Thesis (Ph. D.)--University of Hong Kong, 2005. / Title proper from title frame. Also available in printed format.

No description available.

Thesis (Ph.D.)--Washington State University. / Includes bibliographical references.

No description available.

Thesis (M.S.)--Ohio State University, 2009. / Title from first page of PDF file. Includes vita. Includes bibliographical references (p. 108-109).

Thesis (M. S.)--Materials Science and Engineering, Georgia Institute of Technology, 2006. / Gokhale, Arun, Committee Chair ; Gall, Ken, Committee Member ; Thadhani, Naresh, Committee Member.

The influence of microstructure on the corrosion behaviour of magnesium alloys has been investigated using advanced microscopy approaches including optical microscopy, SEM, TEM and SKPFM with a focus on the effect of melt-conditioned twin roll casting (MCTRC) and friction stir welding (FSW) on the resultant microstructure of magnesium alloys.The microstructure characterization revealed that intense shearing, generated through the advanced shear technology, resulted in grain refinement and a uniform distribution of the β-phase and reduced micro-porosity in the MCTRC Mg-Al alloys, of which were attributed to the enhanced heterogeneous nucleation, which resulted in a highly refined grain structure. The TRC Mg-Al alloys displayed a coarse grained microstructure, with a random distribution of grain sizes. Deformation features like twinning, localized shear, microporosity and centre-line segregation were some of the commonly observed defects in the TRC alloys. The general microstructure of the AZ series Mg-Al alloys was composed of α-Mg grains, the β-phase, rosette-shaped Al8Mn5 intermetallic particles and β-precipitates.The MCTRC Mg-Al alloys showed improved corrosion resistance owing to the reduced grain size and the β-phase network acting as a corrosion barrier, thereby retarding the corrosion process. The TRC Mg-Al alloys exhibited higher susceptibility to galvanic corrosion due to the coarse and random distribution of grain sizes, and segregation. The corrosion testing results showed different corrosion morphologies, including filiform-like and spherical channel-like along with overall general corrosion. However, galvanic corrosion, initiating at localized sites due to Al8Mn5 intermetallic particles and the Si/Fe impurities accounted for a major deterioration in the performance of the Mg-Al alloys. The polarization curves revealed no evidence of passivation, suggesting that the alloy surface was continuously attacked. SKPFM results indicated that the micro-constituents, namely Al8Mn5 intermetallic particles and the β-phase exhibited higher nobility relative to the α-Mg matrix, suggesting formation of micro-galvanic couples at localized sites leading to the initiation of galvanic corrosion.The AM60 and AZ91 Mg-Al alloys, subjected to FSW, revealed that the traverse speed had a direct influence on the weld zone microstructure, where the size of the friction stir/weld nugget zone decreased with increase in the traverse speed and the increase in the rate of deformation, led to widening of the friction stir zone, below the shoulder. The weld microstructure displayed a prominent friction stir zone, with an ultrafine grain structure of an average grain size ranging from 2-10 μm. The localized increase in temperatures, in the TMAZ, due to the lower tool rotation rates and traverse speeds, which rise above the eutectic melting point (430°C), showed evidence of partial melting followed by re-solidification of the β-phase and evidence of liquation below the shoulder regions in the TMAZ. The morphology of the β-phase clearly revealed solute segregation, inconsistent with the β-phase observed in the parent alloy microstructure.The polarization curves obtained from the weld zones in the FSW AM60 alloy showed an improved corrosion resistance compared with the parent metal zone. SKPFM results revealed that the α-Mg matrix in the friction stir zone showed higher surface potential values compared with the parent alloy microstructure, due to the dissolution of the β-phase, suggesting higher nobility. However, the polarization behaviour of the AZ91 alloys did not show a significant difference in the corrosion resistance in the weld zones due to the higher volume fraction of the β-phase in the AZ91 alloys. The immersion testing results revealed higher susceptibility to corrosion in the transition zone due to the flash formation and the banded microstructure leading to failure of the weld zone.

Engineers constantly seek advancements in the performance of aircraft and power generation engines, including, lower costs and emissions, and improved fuel efficiency. Nickel-base superalloys are the material of choice for turbine discs, which experience some of the highest temperatures and stresses in the engine. Engine performance is proportional to operating temperatures. Consequently, the high-temperature capabilities of disc materials limit the performance of gas-turbine engines. Therefore, any improvements to engine performance necessitate improved alloy performance. In order to take advantage of improvements in high-temperature capabilities through tailoring of alloy microstructure, the overall objectives of this work were to establish relationships between alloy processing and microstructure, and between microstructure and mechanical properties. In addition, the project aimed to demonstrate the applicability of neural network modeling to the field of Ni-base disc alloy development and behavior. A full program of heat-treatment, microstructural quantification, mechanical testing, and neural network modeling was successfully applied to next generation Ni-base disc alloys. Mechanical testing included hot tensile, hot hardness, creep deformation, creep crack growth, and fatigue crack growth. From this work the mechanisms of processing-structure and structure-property relationships were studied. Further, testing results were used to demonstrate the applicability of machine-learning techniques to the development and optimization of this family of superalloys.

Free machining alloys containing soft immiscible phases in the aluminium (Al) matrix, like lead (Pb) and bismuth (Bi), are of great industrial interest. Typical applications in automotive industry are components requiring very high machinability, such as braking pistons and antiblocking system (ABS) housings. Presence of soft immiscible phases is giving their machining properties to this class of alloys. These phases melt due to localised heat build-up generated by machining process and induce chips breaking. Such type of alloys offers best in class performance when the soft phase is uniformly distributed in the Al matrix. The main objective of this work was to develop a method to tailor the distribution of the immiscible phase particles in the final solidified structure of DC cast billets in order to provide enhanced machinability while keeping low levels of Pb and/or Bi additions. As a consequence, another objective of this study was to improve recyclability of such alloys as well as to reduce their environmental impact. Three categories of Al-Pb alloys and different solidification paths were studied: hypermonotectic Al-3Pb, monotectic Al-1.2Pb and industrial hypo-monotectic free machining alloy containing both Pb and Bi. A newly developed melt conditioning combines mechanical, thermal and chemical treatments to obtain a very fine and uniform distribution of the immiscible phase droplets and eliminate compositional heterogeneities. The effect of these new melt treatments on microstructure was evaluated. For the soft phase droplets size was reduced and distribution becomes finer and more homogeneous under the individual effect of each of the treatments and optimum results obtained with the combination of them. These new melt treatments affect not only the nucleation of the Pb/Bi droplets, enhancing their heterogeneous nucleation but reduces considerably the Marangoni motion and Stokes sedimentation reducing therefore the droplet coalescence and restricting their growth. As a consequence of this improved microstructure, mechanical properties and machining performance were enhanced considerably. The results from this study provide a promising new microstructure with a fine and uniform distribution of droplets.

Mechanical properties of structural materials are highly correlated to their microstructure. The relationship between microstructure and mechanical properties can be established experimentally. The growing need for structural materials in industry promotes the study of microstructural evolution of materials by design using computational approaches. This thesis presents the microstructural evolution of two different structural materials. The first uses a genetic algorithm approach to study the microstructural evolution of a high-temperature nickel-based oxide-dispersion-strengthened (ODS) alloy. The chosen Ni-20Cr ODS system has nano Y2O3 particles for dispersion strengthening and submicron Al2O3 for composite strengthening. Synergistic effects through the interaction of small dispersoids and large reinforcements improved high-temperature strength. Optimization considered different weight factors on low temperature strength, ductility, and high temperature strength. Simulation revealed optimal size and volume fraction of dispersoids and reinforced particles. Ni-20Cr-based alloys were developed via mechanical alloying for computational optimization and validation. The Ni-20Cr-1.2Y2O3-5Al2O3 alloy exhibited significant reduction in the minimum creep rate (on the order of 10-9 s-1) at 800oC and 100 MPa. The second considers the microstructural evolution of AA 7050 alloy during friction stir welding (FSW). Modeling the FSW process includes thermal, material flow, microstructural and strength modeling. Three-dimensional material flow and heat transfer model was developed for friction stir welding process of AA 7050 alloy to predict thermal histories and extent of deformation. Peak temperature decreases with the decrease in traverse speed at constant advance per revolution, while the increase in tool rotation rate enhances peak temperature. Shear strain is higher than the longitudinal and transverse strain for lower traverse speed and tool rotation rate; whereas for higher traverse speed and tool rotation rate, shear and normal strain acquire similar values. Precipitation distribution simulation using TC-PRISMA predicts the presence of η' and η in the as-received AA 7050-T7451 alloy and mostly η in the friction stir welded AA7050 alloy, which results in the lower predicted strength of friction stir welded alloy. Further, development of modeling assists in process optimization and innovation, and enhances the progression rate. Accelerating the development process requires coupling experimental methods with predictive modeling. The overall purpose of this work was to develop an integrated computational model with predictive capabilities. In the present work, an application tool to predict thermal histories during FSW of AA7050 was developed using COMSOL software.