Papers by Author: Akira Ikenaga

Abstract: We focused on the surface reinforcement of Al casting alloys with Ni-Al intermetallic compounds by in-situ combustion reaction to improve the surface properties of Al casting components. Microstructure and phase formation behavior of Ni-Al based intermetallic compounds synthesized by combustion reaction were investigated in terms of thermal and phase analysis using scanning electron microscope(SEM) equipped with energy dispersive x-ray spectrometer (EDS) and x-ray diffractometer(XRD) in Ni-Al intermetallic compounds. Three kinds of nickel aluminides, NiAl3, NiAl and Ni3Al, were synthesized by emission heat from the Al molten metal in order to form a coating layer of intermetallic phase simultaneously on the solidifed Al alloy surface. The synthesized shapes and microstructures of nickel aluminides were varied by casting temperature, Si contents, and the mixing ratio of elemental powders. The synthesized reaction products formed in nickel aluminides were observed to be different depending on the mixing ratio of elemental powders. The reaction layer of about 25
m thickness was formed at the interface, and it mainly consisted of NiAl3 phase by the reaction between liquid molten Al alloy and solid Ni powders in green compact. With this information, we successfully produced a coating layer of Ni3Al intermetallic compound onto the casting Al alloy surface using molten metal heat without any additional process. These findings led us to conclude that a near-net shaped nickel aluminide coating layer can be formed using this unique process.

Abstract: The Ni3Al intermetallic compound is of great interest because of its oxidation, corrosion-resistance, and high melting point. The low-temperature hot press + thermal diffusion process method is a technique that uses the thermal reactive diffusions between the elements that compose the intermetallic compound. In this method the powder mixture is heated and be able to generate the diffusions of the powder elements by keeping the heating temperature comparatively lower temperature with other technique. The authors evaluated the preparation conditions and joining quality in Ni3Al coating layer of particular interest is the residual stress due to the different mechanical properties of the coating and the substrate and its effect on the interface joining quality. It is known that residual stresses were generated by the difference in the coefficient of thermal expansion (CTE) of coating and substrate during cooling process. Such a residual stress caused by the differences of mechanical properties has strong influence on composite material strength. X-ray stress measurement techniques has been developed for experimental determination of residual stresses. In this paper, the Ni3Al intermetallic compound was coated on spheroidal graphite cast iron and austenite stainless steel using the reactive sintering method. Wear characteristics and residual stress on these intermetallic compound layers were investigated to evaluate the effect of substrate materials on coating layer properties.

Abstract: Mold filling characteristics in the Mg Expendable Pattern Casting(EPC) process were investigated in terms of casting conditions such as reduced pressure, pouring temperature and casting modulus including foam materials. With increasing pouring temperature up to 775oC the filling velocity increased. However, the filling velocity decreased at temperatures above 775oC. This is likely due to the increase of back pressure. Concerning the effect of reduced pressure on filling velocity, it increased sharply at lower reduced pressure while became stable at higher reduced pressure. In thick pattern, high reduced pressure would be needed to obtain high filling velocity. In expanded polystyrene(EPS) patterns, mold filling was found to be faster in the thick pattern than thin pattern at temperatures below 750oC. This propensity was observed to be reverse at pouring temperatures above 750oC. In polymethyl methacrylate(PMMA) patterns, the filling velocity almost leveled off without showing a dependence of pouring temperature. This result is attributed to the difference in gas pressure between EPS and PMMA patterns during the EPC process.

Abstract: Nickel aluminide based intermetallic compounds were combustion synthesized from a powder mixture of elemental Al, Ni, and Si and were simultaneously bonded with spheroidal graphite cast iron substrate (FCD). Addition of Si to the elemental mixture of Al and Ni was confirmed to be effective both to the densification of combustion synthesized intermetallic compounds and to the joining between compounds and FCD. When the composition of precursor was Ni-69at%Al-9at%Si (Al/Si is the ratio of the eutectic composition), Al3Ni and Al6Ni3Si were mainly combustion synthesized. In the interface between compounds and FCD, reaction layers were formed to the thickness of 10 µm and the constituent phases were identified as Al7Fe2Si, FeAl3 respectively. In the four point bending test of the dissimilar joints prepared by heating at 973 K for 300 s, the brittle fracture did not occurred around the joint interface but mainly in the inside of nickel aluminide coating. The interface of reaction layers with 10 µm were chemically well bonded. The sample with Ni-69at%Al-9at%Si coating exhibited highest bonding strength of about 56 MPa because of the smallest void ratio of the obtained compounds.