Experimental study of the Ca-Mg-Zn system using diffusion couples and key alloys.

Nine diffusion couples and 32 key samples were prepared to map the phase diagram of the Ca-Mg-Zn system. Phase relations and solubility limits were determined for binary and ternary compounds using scanning electron microscopy, electron probe microanalysis and x-ray diffraction (XRD). The crystal structure of the ternary compounds was studied by XRD and electron backscatter diffraction. Four ternary intermetallic (IM) compounds were identified in this system: Ca3Mg x Zn15-x (4.6 ⩽ x ⩽ 12 at 335 °C, IM1), Ca14.5Mg15.8Zn69.7 (IM2), Ca2Mg5Zn13 (IM3) and Ca1.5Mg55.3Zn43.2 (IM4). Three binary compounds were found to have extended solid solubility into ternary systems: CaZn11, CaZn13 and Mg2Ca form substitutional solid solutions where Mg substitutes for Zn atoms in the first two compounds, and Zn substitutes for both Ca and Mg atoms in Mg2Ca. The isothermal section of the Ca-Mg-Zn phase diagram at 335 °C was constructed on the basis of the obtained experimental results. The morphologies of the diffusion couples in the Ca-Mg-Zn phase diagram at 335 °C were studied. Depending on the terminal compositions of the diffusion couples, the two-phase regions in the diffusion zone have either a tooth-like morphology or contain a matrix phase with isolated and/or dendritic precipitates.

Optimization of the Electrospun Niobium-Tungsten Oxide Nanofibers Diameter Using Response Surface Methodology.

The present research aimed to investigate the effect of working parameters on the electrospinning of niobium-tungsten oxide nanofibers and optimize the process using central composite design (CCD) based on the response surface methodology (RSM). An experiment was designed to assess the effects of five variables including the applied voltage (V), spinning distance (D), polymer concentration (P), flow rate (F), and addition of NaCl (N) on the resulting diameter of the nanofibers. Meanwhile, a second-order prediction model of nanofibers diameter was fitted and verified using analysis of variance (ANOVA). The results show that the diameter of the nanofibers was significantly influenced by all the variables except the flow rate. Some second-order and cross factor interactions such as VD, DP, PF, PN, and P2 also have significant effects on the diameter of the nanofibers. The results of the ANOVA yielded R2 and adjusted R2 values of 0.96 and 0.93 respectively, this affirmed that the predictive model fitted well with the experimental data. Furthermore, the process parameters were optimized using the CCD method and a maximum desirability function of 226 nm was achieved for the diameter of the nanofibers. This is very close to the 233 nm diameter obtained from a confirmatory experiment using the optimum conditions. Therefore, the model is representative of the process, and it could be used for future studies for the reduction of the diameter of electrospun nanofibers.

Effect of homogenization and solution treatments time on the elevated-temperature mechanical behavior of Inconel 718 fabricated by laser powder bed fusion.

In the present study, the effect of homogenization and solution treatment times on the elevated-temperature (650 °C) mechanical properties and the fracture mechanisms of Inconel 718 (IN718) superalloy fabricated by laser powder bed fusion (LPBF) was investigated. Homogenization times between 1 and 7 h at 1080 °C were used, while solution treatments at 980 °C were performed in the range from 15 to 60 min. The as-printed condition showed the lowest strength but the highest elongation to failure at 650 °C, compared to the heat-treated conditions. After heat treatments, the strength of the IN718 alloy increased by 20.3-31% in relation to the as-printed condition, depending on the treatment time, whereas the ductility decreased significantly, by 67.4-80%. Among the heat treatment conditions, the 1 h homogenized conditions at 1080 °C (HSA1 and HSA2) exhibited the highest strength and ductility due to the combined effects of the precipitation hardening and sub-structural changes. Further increases in the homogenization time to 4 and 7 h led to a decrease in the strength and significant ductility loss of the LPBF IN718 due to the considerable annihilation of the dislocation tangles and a greater precipitation of coarse MC carbide particles. Furthermore, it was found that the solution treatment duration had a crucial influence on the mechanical properties at 650 °C due to the increase in the grain boundary strength through the pinning effect of the intergranular δ-phase. In addition, the fracture mechanism of the LPBF IN718 was found to be dependent on the heat treatment time. Finally, this investigation provides a map that summarizes the effect of homogenization and solution treatment times on the high-temperature mechanical behavior of LPBF IN718 by relating it to the corresponding microstructural evolution. This effort strives to assist in tailoring the mechanical properties of LPBF IN718 based on the design requirements for some specific applications.

Influence of Homogenization and Solution Treatments Time on the Microstructure and Hardness of Inconel 718 Fabricated by Laser Powder Bed Fusion Process.

In the present study, Inconel 718 (IN718) superalloy fabricated by laser powder bed fusion (LPBF) has been characterized focusing on the effect of both homogenization and solution treatment time on grains structure, crystallographic texture, precipitates formation/dissolution and material hardness. For this purpose, a heat-treatment time window with a wide range of soaking times for both treatments was established aiming to develop the optimal post-treatment conditions for laser powder bed fused IN718. It was found that the as-printed IN718 is characterized by very fine columnar/cellular dendrites with Laves phase precipitating at the grain boundaries as well as inter-dendritic regions, which differs from the microstructure of wrought and cast materials and requires special heat-treatment conditions different from the standard treatments. The results reveal that the relatively short homogenization treatment at 1080 °C for 1 h was not enough to significantly change the as-printed grain structure and completely dissolve the segregates and Laves phase. However, a completely recrystallized IN718 material and more Laves phase dissolution were obtained after homogenization treatment for 4 h. A further increase in time of the homogenization treatment (7 h) resulted in grain growth and coarsening of carbides precipitates. The solution treatment time at 980 °C did not cause noticeable changes in the crystallographic texture and grain structure. Nevertheless, the amount of δ-phase precipitation was significantly affected by the solution treatment time. After applying the heat-treatment time window, the hardness increased by 51%-72% of the as-printed condition depending on the treatment time due to the formation of γ' and γ″ in the γ-matrix. The highest material hardness was obtained after 1 h homogenization, whereas the prolonged time treatments reduced the hardness. This study provides a comprehensive investigation of the post heat-treatments of the laser powder bed fused IN718 that can result in an optimized microstructure and mechanical behavior for particular applications.

Water Droplet Erosion of Wind Turbine Blades: Mechanics, Testing, Modeling and Future Perspectives.

The problem of erosion due to water droplet impact has been a major concern for several industries for a very long time and it keeps reinventing itself wherever a component rotates or moves at high speed in a hydrometer environment. Recently, and as larger wind turbine blades are used, erosion of the leading edge due to rain droplets impact has become a serious issue. Leading-edge erosion causes a significant loss in aerodynamics efficiency of turbine blades leading to a considerable reduction in annual energy production. This paper reviews the topic of water droplet impact erosion as it emerges in wind turbine blades. A brief background on water droplet erosion and its industrial applications is first presented. Leading-edge erosion of wind turbine is briefly described in terms of materials involved and erosion conditions encountered in the blade. Emphases are then placed on the status quo of understanding the mechanics of water droplet erosion, experimental testing, and erosion prediction models. The main conclusions of this review are as follow. So far, experimental testing efforts have led to establishing a useful but incomplete understanding of the water droplet erosion phenomenon, the effect of different erosion parameters, and a general ranking of materials based on their ability to resist erosion. Techniques for experimentally measuring an objective erosion resistance (or erosion strength) of materials have, however, not yet been developed. In terms of modelling, speculations about the physical processes underlying water droplet erosion and consequently treating the problem from first principles have never reached a state of maturity. Efforts have, therefore, focused on formulating erosion prediction equations depending on a statistical analysis of large erosion tests data and often with a combination of presumed erosion mechanisms such as fatigue. Such prediction models have not reached the stage of generalization. Experimental testing and erosion prediction efforts need to be improved such that a coherent water droplet erosion theory can be established. The need for standardized testing and data representation practices as well as correlations between test data and real in-service erosion also remains urgent.

Binary Phase Diagrams and Thermodynamic Properties of Silicon and Essential Doping Elements (Al, As, B, Bi, Ga, In, N, P, Sb and Tl).

Fabrication of solar and electronic silicon wafers involves direct contact between solid, liquid and gas phases at near equilibrium conditions. Understanding of the phase diagrams and thermochemical properties of the Si-dopant binary systems is essential for providing processing conditions and for understanding the phase formation and transformation. In this work, ten Si-based binary phase diagrams, including Si with group IIIA elements (Al, B, Ga, In and Tl) and with group VA elements (As, Bi, N, P and Sb), have been reviewed. Each of these systems has been critically discussed on both aspects of phase diagram and thermodynamic properties. The available experimental data and thermodynamic parameters in the literature have been summarized and assessed thoroughly to provide consistent understanding of each system. Some systems were re-calculated to obtain a combination of the best evaluated phase diagram and a set of optimized thermodynamic parameters. As doping levels of solar and electronic silicon are of high technological importance, diffusion data has been presented to serve as a useful reference on the properties, behavior and quantities of metal impurities in silicon. This paper is meant to bridge the theoretical understanding of phase diagrams with the research and development of solar-grade silicon production, relying on the available information in the literature and our own analysis.

Phase Equilibria and Magnetic Phases in the Ce-Fe-Co-B System.

Ce-Fe-Co-B is a promising system for permanent magnets. A high-throughput screening method combining diffusion couples, key alloys, Scanning Electron Microscope/Wavelength Dispersive X-ray Spectroscope (SEM/WDS), and Magnetic Force Microscope (MFM) is used in this research to understand the phase equilibria and to explore promising magnetic phases in this system. Three magnetic phases were detected and their homogeneity ranges were determined at 900 °C, which were presented by the formulae: Ce2Fe14-xCoxB (0 ≤ x ≤ 4.76), CeCo4-xFexB (0 ≤ x ≤ 3.18), and Ce3Co11-x FexB4 (0 ≤ x ≤ 6.66). The phase relations among the magnetic phases in this system have been studied. Ce2(Fe, Co)14B appears to have stronger magnetization than Ce(Co, Fe)4B and Ce3(Co, Fe)11B4 from MFM analysis when comparing the magnetic interactions of selected key alloys. Also, a non-magnetic CeCo12-xFexB6 (0 ≤ x ≤ 8.74) phase was detected in this system. A boron-rich solid solution with Ce13FexCoyB45 (32 ≤ x ≤ 39, 3 ≤ y ≤ 10) chemical composition was also observed. However, the crystal structure of this phase could not be found in the literature. Moreover, ternary solid solutions ε1 (Ce2Fe17-xCox (0 ≤ x ≤ 12.35)) and ε2 (Ce2Co17-xFex (0 ≤ x ≤ 3.57)) were found to form between Ce2Fe17 and Ce2Co17 in the Ce-Fe-Co ternary system at 900 °C.

Laser Peening Process and Its Impact on Materials Properties in Comparison with Shot Peening and Ultrasonic Impact Peening.

The laser shock peening (LSP) process using a Q-switched pulsed laser beam for surface modification has been reviewed. The development of the LSP technique and its numerous advantages over the conventional shot peening (SP) such as better surface finish, higher depths of residual stress and uniform distribution of intensity were discussed. Similar comparison with ultrasonic impact peening (UIP)/ultrasonic shot peening (USP) was incorporated, when possible. The generation of shock waves, processing parameters, and characterization of LSP treated specimens were described. Special attention was given to the influence of LSP process parameters on residual stress profiles, material properties and structures. Based on the studies so far, more fundamental understanding is still needed when selecting optimized LSP processing parameters and substrate conditions. A summary of the parametric studies of LSP on different materials has been presented. Furthermore, enhancements in the surface micro and nanohardness, elastic modulus, tensile yield strength and refinement of microstructure which translates to increased fatigue life, fretting fatigue life, stress corrosion cracking (SCC) and corrosion resistance were addressed. However, research gaps related to the inconsistencies in the literature were identified. Current status, developments and challenges of the LSP technique were discussed.

Phase equilibrium in Mg-Cu-Y.

Magnesium-based bulk metallic glasses (BMG) have potential in applications ranging from biomedical to sports equipment and the Mg-Cu-Y system offers some of the most promising alloys. Phase relations and ternary solubility of the binary and ternary compounds of this system have been experimentally investigated. The Isothermal section of Mg-Cu-Y system at 673 K for the entire composition range has been constructed. Phase relations in the Cu-rich (>66 at.% Cu) region of the Mg-Cu-Y system has been determined for the first time. The homogeneity range of three ternary compounds has been determined. Solidifications behavior of several key alloys have been discussed based on the differential scanning calorimetry (DSC) experiments and thermodynamic calculations. Extensive analysis of the DSC curves has been carried out to relate them to the corresponding phase transformation reactions and temperatures. Some of the most promising metallic glass forming regions have been analyzed using thermodynamic calculations.