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The transportation industries are constantly striving to achieve minimum weight to cut fuel consumption and improve overall performance. Different innovative design strategies have been placed and directed toward weight saving combined with good mechanical behavior. Among different materials, aluminum-based alloys play a key role in modern engineering and are widely used in construction components because of their light weight and superior mechanical properties. Introduction of different nano-structure features can improve the service and the physical properties of such alloys. For intelligent microstructure design in the complex Al-based alloy, it is important to gain a deep physical understanding of the correlation between the microstructure and macroscopic properties, and thus atom probe tomography with its exceptional capabilities of spatially resolution and quantitative chemical analyses is presented as a sophisticated analytical tool to elucidate the underlying process of precipitation phenomena in aluminum alloys. A complete study examining the influence of common industrial heat treatment on the precipitation kinetics and phase transformations of complex aluminum alloy is performed. The qualitative evaluation results of the precipitation kinetics and phase transformation as functions of the heat treatment conditions are translated to engineer a complex aluminum alloy. The study demonstrates the ability to construct a robust microstructure with an excellent hardness behavior by applying a low-energy-consumption, cost-effective method. The proposed strategy to engineer complex aluminum alloys is based on both mechanical strategy and intelligent microstructural design. An intelligent microstructural design requires an investigation of the different strengthen phases, such as T1 (Al2CuLi), θ′(Al2Cu), β′(Al3Zr) and δ′(Al3Li). Therefore, the early stage of phase decomposition is examined in different binary Al-Li and Al-Cu alloys together with different ternary Al-Li-Cu alloys. Atom probe tomography and statistical testing are combined to investigate the fine scale segregation effects of dilute solutes in aluminum alloys. The optimum application of atom probe tomography in a wide range of materials is enabled by the integration of a laser pulse mode in the atom probe analysis. However, the nature of the laser mechanism used during atom probe tomography analyses is still debated. Systematic investigation of the microstructural change of δ′(Al3Li) precipitates influenced by different pulsed laser energies are used to describe the important phenome associated with the laser pulse mode. In this study, atom probe tomography presented a series of snapshots during in-situ reversion of δ′(Al3Li) precipitates, initiated by laser irradiation, using different laser energies for the first time. An estimation method to investigate real sample temperatures during laser-APT analyses using an interface reaction itself as a probe has been proposed. Finally, the considerable potential of aluminum liquid is demonstrated as a powerful synthesis solvent of important intermetallic phases such as: Mg2Si, Al2Mg and CaMgSi. The atom probe tomography technique is utilized to characterize the intermediate reaction steps of the flux-grown intermetallic phases. The study proposed a direct approach to investigate the involved reactions during the formation of the synthesized intermetallic phase.

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Influence of different microstructure of La-based fully amorphous samples and its composites on the impact fracture energy were investigated and discussed. Results showed improvement in fracture energy of glassy metals with the presence intermetallic phases, but deteriorated in the presence of dendrite phases and high volume % of crystalline phases. / Singapore-MIT Alliance (SMA)

L'étude du comportement électrochimique des phases intermétalliques Al2Cu, Al2CuMg, Al7Cu2Fe, (Al,Cu)16Mn4Si3 et MgZn2, caractéristiques des alliages d'aluminium 2214-T6 et 7050-T74 et réalisée à partir d'échantillons massifs synthétisés, a montré que la formation de défauts majeurs dans la couche d'oxyde, obtenue par anodisation des alliages en milieu H2SO4 200 g/l, était directement due à la présence de ces particules au sein des alliages. L'important dégagement gazeux d'oxygène qui se produit à la surface de ces particules lors de l'étape d'anodisation explique la formation de trous et de fractures dans la couche d'oxyde. En milieu marin, ces défauts facilitent la migration des ions chlorures à la surface de l'alliage mise à nu localement et favorisent par conséquent le développement de la corrosion localisée. Les résultats obtenus en milieu NaCl 35g/l ont permis de mieux comprendre le mécanisme de corrosion des phases intermétalliques ainsi que leur rôle sur la propagation des piqûres. L'élimination des particules intermétalliques de la surface des alliages lors de l'étape de décapage (avant anodisation) permet de favoriser une croissance plus régulière de la couche d'oxyde lors de l'anodisation. Par conséquent, la résistance à la corrosion des alliages 2214 et 7050 augmente considérablement, permettant d'atteindre les objectifs fixés lors de ce projet / The electrochemical behaviour of the bulk intermetallic particles such as Al2Cu, Al2CuMg, Al7Cu2Fe, (Al,Cu)16(Mn,Fe)4Si3 and MgZn2 showed that the formation of wide defects in the oxide layer during the 2214-T6 and 7050-T74 alloys anodization was directly due to the presence of these kind of particles in the microstructure which are able to sustain both high dissolution rate and high water oxidation kinetics in acidic electrolyte. In marine environment, these defects facilitate the migration of aggressive ions like chloride on the locally bare alloys and are the onset of the pitting corrosion. The results obtained in 3.5 wt.% sodium chloride electrolyte permit to understand the corrosion mechanism of the intermetallic phases and their influence on the pits propagation. The optimization of the alloys pickling conditions in order to remove this kind of particles (prior to the anodization step) has been investigated in this work. Consequence of removing intermetallic particles, the aluminium enrichment of the surface facilitates the oxide growth and the formation of regular layer. The corrosion tests on treated aluminium alloys have clearly showed the influence of the pickling step on the resistance corrosion of 2214 and 7050 alloys, reaching the objectives fixed in this project

Pesquisas anteriores sobre aÃos ferrÃticos experimentais com alto teor de molibdÃnio (Mo) constataram que embora o Mo seja responsÃvel por aumentar a resistÃncia à corrosÃo em meios ricos em Ãcidos naftÃnicos e em complexos de enxofre, teores acima de 5% Mo favorecem a formaÃÃo de fases deletÃrias e reduzem a tenacidade do aÃo. Para melhorar a tenacidade dessas ligas, mantendo-se a estabilidade da fase ferrÃtica, o presente trabalho adicionou nÃquel (Ni) à composiÃÃo, elevou o teor de cromo (Cr) para 25% e manteve o elevado teor de Mo. Essas novas ligas pertencem a uma famÃlia de aÃos denominados aÃos inoxidÃveis superferrÃticos, desenvolvidos inicialmente para uso em trocadores de calor e ambientes marinhos. Este trabalho faz parte de um estudo para adaptar a composiÃÃo de aÃos superferrÃticos comerciais para utilizaÃÃo em plantas petrolÃferas que refinam petrÃleos ricos em compostos de enxofre atravÃs do aumento do teor de Mo na liga. A cinÃtica de precipitaÃÃo de fases em ligas com composiÃÃes experimentais (Fe25%Cr5-7%Mo2-4%Ni) com adiÃÃo de niÃbio (Nb) e titÃnio (Ti) foi estudada para temperaturas de 400ÂC a 900ÂC em diferentes tempos de tratamento. Foi realizado o estudo termodinÃmico das ligas empregando o Thermo-Calc para determinar a temperatura de estabilidade da fase ferrÃtica e identificar as possÃveis fases intermetÃlicas precipitadas em condiÃÃes de equilÃbrio. As ligas foram envelhecidas a 400 e 475ÂC para estudar a precipitaÃÃo da fase alfa linha (αâ) e seus efeitos nas propriedades mecÃnicas, magnÃticas e de resistÃncia à corrosÃo. Foram realizados tratamentos isotÃrmicos de 600 a 900ÂC para estudar a cinÃtica de precipitaÃÃo das fases intermetÃlicas. As alteraÃÃes microestruturais, nas propriedades mecÃnicas e na resistÃncia à corrosÃo devido a variaÃÃo da composiÃÃo e do tratamento tÃrmico foram estudadas. Os resultados obtidos nas ligas experimentais tratadas a 400 e 475ÂC indicaram aumento na dureza e reduÃÃo da fase ferrita, acompanhada de aumento da suscetibilidade a corrosÃo por pite sendo mais crÃtico a 475ÂC, com melhor desempenho observado para a liga 5Mo4Ni. Para as amostras tratadas de 600 a 900ÂC a liga 7Mo2Ni apresentou a menor quantidade de fases deletÃrias precipitadas e menor suscetibilidade a corrosÃo por pite. Ocorreu precipitaÃÃo de austenita para as ligas contendo 4%Ni tratadas a 800ÂC e 900ÂC. A liga 7Mo4Ni apresentou pior desempenho comparada Ãs outras ligas experimentais em todas as condiÃÃes estudadas. / Previous research on experimental ferritic steel with high Mo content showed that Mo increases the resistance to naphthenic corrosion and sulfur complexes. However, Mo content above 5 wt% favored the formation of deleterious phases and reduced the toughness of the steel. To improve the toughness of these alloys and keep the ferrite phase stable, was added Ni, increased Cr content to 25% and maintained high Mo content. These new alloys belong to a family of steels known as superferritic stainless steels. They were originally developed for use in heat exchangers and marine environments. There is a current trend to use these alloys in the oil industry driving the research on the effect of the increase of Mo content on the microstructure of these steels. The kinetics of phase precipitation in experimental compositions (Fe25%Cr 5-7%Mo 2-4%Ni) with addition of Nb and Ti will be investigated for temperatures from 400  C to 900  C for different treatment times. In this first stage, Thermo-Calc software was used to determine the temperature stability of the ferritic phase and to identify possible intermetallic phases precipitated at thermodynamic equibrium. The alloys were aged at 400 and 475ÂC for study the alfa prime phase precipitation and their effects on the mechanical, magnetic and corrosion properties. Isothermal treatments were carried out 600 ÂC to 900  C to study the kinetics of precipitation of intermetallic phases. The microstructural changes on the mechanical and corrosion properties due to variation in composition and heat treatment were studied. The results obtained in the experimental alloys treated at 400 and 475ÂC indicated an increase in hardness, while wt% of ferrite had decreased, accompanied by increased susceptibility to pitting corrosion, the best performance observed for 5Mo4Ni alloy these conditions. For samples treated 600 to 900ÂC the 7Mo2Ni alloy showed the smallest amount deleterious phase precipitated and less susceptibility to pitting corrosion. Austenite phase precipitation occurred for the alloys containing 4%Ni treated at 800ÂC and 900ÂC. The 7Mo4Ni alloy showed worse performance compared to other experimental alloys in all conditions studied.

The work is aimed at studying the thermal degradation of the protective zinc coating. Its large part deals with the structure of the various stages of transition and their arrangement, the main emphasis is on analysis of brittle intermetallic phases, which arise due to increased temperature. Conclusion of the work is trying to clear itself causes degradation of this protective layer.

<p>Al-Si cast alloys have been in the fore-front of commercial casting application for more than a century. Iron containing intermetallic phases that evolve during the solidification of these alloys play a major role in the resultant mechanical properties and performance of the cast products. Changes in alloy composition and casting parameters significantly alter the evolution of the Al-Si-Fe intermetallic phases. There was a lack of clear understanding of the complex relationships between the solidification parameters and nature intermetallic phases in these alloys. Current thermodynamic model predictions for the nature of these intermetallic phases in the Al corner of the Al-Si-Fe ternary system are strikingly different from the experimental results in this project. Trace levels of Sr (about 0.02wt%) are typically added to the Al-Si commercial alloys to effect a morphological modification of the eutectic phases to improve the properties and performance of the cast products.</p> <p>The nature of the Fe containing intermetallic phases have been characterized as a function of alloy composition (Si, Fe and Sr) and cooling rates during solidification. There was an anomalous evolution of the t₅-Al₈Fe₂Si phase which transformed into the t₆-Al₉Fe₂Si₂ phase during solidification at lower cooling rates and higher Fe concentration in the alloy, alike. Further, Sr addition to these alloys prevented the evolution of the t₅ phase and promoted the evolution of an unidentified Al₅Fe₂Si₃ phase which was noted as k in this dissertation; the k phase also transformed into the t₆ phase at lower cooling rates and higher Fe concentration in the alloy, alike.</p> / Doctor of Philosophy (PhD)

Os aços inoxidáveis duplex são materiais com um excelente desempenho, devido às suas sobressalentes propriedades mecânicas e excelente resistência à corrosão. Uma composição química adequada e microestrutura balanceada são as responsáveis por esta combinação de propriedades. No entanto, são estes mesmos fatores que os fazem especialmente susceptíveis à precipitação de fases intermetálicas, com efeitos maléficos no seu desempenho. Durante os ciclos térmicos de uma soldagem multipasse, a precipitação de intermetálicos é crítica. Foi desenvolvido um método para simular os ciclos térmicos de uma solda multipasse. Usando este método, foi estudada a precipitação de nitreto de cromo e fase sigma na zona afetada pelo calor submetida a temperaturas abaixo de 950°C dos aços inoxidáveis duplex UNS S31803 e S32550. Foram estudadas energias de soldagem na faixa de 0,4 a 1,0 kJ/mm. Foi determinada mediante extração de precipitados, seguida de difração de raios X na câmara de Debye-Scherrer e microscopia eletrônica de transmissão, a precipitação de nitreto de cromo para energias de soldagem de 0,4 a 1,0 kJ/mm e de fase sigma para energias de soldagem de 0,6-1,0 KJ/mm, no UNS S32550. Já o UNS S31803 não apresentou precipitação alguma para as energias de soldagem estudadas. Baseando-se nos resultados verifica-se que durante uma soldagem multipasse o UNS S31803 é menos propenso que o UNS S32550 à precipitação de intermetálicos na zona afetada pelo calor submetida a temperaturas abaixo de 950°C. / Duplex stainless steels belong to a group of high performance stainless steels regarding to corrosion and mechanical properties. These achievements are related to a suitable chemical composition and a balanced microstructure. During welding thermal cycles the microstructure changes and, consequently, corrosion and mechanical properties might be impaired due to a precipitation of intermetallic phases. This precipitation is an issue to be addressed for multipass welding. It was developed a method for simulate the multipass welding thermal cycles. Using this method chromium nitride and sigma phase precipitation was studied in a simulated heat affected zone of multipass welding (three passes) of UNS S31803 and UNS S32550 duplex stainless steels with different heat inputs (0,4 to 1,0 kJ/mm). The HAZ simulated region was below 950°C maximum temperature. Microstructural characterization of simulated samples showed discontinuous films of a precipitated phase at ferrite/ferrite grain boundaries and ferrite/austenite interfaces were observed only in a UNS S32550 duplex grade for all heat inputs simulated. This suggests that sigma phase and chromium nitride precipitation took place during sample thermocycling. X-ray diffraction in a Debye-Scherrer chamber of extracted precipitates and electron diffraction by TEM confirmed the presence of chromium nitrides for all range of heat input studied and sigma phase for heat input above 0,6 kJ/mm. On the other hand, microstructural analysis of UNS S31803 simulated samples did not present precipitation of intermetallic phases in the tested temperature range of HAZ. Based on these results, UNS S31803 is more resistant than UNS S32550 to intermetallic phases precipitation in multipass welding.

The vehicles industry is facing increasing demands for fuel efficiency and cost reduction due to environmental legislation, sustainability and customer demands. Therefore, there is a great need to develop and produce lightweight components by using materials and processes that offer higher specific strength and/or design optimization. Semi‐solid aluminium casting offers design freedom and castings with lower shrinkage and gas entrapment defects compared to high pressure die castings. The lack of understanding of microstructure and defect formation, and design data, for semi‐solid castings is a barrier for foundries and designers in the vehicles industry to use semi‐solid castings. In this study, the effect of two grain refiners on slurry formation and surface segregation of semi‐solid Al‐7Si‐0.3Mg castings produced by the Rheometal™ process was evaluated. The influence of grain refinement on primary α‐Al grain size, shape factor and solid fraction was analysed in addition to the solute content of the surface segregation layer. The influence of magnesium on the formation of intermetallic phases during solidification and the heat treatment response of Al‐7Si‐Mg semi‐solid castings was investigated. The magnesium content was varied from 0.3 to 0.6wt.% and the semi-solid castings were analysed in the T5 and T6 conditions. Energy dispersive spectroscopy was used to identify the intermetallic phases formed during solidification. Tensile testing was performed and the results were correlated to the magnesium and silicon concentration measured in the interior of the α‐Al globules formed during slurry preparation. The results suggest that the addition of grain refiner decreases the solid fraction obtained in the Rheometal™ process. However, no significant effect was observed on the α‐Al grain size and shape factor. A good correlation was obtained between the magnesium concentration in the interior of the α‐Al globules formed during slurry preparation and the offset yield strength for all alloys. The low magnesium solubility in α‐Al at temperatures in the solidification range of the Al‐7Si‐Mg alloys is suggested to be the reason for the low hardening response for the T5 heat treatment compared to the T6 condition.