Papers by Keyword: Microstructure Control

Abstract: Nucleation and growth conditions of single-crystallinity control are convincingly elaborated by multi-scale mathematical modeling of heat and mass transport to totally abate undesirable weld defects, e.g. disoriented crystal and hot cracking inside molten pool of nonequilibrium crystallization, in order to illustrate the usefulness of predictive capability through theory and experiment procedures. Crystal growth is complicated by crystallinity-dependent thermal and chemical driving forces in front of dendrite tip during viable laser surface modification of Ni-based single-crystal superalloy. These two thermal metallurgical determinants play crucial role in crack-insusceptible columnar crystal growth, which is favorably oriented throughout weld depth. There is particular challenge in complete elimination of disoriented crystal, i.e. stray grain formation, for acceptable surface quality. Conservative (001)/[100] crystalline orientation is desired to diminish Al concentration and supersaturation, and morphologically satisfy epitaxial growth kinetics to successfully lessen central cracking with satisfactory variability of laser power and welding speed. Comparatively, (001)/[110] crystalline orientation is disadvantageous to asymmetrically augment Al concentration and supersaturation and aggressively increase interface instability, microstructure heterogeneity and hot cracking vulnerability along disoriented crystal boundaries. Disoriented crystal is increasingly withstood if the Al concentration and supersaturation in front of dendrite tip are low enough and crack-unsusceptible part is relatively large enough in case of attractive (001)/[100] crystalline orientation with optimal range of heat input to ameliorate microstructure homogeneity. Crystalline orientation region varies with diverse welding configurations, and epitaxy across solid/liquid interface is also sensitive to heat input of laser processing, which necessitate high efficient welding conditions optimization. Considerable effort is made to distinguish diffusion-driven crystal growth between a series of combinations of multiple welding conditions, such as critical welding configuration and heat input. Metallographically, the morphologies of crystal growth and hot cracking are experimentally observed to consistently support kinetics calculation result and well explain correlation between solidification behavior and crystal growth.

Abstract: In this study a cyclic rotating bending process for microstructure control of metal tubes was newly proposed. The AZ31 magnesium alloy tube was conducted to investigate the effect of the rotating bending process on the microstructure and mechanical properties of metal tubes. The rotating bending process was carried out with rotation speed of 20r/min for 10min at the temperature of 150, 200, 250, 300 and 350°C. The rotating bending processes carried out with various conditions show that the grains in cross-section and longitudinal section of magnesium alloy tube were refined for all samples by the rotating bending process with rotation speed of 20r/min for different rotation numbers and temperatures. The rotating bending temperature shows a various effects on the mechanical properties. When the temperature was 200°C, the highest strength as well as ductility was obtained.

Abstract: In order to spheroidize -Nb5Si3 strengthening phase embedded in Nb matrix for attaining a good room temperature toughness of Nb-Si alloy, the authors have proposed a microstructure control technique by combining eutectic and eutectoid reactions. Nb3Si intermetallic compound formed during solidification is a key phase for the microstructure control, but its stability is very sensitive to the alloying elements. Nb3Si disappears by adding as small as 3 at% of W and Mo, while these elements are very effective for the solid solution strengthening of Nb phase. For a further alloy development, establishment of an alloy design concept based on the control of phase stability of Nb3Si is needed. Similarly to ferrous alloys such as stainless steels where Cr and Ni are added to control the stability of bcc phase and fcc phase, two alloying elements (one is a stabilizing element and the other is a destabilizing element for Nb3Si phase) are added to a Nb-Si binary master alloy and their microstructure is investigated using SEM. The stabilizing element Ta is found to enlarge the composition area where Nb3Si exists even with the destabilizing element Mo, and it is confirmed that the phase stability concept is useful for designing Nb-Si based alloys.

Abstract: Parameters for multi-pass FSP include the pattern of tool traverse and step-over distance between successive passes. Multi-pass FSP was conducted on as-cast NiAl bronze and as-cast AA5083 in order to modify stir zone (SZ) microstructures and mechanical properties. Highly refined and homogeneous SZ microstructures may be produced by FSP. Refined and equiaxed grain structures reflect recrystallization during FSP; mechanisms leading to homogenization by redistribution of microstructure constituents remain to be determined. Refined microstructures exhibit enhanced ambient-temperature properties and superplasticity at elevated temperatures.

Abstract: Silicon nitride (Si3N4) is one of the most attractive materials for wear applications because it has excellent wear resistance and offers advantages such as light weight, higher strength and toughness, and good corrosion resistance. In 1984, Materials Div., Toshiba Corp. (today, Toshiba Materials Co., Ltd.) and Koyo Seiko Co. Ltd. (today JTEKT Corp.) successfully utilized high-strength silicon nitride for anti-friction bearings for the first time in the world.1-3 This ceramic bearing was a most successful product and has expanded in area and volume through key innovations such as pioneered compositions, further improvement of durability against a steel ball and the development of a conventional fabrication process. Since 1989, Yokohama National University group has investigated new materials development in silicon nitride ceramics, densification/strengthening mechanisms in an optimized sintering aids system, powder processing for reliable components and tribological evaluation for bearing applications. Subsequently it was confirmed that the addition of TiO2 and AlN to an Si3N4-Y2O3-Al2O3 system promoted densification at low temperatures.4 During firing, the TiO2 changed into TiN at the grain boundary, causing grain boundary strengthening.5,6 Most recently, it has developed a carbon nanotube (CNT) dispersed silicon nitride with high strength and high electrical conductivity that is expected to open up new applications as a new functional silicon nitride.7 However, there are many items to be overcome toward the future, which are the development of cost reduction processes with higher material reliability, and the opening up of new applications supported by validated evaluation techniques including tribology, flaw detection and life prediction, raw powder problems related to cost and production volume, and the classification of silicon nitride bearings for various graded applications.

Abstract: Microwave (MW) processing is advantageous for processing ceramics with tailored microstructures. Its combination of volumetric heating, a wide range of controlled heating rates, atmosphere control and the ability to reach very high temperatures allows processing of 'difficult' materials like high thermal conductivity AlN and AlN composites and microstructure control in more readily sintered ceramics such as ZnO. MW sintering promotes development of thermal conductivity in AlN (225 W/mK) and its composites (up to 150W/mK inAlN-TiB2 and up to 129 W/mK in AlN-SiC when solid solution is avoided). In ZnO, heating rate controls sintered grain size. Increasing the heating rate from 5°C/min. to 4900°C decreases grain size from ~10 μm (comparable to conventional sintering of the same powder) to nearly the starting particle size (~ 1μm). Microstructural uniformity increases with sintering rate since ultra-rapid MW sintering minimizes the development of thermal gradients due to heat loss.

Abstract: Porous clay materials with columnar type pore channels were fabricated from water-based clay slurry and a specially designed mold by using a freeze casting technique. Ice was stimulated to grow vertical direction, and aligned macro pores were formed to the same direction. The phase separation between the ice and clay particles might be responsible for the formation of the columnar type pores. It appears that it is possible to control the size and morphology of pores by modifying a freezing mold, refrigerant temperature, and the weight fraction of clay in slurry.

Abstract: Aiming for further improvement of mechanical properties of Co3AlC-based heat resistant alloys, microstructure control was conducted using optical floating zone (OFZ) melting. Unidirectional solidification was performed to align Co3AlC/a(Co) two-phase eutectic microstructure. Co3AlC single phase poly-crystal alloys were successfully fabricated for the first time by taking advantage of OFZ. Mechanical properties were evaluated for selected alloys by compression tests at ambient temperature, 1073 K and 1273 K. Excellent elevated temperature strength is achieved in Co3AlC single phase alloys and ductility is sufficiently improved in Co3AlC/a(Co) two-phase alloys.