Papers by Author: Sonja Steinbach

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Authors: Sonja Steinbach, Johannes Dagner, Marc Hainke, Jochen Friedrich, Lorenz Ratke
Abstract: A quantitative understanding of the effect of fluid flow on the microstructure of cast alloys is still lacking. The application of time dependent magnetic fields during solidification offers the possibility to create defined flow conditions in solidification processing. The effect of rotating magnetic fields (RMF) on the microstructure formation in cast Al-alloys (Al-7wt.%Si, Al-7wt.%Si- 0.6wt.Mg) is studied experimentally and numerically. The forced fluid flow conditions result in pronounced macrosegregation effects and affect microstructural parameters. With increasing fluid flow the primary dendrite spacing decreases whereas the secondary dendrite arm spacing increases. The experimental analysis is supported by a rigorous application of numerical modeling with the software package CrysVUn.
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Authors: Galina Kasperovich, Sonja Steinbach, Lorenz Ratke
Abstract: Gradient annealing experiments of a near-eutectic AlCu30 alloy with artificial stirring induced by a rotating magnetic field (RMF) of 6 mT were performed. The specific surface area of the primary phase was measured on metallographic sections perpendicular to the sample axis with a fixed amount of fraction solid. The variation of the specific surface area with fluid flow is compared to flow free experiments: the specific surface area varies as the inverse cube root of annealing time if no RMF is applied, but varies as an inverse forth root at 6 mT. The experimental procedure and results are presented in detail and discussed with models of convective coarsening of dendrites.
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Authors: Gerhard Zimmermann, Elke Schaberger-Zimmermann, Sonja Steinbach, Lorenz Ratke
Abstract: This paper provides an analysis of the formation of intermetallic phases in AlSi7Fe1 alloy in samples processed onboard the ISS. Based on axial 2D cross-sections obtained from regions of pure diffusive growth and also solidified with forced melt flow, the sizes and distribution of intermetallic β-Al5FeSi phases were determined for different solidification velocities. In diffusive case the phases are larger and more homogeneously distributed than in case of induced melt flow. Additionally, especially for lower solidification velocity, the enrichment of Si and Fe in the centre part of the sample results in a few but rather large β-Al5FeSi particles.
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Authors: Sonja Steinbach, Lorenz Ratke
Abstract: In this paper we report on a new optical technique to measure in situ the fraction solid during solidification. The technique utilizes the extreme properties of silica aerogels, being optically transparent in the visible and near infrared. From measured brightness time profiles the fraction solid can be derived using a suitable theoretical approach. The technique is tested on a technical AlSiMg alloy (A357) solidified directionally in the furnace facility Artemis. The results are compared with the well known theoretical expressions of the lever rule and the Scheil relation. The measured fraction solid as a function of temperature agrees well with model of Scheil which shows the capabilities of the new technique.
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Authors: Lorenz Ratke, Sonja Steinbach, Georg Müller, Marc Hainke, András Roósz, Yves Fautrelle, M.D. Dupouy, Gerhard Zimmermann, A. Weiß, Hermann-Josef Diepers, Jacques Lacaze, R. Valdes, G.U. Grün, H.-P. Nicolai, H. Gerke-Cantow
Abstract: The MICAST research program focuses on a systematic analysis of the effect of convection on the microstructure evolution in cast Al-alloys. The experiments of the MICAST team are carried out under well defined thermally and magnetically controlled, convective boundary conditions and analyzed using advanced diagnostics and theoretical modeling, involving phase field simulation, micro-modeling and global simulation of heat and mass transport. The MICAST team uses binary, ternary and technical alloys of the Al-Si family. This paper gives an overview on recent experimental results and theoretical modelling of the MICAST team.
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Authors: Olga Budenkova, Florin Baltaretu, Sonja Steinbach, Lorenz Ratke, András Roósz, Arnold Rónaföldi, Jenõ Kovács, Anna Maria Bianchi, Yves Fautrelle
Abstract: Recently several experiments on directional solidification of Al-6.5wt.Si-0.93wt.%Fe (AlSi7Fe1) alloy were performed under terrestrial conditions and onboard the International Space Station (ISS) in the Materials Science Lab (MSL) with use of electromagnetic stirring and without it. Analysis of the samples showed that stirring with a rotating magnetic field lead to the accumulation of iron-rich intermetallics in the center of the sample and influenced the primary dendrite spacing while the secondary dendrite arm spacing were not affected. In the present paper the accumulation of the intermetallics b-Al5SiFe in the center of the samples due to RMF stirring is demonstrated numerically and the evolution of primary and secondary dendrite arm spacing is discussed.
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Authors: Marc Hainke, Sonja Steinbach, Johannes Dagner, Lorenz Ratke, Georg Müller
Abstract: The solidification microstructure is the consequence of a wide range of process parameters, like the growth velocity, the temperature gradient and the composition. Although the influence of these parameters is nowadays considerably well understood, an overall theory of the influence of convection on microstructural features is still lacking. The application of time dependent magnetic fields during directional solidification offers the possibility to create defined solidification and flow conditions. In this work, we report about solidification experiments in the ARTEMIS and ARTEX facilities including rotating magnetic fields (RMF). The effect of the forced melt flow on microstructural parameters like the primary and secondary dendrite arm spacing is analyzed for a wide range of magnetic field parameters. The experimental analysis is supported by a rigorous application of numerical modeling. An important issue is hereby the prediction of the resulting macrosegregation, i.e., differences in the composition on the scale of the sample (macroscale) due to the RMF. For the considered configuration and parameters an axial enrichment of Si is found beyond a certain magnetic field strength. The results are compared to available theories and their applicability is discussed.
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Authors: Sonja Steinbach, Natasja Euskirchen, Victor T. Witusiewicz, Laszlo Sturz, Lorenz Ratke
Abstract: Technical Al-Si alloys always contain sufficient amounts of Fe and Mn, especially alloys made from scrap. During casting, Fe-containing intermetallics, such as Al-Fe, Al-Fe-Si and Al-Fe- Mn-Si phases, are formed between the aluminum dendrites. Fe and Mn-rich intermetallic phases are well known to be strongly influential on mechanical properties in Al-Si alloys. In the present work the influence of controlled fluid flow conditions on the morphology and spatial arrangement on intermetallic phases in cast Al-Si alloys is characterized. A binary Al-7wt.%Si and a ternary Al- 7wt.%Si-1wt.%Fe alloy was solidified under and without the influence of a rotating magnetic field (3mT at 50Hz) over a range of solidification velocities (0.015- 0.18mm/s) at a constant temperature gradient G of 3K/mm. The scientific results reached so far indicate a strong influence of the electromagnetic stirring on the primary dendrite and secondary dendrite arm spacings.
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