Papers by Author: Mark Easton

Abstract: The Interdependence model currently uses an analytical expression for a moving planar interface to calculate the solute diffusion length designated as x’_dl in the model. Upon nucleation within an alloy melt (i.e. when the solid embryo starts to grow), the interface grows with a spherical front which then breaks down into a dendritic interface. The time required for this breakdown is a subject for separate research. In this paper, we explore the validity of using a planar interface in the early stages of nucleation and growth of metal alloys as used in the Interdependence model. The diffusion field ahead of a planar interface, in theory, has an exponentially changing composition of infinite length. In the Interdependence model, x’_dl is assumed to be where this exponentially decreasing composition profile in the liquid ahead of the interface (for k < 1) reduces to within 1% of a quantity proportional to the nominal alloy composition, C₀, far from the interface. A numerical solidification model, μMatIC, is used to simulate the growth of a single grain with a dendritic interface in 2D and 3D. The numerical model is capable of generating the solute profile ahead of the growing grain which is used to evaluate the solute diffusion length that can be compared with the results obtained from the planar interface model. The comparisons were made with both 1% and 0.1% cut-off criteria. The results indicate that the 1% assumption being used in the planar front diffusion length calculation is a good approximation for the Interdependence model.

Abstract: Control of impurity elements in Al-based alloys is of increasing technological importance, both in primary and secondary alloy production. In primary alloy production, Ni and V concentrations in the coke are rising and this is increasing the level of impurities in the final products to the extent that they are out of specification. Impurity control is also of concern in recycling due to the pickup of elements such as Fe from contaminants in the scrap, which can detrimentally affect the alloy properties. Dissolved elemental impurities can be removed by a number of different processes including boron treatment for some of the transition metals. Other processes in the cast shop for removing impurities and inclusions from Al melts include fluxing, floatation, and filtration. Gas purging, vacuum treatment, filtration, the use of salts, and combinations of these presently find commercial applications. Ultra purity Al and its alloys can be obtained using zone refining and three-layer electrolysis methods. The demand for higher purity Al has been largely met by additional electrolytic refining processes. This paper reviews the tools that are currently available to the casthouse for removing impurities and inclusions from Al melts and suggests approaches that may be useful to meet future challenges.

Abstract: In high strength AlMgSi alloys additions of Mn and Cr lead to the formation of dispersoid phases whose primary functions are to improve fracture toughness and control grain structure. Whether or not dispersoid phases form during heating to the homogenisation temperature and which dispersoid forms is strongly dependent on the alloy composition. By correlating dispersoid features after different homogenisation heat treatments to TEM investigations into the crystal structure, it is proposed that the crystal structure and chemical composition of the dispersoids changes as the dispersoids coarsen at increased temperatures and times.

Abstract: Cross-sectional microhardness maps of cast-to-shape flat tensile specimens have been obtained for a binary Mg-3.44 mass% La alloy. Higher microhardness numbers were generally found near the casting surface, at the corners and along the segregation band. The higher hardness values were ascribed to the finer solidification microstructure near the surface and to localized positive macro segregation. The majority of lower hardness numbers was found at the core region. Lower hardness values were ascribed to the coarser grain size prevalent at the core and to dispersed microporosity. The non uniformity of the harder surface layer in both depth and hardness appeared related to local homogeneities in the grain size distribution caused by the scattered presence of large externally solidified grains.

Abstract: The impact properties of high-pressure die cast Mg-RE alloys were investigated. It was found that, for rare earth contents between 2-4 wt.%, the Mg-La and Mg-Nd alloys performed better than the Mg-Ce alloys in un-notched tests. The notched results appear to be related to the amount of intermetallic. In contrast, the un-notched results indicate that at some compositions the Mg-La alloys out-performed the other alloys when compared to the amount of intermetallic. It was apparent that a lamellar eutectic structure can improve the un-notched impact properties of Mg-RE based alloys even when this is not evidenced in tensile test or notched impact results.

Abstract: Specimens of rectangular and circular cross section of a Mg-9Al binary alloy have been tensile tested and the cross section of undeformed specimens examined using scanning electron microscopy. The rectangular cross sections showed three scales in the cellular intermetallics network: coarse at the core, fine at the surface and very fine at the corners, whereas the circular ones showed only two, coarse at the core and fine at the surface. The specimens of rectangular cross section exhibited higher yield strength in comparison to the circular ones. Possible reasons for the observed increased strength of the rectangular sections are discussed.

Abstract: Grain refinement and hot tearing are important key factors affecting the quality of castings. There have been substantial advances in the understanding of both of these phenomena over the last two decades. The paper discusses strategies for obtaining the lowest cost grain refiner addition and provides an explanation for how the refinement of equiaxed grains leads to a reduction in hot tear susceptibility. However, it also provides a warning that adding more grain refiner may not be better for reducing hot tear susceptibility. Alloy factors affecting hot tearing are also discussed. Finally, a list of six key considerations is provided to help casthouse and foundry engineers when trying to optimise grain refinement and reduce hot tearing.

Abstract: Scanning electron microscopy has been used to characterize the intermetallic structure development across the tensile cross-section of binary Mg-Al alloys with solute content between ~0.5 and 12 mass%Al. The alloys which contain less than 1 mass%Al exhibited a single phase grain structure. For compositions greater than 1 mass% Al, an eutectic network with a discontinuous distribution of intermetallics across the cross-section became apparent. In alloys with greater than 8.77 mass%Al, the intermetallics form a continuous network over the entire cross-section. The scale of the intermetallics network is finer at the surface and corner regions of the cross section in comparison with the core regions.

Abstract: This paper presents an analysis, based on microstructural observations by transmission electron microscopy, of the influence of chemical composition on creep resistance of high pressure die casting (HPDC) Mg-4RE-0.6Zn alloys. The improved creep resistance, by increasing the Nd/La ratio of the rare earth (RE) mixture, is shown to be associated with the supersaturation of Nd solute in the -Mg matrix, evidenced by the formation of Nd-rich precipitates on dislocations after a thermal ageing treatment. The result indicates that solid solution/precipitation strengthening of the -Mg matrix is important to the creep resistance of HPDC Mg-RE based alloys.

Abstract: SiC particles are effective grain refiners in Mg-Al alloys. Several investigations, from different researchers, into their effect on a range of alloys with different Al contents has been undertaken and it has been found that the greatest reduction in grain size occurs in alloys having low Al contents. Performing grain refinement studies on a range of alloy contents also allows for further investigation into the mechanisms of grain refinement. It was found that the size of the SiC particles is also important in magnesium grain refinement. However, the presence of Mg2Si in the microstructure and the consideration of phase equilibria suggest that SiC can transform into other binary or ternary carbides. If such carbides are formed, they may also act as an effective grain refiner for Mg-Al alloys. In this study, the possibility of formation of new carbides (Al4C3, Al2MgC2, Mn7C3, Mg2C, Mg2C3, Al2CO etc.) and their ability to be good grain refiners for Mg-Al alloys is discussed.