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14MT91R03
Sarat
Kunal Kumar Majhi
14MT60R15
Ratikanta Pradhan
14MT60R06
Satyabrata Mishra
14MT60R29
Manik Mahali
14MT60R44
introduction
Rapid solidification processing ,known from its name ,implies that
the metals are rapidly solidified using various techniques. Among
these melt spinning,atomization,laser melting and laser remelting
by electron beam etc..
From the different rapid solidification process, the meltspinning
process is useful owing to its following properties. Meltspinning
creats high cooling rate and has optimization cost:performance
ratio. For very fast solidification, it is necessary to form a small
dimensioned shape.
In the meltspinning process a continuous ribbon is created in
vaccum for most engineering applications. The melt is cast on a
rotating Cu wheel and instant solidification takes place as soon as
the melt hits the wheel.
The ribbon is several millimetres wide and around 80 micron thick.
In this way not only a very high, but also a very optimized
cooling rate is obtained.
Cooling rate (product quality) is a controllable parameter that can
be easily varied by the wheel speed. From the ribbon on two more
steps are needed to obtain a billet.
The ribbon is chopped directly after meltspinning and then
compacted at elevated temperature into a billet.
The density of the billets reaches a level of 99% of the theoretical
density. The RSA billet can then follow the conventional extrusion
route: saw to preferred length, preheat in a billet furnace and
extrude into a profile.
Experimental processes
As part of a continuous process line RSP Technology is
including an alternative compaction and extrusion technique
also known as the Conform process.
Continuous rotary extrusion was a process initially developed
as Conform by the UK Atomic Energy Authority for
processing copper-based materials. The Conform principle is a
continuous process where usually solid bars (from a coil) are
fed into a wheel with a groove.
The wheel transports the rod until it is blocked by a die. The
pressure provided by the rotation of the wheel generates
friction and heat. When temperature and pressure are right,
the metal moves through the die.
To process powders into full density bars encounters big
difficulties, one of the major problems being the tenacious
nature of aluminium oxide on the surface of aluminium-based
powders which inhibits consolidation to high density. The
flakes contain significantly less oxide layers compared to
powders which eases a full consolidation.
At this moment, RSP Technology is capable of processing
flakes into rod sections with diameters up to 90 mm in alloys
varying from AlSi20X to AlCu5FeX.
(melt spinnig)
(Atomisation)
The material studied was an as-cast AZ91D Mg alloy with the
following chemical composition (wt.%): Al 8.97, Zn 0.78, Mn
0.31, Si 0.023, Cu 0.002, Ni 0.0005 and Mg balance.
The specimens were extracted from the ingot, ground with
progressively finer SiC paper (180, 400, 800, 1200, 2400 and 4000
grit), cleaned with alcohol.
Then irradiated with Lumonics JK704 Nd:YAG laser system (with
wavelength of 1084 nm) using the following parameters under
high purity Ar gas protection: power density 3.82 104 W/cm2,
scanning speed 10 mm/s, frequency 100 Hz, pulse duration 1.0 ms,
and spot overlap 50%. The laser was operated in a near TEM00
mode at a chosen power.
(Laser melting)
Electron beam surface remelting experiments were carried out on a
60 kW moderate voltage electron beam welding machine made in
Russia.
The operation conditions for both stainless steel and aluminum
alloy were as follows: 60 kV for accelerating voltage, 18 mA for
beam current, 1.8 m/min for scanning speed of the electron beam.
To comprehensively understand the morphologies of the
resolidification microstructure, longitudinal section of the electron
beam traces were cut as specimens for metallographic examination
by optical microscopy (OM).
All the specimens were ground and polished. Etching for stainless
steel was performed using a solution containing 33 ml HNO3 and
67 ml HCl while etching for aluminum alloy was performed using
a solution containing 0.5 ml HF and 95.5 ml distilled water.
Microstructure
Fig. a Distribution of Al and Mg in the laser-melted zone and substrate of AZ91D alloy.
Fig. Measurement of dendrite cell size of three different regions in the melted zone from high
magnification SEM images. (a) Top surface layer; (b) middle region in the melted zone; (c) the boundary
between the melted zone and the substrate.
Fig. Optical micrographs showing the microstructure of base AISI 321 stainless steel (a); and electron
beam melted pool bottom (b); center (c); and surface (d).
Fig. TEM micrographs of Ni 50 Mn 20 Co 8 Ga 25 alloy melt-spun at high wheel speed. (a) Bright field image
showing martensite phase with twins (b) and (c) Bright field images of martensite phase at higher magnification (d)
Corresponding SAED pattern
Properties
Fig. Effect of Co concentration and corresponding e/a ratio on (a) Saturation magnetization (b) Martensite
transformation temperature and (c) Curie temperature of samples of Ni 2 (Mn,Co)Ga processed in different
conditions. (melt spinning)
(gas atomisation)
Fig. Tensile properties of SLM fabricated AlSi10Mg alloy, compared to die cast A360 alloy
Fig. shows the tensile test results of horizontal and vertical samples
together with data from die cast samples . All samples were built
using the parameters set E .
There is no major influence for the build orientation on the tensile
properties, although the horizontal samples show 10% high strength.
Fig. 9 Creep curves of SLM fabricated AlSi10Mg alloy (horizontal samples) at the following conditions: (a) 180 C/200
MPa, (b) 150 C/200 MPa, and (c) 180 C/150 MPa
Fig. shows the timestrain curves of horizontal samples, for test conditions:
(a) 180 C/200 MPa, (b) 150 C/200 MPa, and (c) 180 C/150 MPa. All the
straintime relations show normal creep behaviour, such as primary,
secondary and tertiary creep.
For test condition (a), the sample ruptured at 18.7 h. Using creep rupture
data for Larson miller plot for the same alloy, the predicted rupture time
was 14.8 h.
Conclusion
Meltspinning offers a cost-effective solution compared to competing
P/M processes and at the same time generates improved properties.
Meltspinning is, therefore, claimed to be the most promising
technology for generating the next generation metals.
Especially for automotive applications such as pistons, conrods and
hydraulic components the meltspun RSA alloys have a large potential.
RSA-4XX (AlSi20X), RSA-90X (AlCuFeX) and RSA-70X (AlZn)
alloy systems are already used in several niche markets such as racing
and sporting goods and have proved their superiority over
conventional metals. Pre-series testing for two automotive engines is
currently taking place.
Recent research on Conform promises further cost reductions so that
the use in mass applications can be further increased. Additional
research is needed to optimise quality and production efficiency.
References
L. Katgerman, in: S. Steeb, H. Warlimont (Eds.), Rapidly
Quenched Metals V, Elsevier, Amsterdam, 1985, pp. 819822.
L. Katgerman, in: H.D. Merchant, D.E. Tyler, E.H. Chia (Eds.),
Continuous Casting of Non-Ferrous Metals and Alloys, TMS,
Warrendale, 1989, pp. 6786.
E.J. Lavernia, J.D. Ayers, T. Srivatsan
Rapid solidification processing with specific application to
aluminum alloys Int Mater Rev, 37 (1992), pp. 144
C. Casavola, S.L. Campanelli, C. Pappalettere
Preliminary investigation on distribution of residual stress
generated by the selective laser melting process J Strain Anal Eng
Des, 44 (2009), pp. 93104
R.G. Song, W.Z. He, W.D. Huang
Surf Coat Technol, 130 (2000), p. 20