Structure refinement, mechanical properties and feasibility of deformation of hypereutectic Al–Fe–Zr and Al–Ni–Zr alloys subjected to ultrasonic melt processing

Journal article

Authors/Editors

CHAOWALIT LIMMANEEVICHITR

Strategic Research Themes

Materials Processing (Innovative Materials, Manufacturing and Construction)

Publication Details

Author list: Chankitmunkong S., Eskin D.G., Limmaneevichitr C.

Publisher: Elsevier

Publication year: 2020

Journal: Materials Science and Engineering: A (0921-5093)

Volume number: 788

ISSN: 0921-5093

URL: https://www.scopus.com/inward/record.uri?eid=2-s2.0-85085271734&doi=10.1016%2fj.msea.2020.139567&partnerID=40&md5=d40843fe455d1c187e734b90e683ee95

Languages: English-Great Britain (EN-GB)

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Abstract

Hypereutectic Al–Fe and Al–Ni alloys offer a potentially attractive combination of properties, e.g. high-temperature strength and stability, high elastic modulus and low coefficient of thermal expansion. This potential, however, cannot be reached unless the structure of these alloys is refined so that their processing becomes possible. In this study, we for the first time apply ultrasonic melt processing for refining the structure of hypereutectic Al-4% Fe and Al-8% Ni alloys with 0.3 wt% Zr addition. Both primary Al3Fe and Al3Ni particles as well as aluminum/eutectic grains are significantly refined. It is suggested that cavitation-induced fragmentation of primary Al3Zr crystals plays a significant role in the nucleation of intermetallics as well as aluminum. Furthermore, the hardness and tensile properties of the alloys substantially increase after ultrasonic treatment due to the refined structure, which also contributes to the considerably enhanced ductility of the alloys. As a result, the fracture mode changes from brittle fracture to ductile fracture. The increase in ductility makes the alloys suitable for hot deformation, which is demonstrated by lab-scale hot rolling. In addition, precipitation hardening of the alloys can be achieved by high-temperature annealing at 450 °C due to retained Zr in the Al solid solution upon solidification. The results are supported by the analysis of the composition of a supersaturated solid solution of Zr in Al and scanning and transmission electron microscopy that confirms the precipitation of coherent Al3Zr nanoparticles. It is demonstrated that a combination of ultrasonic melt processing and alloying with Zr makes it feasible to develop new class of hypereutectic casting and wrought alloys based on the Al–Fe and Al–Ni systems. © 2020 The Author(s)

Keywords

Hot rolling, Hypereutectic alloy, Structure refinement