Papers by Author: Barry C. Muddle

Abstract: The thermal stability of constituent particles in both as-cast and homogenised alloy AA7150 has been investigated by means of scanning electron microscopy (SEM) and differential scanning calorimetry (DSC). The results indicate that the as-cast eutectic starts to melt at 474°C and that the melting onset temperatures of the η- and S-phase particles after homogenisation are 474°C and 484°C, respectively. Two types of homogenisation treatments were used to dissolve eutectic particles: a two-step homogenisation treatment (40 h at 465°C + 4 h at 480°C) can completely dissolve the η- and S-based constituents, whereas a significant amount of S-phase still exists after a single-step homogenisation treatment of 40 h at 465°C. After utilising the two-step homogenisation treatment to dissolve all the η- and S-based constituents without overheating, samples were cooled at different controlled cooling rates and analysed by SEM and DSC to understand the effect of cooling rate on the type, size, distribution and density of precipitates formed during the cooling process. Slow cooling was found to result in the precipitation of coarse η-phase particles, with both the amounts and sizes of these η-phase particles increasing with decreasing cooling rate.

Abstract: The precipitation of a-phase has been investigated in a concentrated b-alloy of the Ti-V-Cu system. a-precipitates in geometrically coupled forms were developed in the alloy when subject to isothermal ageing at 500°C. High-resolution transmission electron microscopy (HRTEM) revealed that a-phase embryos tend to nucleate in a symmetrical manner directly from an early-stage solute-partitioned diffusional product. The a-precipitates so developed constitute twin-related variants characterized by a twin plane lying on one of the {0111}_a planes. The results are discussed with respect to the role of Cu on the formation of heterogeneous nucleation sites for a-phase.

Abstract: In this work, the influence of multi-step solution (MSS) treatments on the constituent particle dissolution, overheating and associated quench cracking behaviour in room temperature water-quenched 7150 Al alloy has been investigated. For comparison, the microstructure and quench cracking behaviour of single step solution treated samples water-quenched from 505°C were also investigated. Based on optical microscopy of differently quenched samples, the quench cracking mode and the influence of overheating of constituents on the quench cracking behaviour have been demonstrated. The results reveal that the constituent particles can be effectively dissolved in the MSS-505°C samples. When the quench temperature of MSS-505°C samples is equal to or higher than 485°C , macro quench cracks can be clearly observed. Moreover, the density and length of the quench cracks increase with increasing quench temperature. Etched microstructures indicate that the quench crack propagation mode is intergranular. However, for samples directly heated to 505°C , typical overheating can be observed at the triple junctions and these regions preferentially act as crack propagation routes.

Abstract: The effect of different pre-ageing treatments on the subsequent artificial ageing response of Al-Mg-Si(-Cu) alloys have been investigated using hardness, tensile and electrical conductivity testing. The microstructural evolution was characterised by differential scanning calorimetry (DSC) and 3-dimensional atom probe (3DAP) analysis. Pre-ageing treatments were carried out at 160-250°C for short times. Results show that the early stage artificial ageing response after 30 minutes at 170°C is strongly influenced by the pre-ageing and natural ageing conditions. A pre-ageing treatment performed for a short time at a high temperature and within a short delay after solution treatment and quenching was found to give a promising hardening response during subsequent artificial ageing. The mechanisms by which pre-ageing can reduce the detrimental effect of natural ageing on the artificial ageing response will be discussed in relation to the formation and distribution of clusters, GP zones and/or precipitates.

Abstract: The composition of  precipitates in aluminium alloy 8090 has been analysed using a 3 dimensional atom probe with fast data acquisition rates. The effects of experimental conditions for the quantitative atom probe analysis have been examined in detail. The results show that i) lithium is prone to preferential DC field evaporation at temperatures > 25K and with a pulse fraction < 20%; ii) the lithium concentration of  precipitates can vary from precipitate to precipitate, ranging from 19.1 to 25.3 at.%, and iii) the stoichiometric composition of the  phase can be obtained provided that the probing temperature is  25K and pulse fraction is  20%.

Abstract: Plate samples of Al-2Sc were processed with an electron beam (EB) gun in a vacuum of 10-3 Pa at 50kV and 30 µA. EB processing suppressed the formation of primary Al3Sc, altered the morphology of the eutectic (Al)-Al3Sc, and increased the solubility of Sc in the eutectic (Al). In addition, its cyclic heating effect induced the precipitation of Al3Sc. EB processing resulted in more profound hardening than conventional high temperature solid solution and ageing.

Abstract: A good combination of high strength and hardenability makes the alloy Ti 10V-2Fe-3Al a prime candidate for applications in the aerospace arena. However, these properties are very dependent on a post-forming heat treatment. The overall objective of this work is to determine the effect of prior deformation on the aging behaviour. In this particular study, the influence of the heat treatment, either solution and/or aging, on the microstructures, and consequently on the mechanical properties, without introduced strain is reported. Various solution heat treatments have been conducted, either in the β phase or in the (α+β) phase field, followed by rapid quenching or slow cooling, and aging treatments at different temperatures (250, 350, 400, 500C°) above and below the ω-transus temperature. Vickers hardness indentations were used to follow the precipitation hardening behaviour, and mechanical properties were determined using a shear punch test. The aging response is dependent not only on the presence of the athermal ω phase but also on the proximity of the aging temperature to the ω-transus. Most treatments showed an unusual initial softening behaviour prior to age hardening, however this appears to be related again to the composition and fraction of the β phase retained after solution treatment.

Abstract: The green strength of a powder compact results from the mechanical interlocking of the irregularities on the particle surfaces. During compaction, particle rearrangement, plastic deformation and particularly surface deformation of powders occur. Titanium powder is susceptible to interstitial element contamination, which may lead to solid solution strengthening of the particles and/or the formation of non-metallic compounds on the surface. However, the influence of these various impurities, namely oxygen and nitrogen, on the green strength has not been investigated. This work investigates and quantitatively evaluates the factors influencing the green strength of the powder compacts. The indirect tensile test was applied for the determination of the green strength of the powder compacts, and test results were compared to that of a more conventional 3-point bending test. The substantial dependence of green strength on both the amount of impurity element in the core of the powder particles and the compaction pressure is demonstrated. The effect of the surface condition of the powder particles on green strength is also reported.

Abstract: Electron beam (EB) direct manufacturing is an additive near-net shape digital fabrication process developed recently. The process offers a promising route for the fabrication of intricate speciality aluminium alloy parts for aircraft and aerospace applications because of the excellent energy coupling between an electron beam and aluminium. As part of a fundamental study on EB manufacturing of Al alloys, this work investigates the effect of the EB processing parameters on the development of the molten pool and the solidification characteristics of Al 2219 and Al 6061 alloys. The samples were processed using a 50kV electron beam gun over a wide range of beam currents (10-40mA) and welding speeds (0.3-0.86m/min) in both the static and oscillation focus modes. In the static focus mode, the molten pool is wedge-shaped; while in the oscillation focus mode, the molten pool is hemispherical, wider and shallower. In both cases, the depth and width of the molten pool increase with increasing beam current but they are less affected by the moving speed of the EB gun in the range 0.3-0.86m/min. Electron beam re-melted and subsequently re-solidified Al 2219 and Al 6061 alloys show microstructural features distinct from those obtained under sand casting and direct chill casting conditions. In particular, fine intermetallic precipitates in the size range 100-200nm are prominent in the equiaxed grains formed in the re-solidified weld beads of Al 6061 compared to the coarse intermetallic particles up to 10m in size prior to EB processing. EB processing offers opportunities for aluminium alloy development.

Abstract: The range of commercial titanium alloys available is currently extremely restricted, with one alloy (Ti-6Al-4V), and derivatives of it, accounting for a very large proportion of all applications. High performance alloys are costly to fabricate and limited to low-volume applications that can sustain the cost. With the emergence of new processing technologies that promise to reduce significantly the cost of production of titanium metal, especially in powder form, there is an emerging imperative for cost-effective near net shape powder processing techniques to permit the benefit of reduced metal cost to be passed on to higher-volume applications. Equally, there is a need for the design and development of new alloys that are intrinsically low-cost and lend themselves to fabrication by novel cost-effective net shape processing. The approaches that might be used to select, design and process both conventional alloys and novel alloy systems will be reviewed, with a focus on innovation in design of low-cost alloys amenable to new processing paths and increasingly tolerant of variability in composition.