is being applied to the understanding and development of emerging metal processes that operate further from equilibrium, such as additive manufacturing. Finally, the outlook for future research opportunities and challenges is presented.

Synergistic Effect of La and TiB2 Particles on Grain Refinement in Aluminum Alloy

Synergistic effect of TiB₂ (in form of Al-5Ti-1B) and La on grain refining results in Al-2Cu alloy was investigated. α-Al grains are significantly refined by Al-5Ti-1B. When trace La is added to the melt, further refinement is exhibited. Average grain size and nucleation undercooling of α-Al reduce first and then almost remain unchanged with La addition. Satisfactory grain refining result achieves when La addition level reaches 600 ppm. When more than 600 ppm La is added to the melt, La-rich particles form and the effect of solute La left in matrix on the microstructure almost no longer changes. Theoretical calculation results demonstrate that solute La segregates to Al melt/TiB₂ particles interface along with Ti and Cu prior to α-Al nucleation and the synergistic effect of La and TiB₂ particles on grain refinement mainly attributes to the enhancement in the potency of TiB₂ particles to heterogeneously nucleate α-Al by trace La addition.

The growth restriction effect of TiCN nanoparticles on Al-Cu-Zr alloys via ultrasonic treatment

Ex situ and in situ synchrotron X-radiography study on Al-Cu-Zr alloys with addition of Al-5Ti-1B and TiCN nanoparticles (TiCN_np) were carried out at different cooling rates. Al-Zr alloy can be effectively refined by TiCN_np via Ultrasonic treatment as compared with Al-5Ti-1B which has Zr poisoning effect. The influence of cooling rate on the nucleation and growth of grains have been studied quantitatively. The results show that the grain size was decreased and the growth rate was increased with the increasing of cooling rate. At the same cooling rate, the grain size with addition of 0.5% TiCN_np was smaller than that with the same addition of Al-5Ti-1B. The blocking factor f of TiCN_np decreases with increasing cooling rate. Based on the free growth model, a new numerical model considering the growth restriction effect of nanoparticles was established. The growth of grain was inhibited by the combining effect of solute and nanoparticles. The growth rate of grain is reduced due to part of the solid/liquid interface coated by nanoparticles. The blocking factor f is linearly decreased with the coverage ratio ω which is proportional to the critical grain radius. The grain size decreases with increasing cooling rate and decreasing f . This study is especially beneficial for Al alloys that have poisoning phenomenon inoculated by traditional refiner.

Crystal nucleation in metallic alloys using x-ray radiography and machine learning

The crystallization of solidifying Al-Cu alloys over a wide range of conditions was studied in situ by synchrotron x-ray radiography, and the data were analyzed using a computer vision algorithm trained using machine learning. The effect of cooling rate and solute concentration on nucleation undercooling, crystal formation rate, and crystal growth rate was measured automatically for thousands of separate crystals, which was impossible to achieve manually. Nucleation undercooling distributions confirmed the efficiency of extrinsic grain refiners and gave support to the widely assumed free growth model of heterogeneous nucleation. We show that crystallization occurred in temporal and spatial bursts associated with a solute-suppressed nucleation zone.

Refining Mechanism of 7075 Al Alloy by In-Situ TiB₂ Particles

The nucleation undercooling of TiB₂/7075 Al matrix composites, the microstructure observed after solidification at different cooling rate, and the size and distribution of TiB₂ particles were investigated. The experimental results have shown that the grain sizes of TiB₂/7075 Al matrix composites firstly decreased, then increased, and finally decreased again with the increase of TiB₂ content. The nucleation undercooling of TiB₂/7075 Al matrix composites first increased, then decreased, and finally increased again with the increase of TiB₂ content when the cooling rates was 5 and 10 °C/min respectively, but kept decreasing with the increase of TiB₂ content at a cooling rate of 20 °C/min. The melting and solidification process showed no significant change with the decrease of cooling rate in 9.0% TiB₂/7075 Al matrix composites. Most small particles can act as heterogeneous nucleus, which induced grain growth and were captured into the grain by the solid/liquid interface. At the same time, most of the larger particles and a minority of the small TiB₂ particles are pushed into the grain boundary; locating in the grain boundary can hinder the Al atoms from diffusing during the solidification process and restrain α-Al phase growth. The influence of particles shifted from dominating by locating to dominating by nucleation as the quantity of TiB₂ particles increased.

Crystallography of grain refinement in cast zinc–copper alloys

Adding the peritectic forming element Cu effectively reduced the average grain size of cast Zn by over 85%. At a specified cast condition, the smallest grain size was obtained at 2 wt% Cu addition. A further increase in Cu content led to grain coarsening in the cast Zn–Cu alloys. Although the solute effect of Cu was predominately responsible for the grain refinement through restriction of the grain growth, it was found that the variation of grain size is also closely related to the formation of the pro-peritectic phase, ∊-CuZn4. Crystallographic calculations using the edge-to-edge matching model showed low interatomic misfit and interplanar mismatch between Zn and the ∊-CuZn4phase. In addition, a reproducible h.c.p.–h.c.p. (h.c.p. denotes hexagonal close-packed) orientation relationship between Zn and the ∊-CuZn4particles (located within the Zn grain centres) was also experimentally determined using the electron backscattered diffraction method. This indicated the high potency of the pro-peritectic ∊-CuZn4particles as effective heterogeneous nucleation sites for η-Zn, which further refined the Zn grains. However, when the Cu content was over 2.0 wt%, formation of large ∊-CuZn4particles resulted in grain coarsening of the cast alloys.

Performance Comparison of Al-Ti Master Alloys with Different Microstructures in Grain Refinement of Commercial Purity Aluminum

Three types of Al–5Ti master alloys were synthesized by a method of thermal explosion reaction in pure molten aluminum. Performance comparison of Al–5Ti master alloy in grain refinement of commercial purity Al with different additions (0.6%, 1.0%, 1.6%, 2.0%, and 3.0%) and holding time (10, 30, 60 and 120 min) were investigated. The results show that Al–5Ti master alloy with blocky TiAl₃ particles clearly has better refining efficiency than the master alloy with mixed TiAl₃ particles and the master alloy with needle-like TiAl₃ particles. The structures of master alloys, differing by sizes, morphologies and quantities of TiAl₃ crystals, were found to affect the pattern of the grain refining properties with the holding time. The grain refinement effect was revealed to reduce markedly for master alloys with needle–like TiAl₃ crystals and to show the further significant improvement at a longer holding time for the master alloy containing both larger needle–like and blocky TiAl₃ particles. For the master alloy with finer blocky particles, the grain refining effect did not obviously decrease during the whole studied range of the holding time.

In vitro degradation and cytotoxicity response of Mg-4% Zn-0.5% Zr (ZK40) alloy as a potential biodegradable material

Mg-4 wt.% Zn-0.5 wt.% Zr (ZK40) alloy was studied as a candidate material for biodegradable metallic implants in terms of its biocorrosion resistance, mechanical properties and cytocompatibility. The corrosion characteristics of ZK40 alloy were assessed by potentiodynamic polarization and immersion testing in DMEM+10% FBS solution. Analysis of the degradation characteristics by potentiodynamic polarization measurements shows the corrosion rates of ZK40 alloy in as-cast and solution treatment (T4) condition were slightly higher than those of pure Mg or as-drawn AZ31. Determination of the corrosion rate by the weight loss technique reveals that the as-cast ZK40 resulted in slower degradation than other alloy specimens after 7 days of immersion but exhibited accelerated degradation after 14 and 21 days, respectively. T4-treated ZK40 exhibited stable degradation rates compared to as-cast ZK40 and close to those of pure Mg and AZ31 during immersion testing for 14 and 21 days. In order to examine the in vitro cytocompatibility of ZK40 alloy, live/dead cell viability assay and indirect MTT assay were performed using a murine osteoblast-like cell line (MC3T3). After 3 days of direct culture of MC3T3 on ZK40 alloys the live/dead assay indicated favorable cell viability and attachment. The degradation product of ZK40 also showed minimal cytotoxicity when assessed in indirect MTT assay. The mechanical properties of the as-cast and T4-treated ZK40 alloy were superior to those of pure Mg and comparable to as-drawn AZ31. Solution treatment did not significantly enhance the cytocompatibility and mechanical properties of ZK40 alloy. Overall, the ZK40 alloy exhibited favorable cytocompatibility, biocorrosion, and mechanical properties rendering it a potential candidate for degradable implant applications.

Theoretical and Practical Considerations of Grain Refinement of Mg-Al Alloys

The fundamentals of grain refinement are reviewed with particular focus on magnesium alloys. This is followed by considerations of the theoretical and practical aspects of grain refinement of Mg-Al alloys by carbon-based grain refiners. Finally, experimental results using Al4C3 as a potential grain refiner are presented and discussed.