The role of microstructural evolution during spark plasma sintering on the soft magnetic and electronic properties of a CoFe–Al2O3 soft magnetic composite

Journal of Materials Science - For transformers and inductors to meet the world’s growing demand for electrical power, more efficient soft magnetic materials with high saturation magnetic...     

Fluidized bed heat treatment of cast Al-Si-Cu-Mg alloys

The effects of fluidized bed heat treatment on the microstructural and mechanical properties of Al-Si-Cu-Mg cast alloys, namely, 354 and 319, were studied. The heating rate in fluidized beds (FBs) is greatervis-à-vis conventional electrical resistance furnaces (CFs). The high heating rate in FBs increases the kinetics of metallurgical phenomena such as Si fragmentation and spherodization during solution heat treatment, as well as the precipitation rate of phases such as Al₅Cu₂Mg₈Si₆ and Al₂Cu during aging. It is observed that the dissolution rate of phases such as Mg₂Si and Al₅Cu₂Mg₈Si₆ takes place very rapidly. The solution heat treatment of 319 alloy using FB results in complete dissolution of Mg₂Si and Al₅Cu₂Mg₈Si₆ particles within 45 minutes. However, for phases such as Al₂Cu and Ferich intermetallics, the dissolution rate is relatively slow. Even on prolonged solution heat treatment for 6 hours, these phases do not dissolve completely. It is observed that incomplete dissolution of the Al₂Cu phase does not significantly affect tensile properties of T4-treated alloys. The optimum solution heat-treatment time in FB for both 354 and 319 alloys is 45 minutes at 527 °C and 493 °C, respectively. Thermal analysis shows an exothermic peak owing to recrystallization and coarsening of eutectic grains during solution heat treatment. The high heating rate in FB causes this transformation to take place at a lower temperature than in CF. It is observed that the nucleation rate of Al₅Cu₂Mg₈Si₆ during aging in FB is greater than using CF. Thermal analysis of samples during the ramp-up stage while aging using FB did not show any phase transformation, while those using CF show two endothermic transformations, which are most likely due to the dissolution of GP zones or the co-cluster of solutes. Aging at 200 °C results in a greater number density of precipitates than those at 240 °C. The tensile strength of samples aged at 200 °C is greater than those aged at 240 °C, because the amount of precipitates formed at 200 °C is greater than that at 240 °C. The total heat-treatment time for T6 temper is less than 2 hours in FBs, which is a significant reduction in heat-treatment time, as well as energy consumption.     

Three-Dimensional Solution and Experimental Confirmation for the Electric Resistivity Testing of Surface-Breaking Defects in Green-State Powder Metallurgy Compacts

This paper investigates electrostatic voltage distributions around a surface-breaking flaw due to an injected current of known strength. The direct 3-D solution of the voltage behavior over the flawed surface is obtained numerically by the use of a boundary integral formulation. A novel iteration method is applied to solve the resulting electrostatic integral equation for the unknown surface voltage distribution. In addition to investigating the sensitivity of different flaw sizes to the observed surface voltage distribution, important issues such as suitable probe spacing and current flow orientation are studied. For sufficiently small surface-breaking flaws, a simple image source model is developed to evaluate the voltage response of hairline cracks. The model is tested by comparing it with the developed numerical solution. Experiments aimed at establishing the validity of the modeling approach show remarkable agreement with the theoretical model.     

Melting metal powder particles in an inductively coupled r.f. plasma torch

A numerical model is developed for the prediction of melting metal powder particles in an inductively coupled r.f. plasma torch. The model is developed for dilute spray conditions where the gas phase flow is not affected by the loading condition. The governing equation for the gas phase flow contains the source terms from the electromagnetic field. The theoretical calculations have shown that particle thermal history and its velocity are greatly affected by the plasma operating conditions (i.e., carrier gas flow rate, injector location, and power level,etc.). Without the proper control of particle trajectories, particles may bounce around the fireball and exit the torch as unmelted or resolidified solid particles. With the insertion of an injector or injecting particles with a high carrier gas flow rate, the predictions show that even relatively small size particles can be directed into the fireball and maintained in the molten state before they impact on the substrate. Consequently, more uniform and dense deposits can be achieved.     

Identification of Depth and Size of Subsurface Defects by a Multiple-Voltage Probe Sensor: Analytical and Neural Network Techniques

A theoretical study was conducted using a multiple-voltage probe sensor for detecting nonconducting inclusions in conducting media. Results show that the multiple-voltage probe sensor is capable of providing precise quantitative measurements of submerged nonconducting objects if the surface voltage response has a standard two-peak form. The standard response is observed for well-localized non-slender single inclusions below the sensor surface. In this case, the peak separation distance is associated with the inclusion depth whereas the peak magnitude is associated with the inclusion volume. Linear dependencies of the inclusion depth and the inclusion volume are observed for a wide variety of inclusion shapes. The predefined form of the surface voltage response makes it feasible to identify useful signal responses at very high noise levels. This is accomplished by using a 2D neural network classifier, based on the probabilistic neural network. A reasonable recognition error of less than 20 % is obtained if the signal-to-noise ratio is larger than or equal to 1/10. A metal casting example shows that the multiple-voltage probe sensor can measure inclusion concentrations in hot conducting melts (gas bubbles and sludge) with inclusion radii in the range from 100 to 1000 m. In contrast to existing particle counter technology, this sensor construction is simple to construct and does not require special aperture and vacuum treatment.