Formation of Porous Structures in Metal–Hydrogen Systems

Crystallization of hydrogen-saturated melts under controlled conditions enables one to obtain a new class of porous materials (gasars). The technological parameters of the process such as the partial hydrogen pressure, the total gas pressure, the temperature of the melt, and the crystallization rate affect the porosity, size and form of pores, which enables one to control the structure of gasars. Using methods of quantitative metallography, we determine conditions of its formation. The most homogeneous nickel ingots of gasars are obtained with increase in the total gas pressure in the system during crystallization of the melt and the decrease in the partial hydrogen pressure. The gas gap between the chill and the ingot appearing in the process of directional crystallization of hydrogen-saturated melts limits heat exchange and leads to a disturbance of the cooperative growth of gas bubbles and crystals. However, the negative influence of this process considerably decreases with increase in the partial hydrogen pressure, which also favors the production of homogeneous ingots of gasars.     

Use of Hydrogen for the Production of Materials with Regulated Porosity

We investigate structural features of new porous materials (gasars) produced with the use of hydrogen. We show that the dimension of the pores and their number and form can be controlled through technological parameters. We note that both ordered and disordered structures are formed in gasars. An ordered structure formed due to gas-eutectic crystallization is called a gasarite. We found bubble and dendritic gasarites and analyzed structural features and conditions of their formation. We selected large, medium, fine, and ultrafine pores in gasarites of various kinds. Structural specific features of gas-eutectic materials enable one to predict their properties and determine conditions of production.     

Gasar—A new Class of Porous Materials

The paper summarizes published data and also deals with technology, structure, applications, and properties of gasars – new porous materials based on original findings obtained by authors. The method consists of melting a material in a gas atmosphere to saturate it with hydrogen and directional solidifying under strictly controlled thermodynamic and kinetic conditions. The materials produced by this method, have a monolithic matrix and pores of proper geometric shapes, providing to gasars higher strength, plasticity, thermal and electrical conductivities as compared with those of other porous materials. Gasar is recommended for prospective application as filters, bearings, metal‐matrix composites.     

Properties of gasars-metallic materials with pores formed by released hydrogen

We developed a new type of porous materials with anisotropic structure based on a large number of metals. It is shown that these material, called gasars, have properties different from the properties of the other porous materials. Thus, the strength of gasars is much higher than the strength of powder materials with the same porosity and their impact toughness is readily regulated by the sizes of the pores. The internal structures of gasars and possible versions of the types of pores in these materials are strongly diversified, which makes the spectrum of their possible applications very wide. We discuss some specific directions of the potential applications of gasars. The results of measurements of the thermal conductivity of gasars and monolithic specimens are presented. It is shown that, for a certain level of porosity, the specific thermal conductivity of gasars is higher than for monolithic materials. We also make some basic conclusions concerning the characteristics of new porous materials. __________ Translated from Fizyko-Khimichna Mekhanika Materialiv, Vol. 43, No. 5, pp. 125–127, September–October, 2007.     

Columnar-EquiaxedTransition inSolidification processing: The ESA-MAP CETSOL project

Many castings are the result of a competition between the growth of columnar and equiaxed grains. Indeed, microstructures are at the center of materials science and engineering, and solidification is the most important processing route for structural materials, especially metals and alloys. Presently, microstructure models remain mostly based on diffusive transport mechanisms so that there is a need of critical benchmark data to test fundamental theories of microstructure formation, which often necessitates to have recourse to solidification experiments in the reduced-gravity environment of space. Accordingly, the CETSOL (Columnar-Equiaxed Transition in SOLidification processing)-MAP project of ESA is gathering together European groups with complementary skills to carry out experiments and model the processes, in particular in view of the utilization of reduced-gravity environment that will be afforded by the International Space Station (ISS) to get benchmark data. The ultimate objective of the CETSOL research program is to significantly contribute to the improvement of integrated modeling of grain structure in industrially important castings. To reach this goal, the approach is devised to deepen the quantitative understanding of the basic physical principles that, from the microscopic to the macroscopic scales, govern microstructure formation in solidification processing under diffusive conditions and with fluid flow in the melt. Pending questions are attacked by well-defined model experiments on technical alloys and/or on model transparent systems, physical modeling at microstructure and mesoscopic scales (e.g. large columnar front or equiaxed crystals) and numerical simulation at all scales, up to the macroscopic scales of casting with integrated numerical models.     

熔体过热处理技术及其在镍基高温合金中的应用研究进展

镍基高温合金是先进航空发动机高温叶片不可或缺的关键核心材料,目前通过合金化来提高其承温能力已趋于极限。研究表明,材料熔体结构对合金凝固过程、凝固组织、性能以及成形质量具有重要的影响。熔体结构的变化能够直接导致熔体特性发生改变,进而对性能产生影响,然而在实际合金的制备过程中,熔体结构的作用通常被忽略。熔体过热处理技术通过利用合金熔体的遗传效应,将高温熔体的结构保留到低温熔体,从而大幅提高合金性能。系统介绍了熔体过热的原理、主要处理技术以及如何通过X射线衍射和物性参数测量来确定熔体过热处理参数,重点介绍了熔体过热处理技术在优化高温合金凝固组织和提升性能方面的应用,最后提出了熔体过热处理技术发展的方向和面临的挑战。     

Tailoring of dendritic microstructure in solidification processing by crucible vibration/rotation

Directional solidification of alloys, which allows the independent control of growth parameters (pulling velocity, temperature gradient), is an experimental method of choice for the investigation of many fundamental problems (e.g. microstructure formation and selection, segregation of chemical species) encountered in the processing of structural materials. Upward directional solidification is carried out on hypoeutectic Al-Ni alloys, under natural and controlled fluid-flow conditions. First, the influence of natural convection on solidified dendritic microstructure is analyzed as a function of growth parameters. Then, directional solidification experiments with axial vibration are performed. It results that crucible vibration can be used to either damp or control fluid flow in the melt, and thus tailor columnar or “equiaxed” dendritic mush. Advanced modeling and numerical simulation are essential to clarify and quantify the various physical effects. Microgravity benchmark experiments under diffusion transport, and possibly with crucible rotation, are foreseen using the Materials Science Laboratory of ESA on ISS.     

1Cr18Ni9Ti不锈钢双辊薄带凝固组织区的形成机理

在双辊薄带连铸实验和薄带凝固组织特征分析的基础上,结合对薄带凝固组织区的模拟预测结果,研究了1Cr18Ni9Ti不锈钢双辊薄带凝固组织区(特别是等轴晶区)的形成机理.结果表明:1Cr18Ni9Ti不锈钢双辊薄带凝固组织中的等轴晶区不但在凝固类型为半固态时形成,在轧制或理想型时也能形成.其形成机理为,熔池中悬浮游离晶体的沉积、聚集以及在枝晶生长前沿的长大和薄带离开二铸辊最小间隙(铸辊出口)后,薄带/空气界面换热系数骤然降低抑制了柱状枝晶的生长,并促使薄带中部未凝固熔体中游离晶体的择优长大.     

Computer model of unidirectional solidification of single crystals of high temperature alloys

Abstract

I t has been common practice to use mould withdrawal unidirectional solidification to produce single crystal castings. To grow single crystals successfully, it is important to control several solidification parameters, such as the morphology of the solidification front (solid/liquid interface), thermal gradient, and growth rate during solidification. It is the aim of this study to develop a solidification model that can predict such solidification parameters for various design and operating conditions. The solidification phenomena in the process modelled are basically controlled by two heat transfer mechanisms: conduction and radiation. A set of heat transfer equations and boundary conditions were employed to describe mathematically the heat transfer phenomena. Then the finite difference method was used numerically to solve these equations for specified boundary conditions to obtain the temperature distribution and temperature variation in the casting. The solidification parameters can subsequently be deduced from these temperature data. Several thin plate castings were tested using the model developed. The following design and operating conditions were evaluated: susceptor temperature (power input), withdrawal speed, changes of cross-sectional area in the casting, and geometrical arrangement of the casting tree.

MST/1422     

金属熔体电磁成形过程研究

以制备无污染的航空发动机叶片为背景 ,分析了金属熔体电磁成形定向凝固技术的原理 ,并以铝合金及 1Cr1 8Ni9Ti为研究材料 ,探讨了交流电磁场作用下金属熔体的感应加热熔化及约束成形过程 ,结果表明 :感应器结构决定其内部的磁场及电磁压力分布 ,感应器输入功率、熔体高度、上下液固界面位置、抽拉速度及冷却条件等参数综合影响金属加热熔化特性、熔体形状及其稳定性 ;通过控制合理的工艺参数 ,获得了截面为圆形及近似弯月面形、表面质量和内部定向组织良好的样件 .     

Rapid solidification in thermal spray deposition: Microstructure and modelling

Mechanical thermal and adhesive properties of thermal spray coating are primarily determined by the phase and microstructure of single splats, which ultimately depend on rapid solidification of each splat and on the interactions between the splats and between the splat and the substrate. Significant efforts are being made to develop a better understanding of the physical mechanisms underlying these phenomena. This paper reviews a series of work in the area of mathematical modeling of phase and microstructure formation during the rapid solidification of single splats and coatings. The model development has been complimented by special experiments. Conditions under which plantar interface solidification occurs, columnar celluar or dendritic growth takes place, or banded structure forms, have been identified. A microstructure map can therefore built using the model presented here. The process parameters that promote crystalline nucleation and grain structure formation can be isolated and the effect of interfacial heat transfer, splat substrate temperature difference, and substrate melting and resolidification can be examined using the model. The model prediction agree qualitatively well with the experimental data for alumina, yttria, partially-stabilized zirconia, and molybdenum.     

Modelling the Solidification Microstructure Formation of Cobalt Dendritic Alloys

In the present work a mathematical model has been developed to explain the microstructure characteristics obtained during the solidification process of dendritic cobalt alloys, under ordinary low cooling rate conditions. The model, taking into account physical aspects such as undercooling, cooling rate, solute diffusion, interfacial energy, and dendrite tip morphology, allowed results to explain the experimental microstructure changes observed when the processing conditions were varied. The mathematical model involved micro and macroscopic phenomena occurring during the solidification process of metallic alloys. The solutions of the governing equations were obtained applying a non-coupled scheme, which enables the possibility to simulate the solidification of complex geometry castings.     

A study of the heat parameters during bidirectional solidification

The temperature field and heat parameters are important in controlling metal liquid crystallinity in unidirectional and bidirectional solidification. The temperature field can be divided into three cases: a liquid temperature field; solid temperature field; and a temperature field on the solid-liquid (S–L) interface. Heat parameters can be divided into two cases: technical heat parameters; and solidification heat parameters. The temperature field on the S–L interface and solidification heat parameters are the most important for the structures and properties of materials. The temperature field on the S–L interface is determined by the alloy system, and solidification heat parameters are related to the temperature ield of the environment and technical heat parameters. The temperature ield on the S–L interface is closely related to the solidiication heat parameters.

A theoretical model describing precisely the temperature field on the S–L interface during bidirectional solidification was proposed. A series of heat parameters, including temperature gradients G, solidification rate R, cooling velocity V and characteristic temperature T_c have been derived from this model. A superalloy has been chosen as the experimental object in order to verify the theoretical model. The theoretical calculations are found to be in agreement with the experimental results.     

A study of the heat parameters during bidirectional solidification

The temperature field and heat parameters are important in controlling metal liquid crystallinity in unidirectional and bidirectional solidification. The temperature field can be divided into three cases: a liquid temperature field; solid temperature field; and a temperature field on the solid–liquid (S–L) interface. Heat parameters can be divided into two cases: technical heat parameters; and solidification heat parameters. The temperature field on the S–L interface and solidification heat parameters are the most important for the structures and properties of materials. The temperature field on the S–L interface is determined by the alloy system, and solidification heat parameters are related to the temperature field of the environment and technical heat parameters. The temperature field on the S–L interface is closely related to the solidification heat parameters.A theoretical model describing precisely the temperature field on the S–L interface during bidirectional solidification was proposed. A series of heat parameters, including temperature gradients G, solidification rate R, cooling velocity V and characteristic temperature T_c have been derived from this model. A superalloy has been chosen as the experimental object in order to verify the theoretical model. The theoretical calculations are found to be in agreement with the experimental results.     

中小尺寸高温合金件的无接触电磁成形

介绍了一种新型金属熔体无接触电磁成形技术及其原理,该技术将电磁铸造技术与高梯度定向凝固技术融为一体,对于熔化和成形活泼金属、高温合金难熔金属和高纯金属等中小尺寸构件具有重要的研究与应用价值。另外,从电磁场和凝固过程角度讨论了中小尺寸高温合金样件的电磁成形过程,探讨了工艺参数对成形过程的影响规律,并获得了表面质量较好的高温合金样法。     

材料的成形加工与凝固技术

从对材料成形加工技术进步的分析入手,论述了凝固技术在材料先进成形加工技术中的应用及其重要性。结合对几种凝固新技术的实例的分析指出,不论是传统材料加工过程"控形-控性（控制组织）-控制成本-控制污染"一体化新技术,还是作为新材料研制手段,凝固技术的重要性均是非常突出的。进而分析了近年来受到广泛重视的凝固过程研究的新课题及其由此可能带来的技术进步。     

Bulk synthesis of amorphous and nano‐crystalline materials by spray forming

Bulk amorphous and nano‐crystalline metallic materials have been observed to possess excellent mechanical and physical properties. The conventional process routes, to synthesize such materials, are restricted by their ability to achieve rapid solidification, which limits the dimensions of the materials produced. In the last 10–12 years, spray forming has been employed to avoid these limitations by using its capability of layer by layer deposition of undercooled droplets. The current literature indicates that the opportunities provided by this process can be effectively utilized to produce bulk materials in a single step. In this paper, an attempt has been made to bring out the developments in the synthesis of bulk amorphous and/or nano‐crystalline materials by spray forming. The effect of process parameters, droplet size distribution in the atomized spray, the thermal conditions of droplets prior to deposition and the deposition surface conditions have been discussed. It has been demonstrate that a layer by layer deposition of undercooled droplets of glass forming alloys on a relatively cold deposition surface is the suitable condition to achieve bulk amorphous/nano‐crystalline materials.     

The Research on Surface Technology and Structures for Camouflage Net

This paper is about how to improve camouflage net protecting effect from radar detection, by introducing the layer-composite technology of radar-absorbing materials and optimizing radar-absorbing structure. In the layer-composite technology, materials choices and parameters setting, especially the relation between the content of Phosphor and radar absorption on the Ni-P electroless plating technology, are mentioned. Moreover, four superficial structures, are compared. A conclusion is got that jungle-two structure can do the best to attenuate 5.7 dB over the whole frequency ranges. In addition, according to the theory of the interaction of electromagnetic wave, the study applies physical optics to the RCS computation for optimizing technological parameters and structure by the computing software.