Papers by Author: Barry C. Muddle

Abstract: Powder metallurgy is widely used to produce alloys with low cost of production. The main drawback using powders is the level of residual porosity of final product which often implies the application of a complicated and costly hot isostatic pressing process. However, this issue can be overcome by using equal channel angular pressing (ECAE) with back pressure (BP). The use of severe shear deformation, with imposed hydrostatic pressure, allows a reduction in the range of compaction temperatures compare to those used in conventional practice. The compaction of Ti-6Al-4V powder by the ECAE method has been investigated. The compaction has been performed at temperatures starting from room temperature (RT) and increasing up to 400°C with various back pressures ranging from 0 to 350MPa. A billet processed by ECAE with 43MPa back-pressure at 400°C was found to have improved relative density of 97.5% and increased Vickers hardness of 369HV, compared to values of 96.7% and 325HV respectively obtained at RT. A relative density of 98.2% and 426HV hardness were measured for billets processed with BP = 262MPa at 400°C. A fully compact billet was obtained by applying 350 MPa of BP at 400°C.

Abstract: The effect of Si additions on vacancy behavior following solution treatment and quenching was studied for an Al-Cu-Mg-Ag alloy system using positron annihilation lifetime spectroscopy (PALS). Both the initial positron lifetime and steady state positron lifetime increase as the Si concentration increases. This behavior is interpreted in terms of Si interacting with vacancies, leading to their retention in the alloy. The ability of PALS to monitor vacancy behavior after solution treatment should allow the improved prediction of phase transformation kinetics and hence the tailoring of ageing treatments.

Abstract: Nuclear magnetic resonance (NMR) was used to systematically monitor the amount of copper in the matrix of various age hardenable Al-Cu alloys as a function of ageing treatment. These NMR results were used to compare the measured amount of copper residing in the matrix during microstructural evolution with that suggested from the equilibrium phase diagrams. Our results indicate that the matrix copper composition for under- and peak-aged microstructures is generally far from equilibrium, with much more copper in solution than expected based on equilibrium phase diagrams. NMR is shown to be a sensitive and efficient metallurgical characterization technique to monitor the partitioning of solute in both non-equilibrium and equilibrium phases.

Abstract: The ability to improve mechanical properties through trace alloying additions that enhance the precipitation-hardening response has been a cornerstone of aluminium research and alloy development. It is now known that many of these alloying additions are beneficial (or deleterious) because of their influence on the competitive precipitation kinetics, in many cases arising from the formation of chemical and structural heterogeneities in the matrix. In order to better our understanding of this phenomenon, the earliest stages of microstructural evolution of indium precipitates and θ' plates in an Al-Cu-In ternary alloy have been investigated. Quantitative microstructural characterization reveals that there is a correlation between the size of the pre-existing indium particle and the resulting heterogeneous precipitation kinetics, with larger indium particles favouring θ' precipitation.

Abstract: The trace additions of Ag to binary Al-Mg alloys promote precipitation of a phase in the under-aged condition. The structure of the phase in an Al-10Mg-0.5Ag (mass%) alloy have been characterised using transmission electron microscopy and electron microdiffraction. An icosahedral quasicrystalline phase, which is identified by the electron microdiffraction patterns, has been found in the Al-10Mg-0.5Ag (mass%) alloy after solution treatment, water quenched and then aged during the time between 20 and 40 min. at 513K. The orientation relationship between the quasicrystalline phase and the a - Al matrix is as follows; i5 // <011>a and i3 // <111>a. A uniform distribution of finer-scale (typically 20 nm), faceted precipitate icosahedral quasicrystalline particles was observed within the core of the grains, but the precipitates became coarser (60-80 nm) approaching the grain boundary precipitate-free zone. The quasicrystalline particles contain elements of Al, Mg and Ag. The quasicrystalline precipitate particles, which are the metastable phase, appear to be the primary strengthening phase in the Al-10Mg-0.5Ag (mass%) alloy aged at 513K.

Abstract: The interaction between vacancies and Sn and Cu solute atoms in an Al-1.7at.%Cu- 0.01at.%Sn alloy was investigated by exploring the effect of incorporating natural ageing into conventional age hardening treatment. It was found that provided the artificial ageing temperature does not exceed a critical value between 160°C and 200°C, a narrow window of natural ageing (3-100 h) will result in a significant acceleration of the age hardening response and no decrease in peak hardness. Transmission electron microscopy showed that this effect reflects a large and rapid increase in number density of Cu GP(I) zones, and, to a lesser extent, of θ". The distribution and number density of θ' are essentially unaffected. Three-dimensional atom probe provided strong evidence that refinement of GP(I) zone distribution is not due to clustering of Cu atoms onto pre-existing Sn clusters. Instead it appears to be caused by a subtle interaction between vacancies, Sn and Cu atoms.

Abstract: Regardless of whether it is cast microstructure, the grain structure that is the product of thermomechanical processing or the nanoscale dispersions of strengthening second-phase particles, it is inescapable that the structural scale that controls mechanical properties in Al alloys is determined primarily by processes of nucleation during either solidification, recrystallisation or solid-state phase transformation. In those advanced alloys with bulk amorphous or nanocrystalline structure, production of an amorphous precursor is reliant on initial suppression of the nucleation of crystallisation, and subsequent controlled nucleation of dispersed nanocrystals within amorphous matrix. The processes of nucleation that control structural scale in modern Al alloys are briefly reviewed, with a focus on potential for further structural refinement and advances in properties.