Lamellar cast iron is a very important technical alloy and the most used material in the casting production, and especially in the automotive industry which is the major consumer. Beside the many great properties, it is inclined to form casting defects of which some can be prevented, and some may be repaired subsequently. Shrinkage porosity is a randomly returning problem, which is difficult to understand and to avoid. This defect is a volumetric deficiency which appear as cavities inside the casting in connection to the casting surface. Another frequent defect is the metal expansion penetration. This defect is a material surplus squeezed to the casting surface containing sand inclusion from the mold material. Shrinkage porosity is usually mentioned together with metal expansion penetration as the formation mechanism of both defects have common roots. It is also generally agreed, that these type of defects are related to the volumetric changes occurring during solidification. Additionally, the formation of these defects are in connection with the coherency of the primary austenite dendrites. The purpose of this work was to develop knowledge on factors affecting a volume-change related casting defect formation in order to minimize the presence of these defects in engine component production. This was done by extending the existing solidification investigation methods with novel solutions. Introduction of expansion force measurement in the determination of dendrite coherency combined with multi axial volume change measurement refine the interpretation of the solidification. Comparison of registered axial and radial linear deformation in cylindrical samples indicated an anisotropic volume change. Different methods for dendrite coherency determination have been compared. It was shown that the coherency develops over an interval. Dependent on the added inoculant the coherency is reached at different levels of fractions of a solidified primary phase. It is also shown, that inoculation has an effect on the nucleation and growth of the primary phase. Quantitative image analysis has been performed on the primary phase in special designed samples designed to provoke shrinkage porosity and metal expansion penetration. It was found, that the inter-dendritic space varies within a casting. This was explained by the coarsening of the primary dendrites which originates from differences in the local time of solidification. / <p>QC 20131210</p>

<p> Continuous Casting (CC) is an essential process in the steel industry to transform molten steel into solid product. This process begins with primary cooling (PC) where the molten steel is cooled, and the initial solidification begins. It is important to monitor the process of PC as defects such as thinning of the shell in the mold can lead to breakouts. Key parameters in PC are the mold design, casting condition, and steel composition. In the research conducted, key parameters for PC are investigated to analyze the impact on flow formation and solidification. To optimize mold design, angular taper to the narrow face can be employed to accommodate for any shell shrinkage. Utilizing computational fluid dynamics, a range of mold taper is simulated per the developed solidification model with defined temperature-dependent material properties. When simulated without a taper, significant air gap formation in the corners of the mold is visible due to thermal shrinkage of the shell. This air gap decreases the cooling rate due to the shell’s lack of contact with the cooling mold wall. A parametric study of mold taper ranging from no taper to 3° as well as change in casting conditions, superheat and casting speed, are conducted to analyze the impact of taper with respect to the casting conditions. Per the conditions applied, angular taper between 1° and 2° resulted into reduction of undercooling and overcooling in the corner of the mold which is subjected to cooling from the broad face and narrow face of the cool mold wall. The turbulent flow in the mold region was found to drastically influences the quality of steel produced during continuous casting. The flow itself can lead to surface defects or slag entrainment based on the formation. A high surface wave due to turbulence of the injected melt lead to fluctuations and the instability compromised the quality of the steel produced as well as entrained the slag. To regulate the flow, electromagnetic forces can be applied in the mold, dampening the local turbulent flow. As the electrically conductive molten steel interacts with the induced magnetic field, it reduced the velocity of the steel jet released from the ports of the submerged entry nozzle. Per the simulation-based study conducted increasing the EMBr strength from 2975G to 4350G reduced the peak surface wave height by 59.47% and volume of flux rate of decrease by 4.25%. Additionally, increasing the SEN depth from 110 mm to 350 mm increased the average wave height by 19% and volume of flux rate of decrease by 2.6%. Lastly, increasing the mold width from 1.067 m to 1.50m increased average wave height by 8.71% and volume of flux rate of decrease by 0.9%. </p>

<p>  </p> <p>Due to miniaturization of electronic devices new electronic packaging strategies, such as Heterogeneous Integration Packaging (HIP), are being developed. In HIP, the space in the package is strategically mapped out to maximize the placement of components including all types of materials. Thus, there is a need to develop and understand the behavior of lower-melting point metallic interconnects as they will be located next to lower melting point materials, such as polymers. </p> <p>The composition of alloying elements in Sn-rich solder plays a pivotal role in determining the microstructural properties of the solder joint. However, the complex mechanisms governing the solidification processes of Sn-In, and Sn-Bi alloys are still not fully understood. Furthermore, the experimental characterization of phase formation poses significant challenges.</p> <p>This dissertation focuses on understanding microstructural evolution in Sn-In and Sn-Bi alloys during reflow. A systematic approach to characterizing the microstructure of alloys was developed, utilizing electron microscopy, non-destructive x-ray tomography and diffraction techniques, ranging from lab-scale to synchrotron experiments. The influence of In addition on microstructure was correlated with the mechanical behavior obtained using nanoindentation. The experimental understanding was further correlated with the Density Functional Theory (DFT) calculations. To study the Sn-Bi microstructures, the effect of experimental parameters, such as the cooling rate during solidification was elucidated. A 4D study was conducted, involving the analysis of 3D microstructures along with time evolution, to gain a comprehensive understanding of the solidification dynamics using synchrotron white beam tomography. For the first time, we observed a regular pyramidal morphology of Bi forming in the solder alloy. The 4D analysis provided crucial insights into morphology formation, growth kinetics, defect formation during solidification. The crystallographic analysis unraveled unique insights into the solid-liquid interface stability for semi-metals. Furthermore, the simultaneous Energy Dispersive Diffraction (EDD) analysis yielded a deeper understanding into the phase formation and lattice strain evolution. A fundamental relationship between the diffraction intensity and phase fractions, from imaging, was obtained. The experimental methodology developed in this work has the potential to be extended to investigate a wide range of alloy solidification mechanisms, enabling a deeper understanding of these materials.</p>

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Metal additive manufacturing can be used for producing complex and functional components in the aerospace industry. This thesis deals with the process-structure-property relationships in selective laser melting of three aerospace alloys: Invar 36, stainless steel 316L, and Ti-6Al-4V. These alloys are weldable but hard to machine, which make them good candidates for the selective laser melting process. Invar 36 has a very low coefficient of thermal expansion because of its nickel concentration of 36% and stainless steel 316L contains 16-18% chromium that gives the alloy a corrosion resistance property. Ti-6Al-4V offers high strength-to-weight ratio, high biocompatibility, and outstanding corrosion resistance. Any changes in the chemical composition of these materials could affect their performance during application. In this thesis, a full factorial design of experiments is formulated to study a wide range of laser process parameters. The bulk density, tensile mechanical properties, fractography, microstructure, material composition, material phases, coefficient of thermal expansion, magnetic dipole moments, and residual stresses of the parts produced are experimentally investigated. An optimum process window has been suggested for each material based on experimental work. The thermal cycle, residual stresses, and part distortions are examined using a thermo-mechanical finite element model. The model predicts the residual stress and part distortion after build plate removal. The thesis introduces two laser energy densities for each material: brittle-ductile transition energy density, ET, and critical laser energy density, EC. Below the brittle-ductile transition energy density, the parts exhibited void formation, low density, and brittle fracture. Above the critical energy density, the parts showed vaporization of some alloying elements that have low boiling temperatures. Additionally, real-time measurements were taken using a pyrometer and a high-speed camera during the selective laser melting process. The trends found in the numerical results agree with those found experimentally. / Thesis / Doctor of Philosophy (PhD)

The present thesis investigates the grain refinement in solidifying Al-7wt%Si hypoeutectic alloy driven by electric currents. The grain size reduction in alloys generated by electric currents during the solidification has been intensively investigated. However, since various effects of electric currents have the potential to generate the finer equiaxed grains, it is still argued which effect plays the key role in the grain refinement process. In addition, the knowledge about the grain refinement mechanism under the application of electric currents remains fragmentary and inconsistent. Hence, the research objectives of the present thesis focus on the role of electric current effects and the grain refinement mechanism under the application of electric currents. Chapter 1 presents an introduction with respect to the subject of grain refinement in alloys driven by electric current during the solidification process in particular, including the research objectives; the research motivation; a brief review about the research history; a short introduction on the electric currents effects and a review relevant to the research status of grain refinement mechanism. Chapter 2 gives a description of research methods. This chapter shows the employed experiment materials, experimental setup, experimental procedure, the analysis methods of solidified samples, and numerical method, respectively. Chapter 3 focuses on the role of electric current effects in the grain refinement process. A series of solidification experiments are performed under various values of effective electric currents for both, electric current pulse and direct current. The corresponding temperature measurements and flow measurements are carried out with the increase of effective electric current intensity. Meanwhile, numerical simulations are conducted to present the details of the flow structure and the distribution of electric current density and electromagnetic force. Finally, the role of electric current effects is discussed to find the key effect in the grain refinement driven by electric currents. Chapter 4 investigates the grain refinement mechanism driven by electric currents. This chapter mainly focuses on the origin of finer equiaxed grain for grain refinement under the application of electric current on account of the importance of the origin for understanding the grain refinement mechanism. A series of solidification experiments are carried out in Al-7wt%Si alloy and in high purity aluminum. The main origin of equiaxed grain for grain refinement is concluded based on the experiment results. Chapter 5 presents three further investigations based on the achieved knowledge in chapter 3 and 4 about the role of electric current effects and the grain refinement mechanism. According to the insight into the key electric current effect for the grain refinement shown in chapter 3, this chapter presents a potential approach to promote the grain refinement. In addition, the solute distribution under the influence of electric current is examined based on the knowledge about the electric current effects. Moreover, the grain refinement mechanism under application of travelling magnetic field is investigated by performing a series of solidification experiments to compare with the experiments about the grain refinement mechanism driven by electric currents shown in chapter 4. Chapter 6 summarizes the main conclusions from the presented work.

La compréhension du comportement des matériaux en présence d'impuretés, durant le processus de solidification, nécessite le développement de méthodologies appropriées pour une analyse et un contrôle efficace des changements topologiques des microstructures (par exemple, la formation des dendrites) au cours des différentes phases de transformation. L'objectif de cette thèse est de construire un modèle pertinent de solidification d'alliages binaires sous l'action de champs magnétiques, d'analyser les systèmes issus du modèle mathématique ainsi développé, d'un point de vue théorique et numérique, et enfin de développer une méthode de contrôle optimal afin de contrôler la dynamique du front de solidification par l'action du champs magnétiques. Dans un premier temps, nous avons décrit la physique du problème et les lois fondamentales nécessaires à la modélisation, puis nous avons construit un nouveau modèle de champ de phase, qui tient compte de l'influence de l'action du champ magnétique sur le mouvement du front de solidification. Le modèle ainsi développé est caractérisé par le couplage de trois systèmes : un de type magnétohydrodynamique, un second de type Warren-Boettingger avec convection (représentant l'évolution du front de solidification et la concentration du mélange binaire) et un troisième représentant l'évolution de la température. Les équations du système complet décrivant le modèle, dans un domaine Ω inclus dans R^{n}, n ≤ 3, sont évolutives, non linéaires, couplées et anisotropes. Dans une seconde partie, nous avons effectué l'analyse théorique du modèle développé dans le cas isotherme et isotrope en dimension deux. Nous avons obtenu des résultats d'existence, de régularité, de stabilité et d'unicité d'une solution, sous certaines conditions sur des opérateurs non linéaires du système. Enfin, nous avons développé une méthode de contrôle optimal non linéaire : le champ magnétique (qui intervient sous forme multiplicative) joue le rôle de contrôle, et l'observation est l'état désiré de la dynamique du front. Nous avons démontré l'existence d'une solution optimale et obtenu la sensibilité de l'opérateur solution et les conditions d'optimalité en introduisant un problème adjoint. Cette partie théorique de la thèse est complétée par un important travail numérique. L'analyse et les simulations numériques ont été menées sur le problème complet bi-dimensionnel non linéaire (isotrope et anisotrope). Nous avons utilisé pour la discrétisation la méthode des lignes qui consiste à considérer séparément la discrétisation temporelle et spatiale. La discrétisation spatiale est effectuée par un schéma d'éléments finis mixtes et le système différentiel algébrique obtenu est résolu par l'utilisation du solveur DASSL. La discrétisation du domaine est effectuée par des mailles triangulaires non structurées. Dans le cas réaliste, elles correspondent à un maillage non uniforme et trés fin dans la zone de la dendrite et au niveau de l'interface. Nous avons obtenu des estimations d'erreur pour les différentes variables d'état du modèle et analysé la robustesse et la stabilité des schémas d'approximation. Ce code numérique a été validé sur différents exemples, et donne d'excellents résultats. Ensuite, nous avons exploité le code pour traiter un problème réaliste, à savoir la solidification dendritique d'un alliage binaire Nickel-Cuivre, et analyser l'influence de champs magnétiques sur l'évolution des dendrites. Les résultats obtenus montrent l'efficacité de l'approche à reproduire les observations expérimentales.

L'objectif de la thèse est de traiter des sédiments marins et des sols fins équivalents (fines de carrière) considérés comme des déchets, par un procédé de solidification/stabilisation et de les valoriser en matériau pour des sous couches routières. Ces traitements ont donné lieu à des mélanges composites sédiments-liants et/ou ajouts de cendres volantes, de fumée de silice, de produits chimiques réactifs et de fibres suivis d'une analyse comportementale des performances mécaniques et de durabilité. Après avoir sélectionné un panel représentatif de sédiments marins et une fine de carrière, une phase de caractérisation a été entreprise sur les paramètres déterminants en vue de traiter ces sédiments. Elle repose sur l'étude des propriétés physiques (répartition des grains, limites d'Atterberg) et chimiques (la teneur en matière organique et en carbonates). Les différentes caractéristiques, dosages et paramètres dimensionnels des constituants (ciment, chaux, cendre volante, fumée de silice, sables correcteur, produit chimique réactif et fibres naturelle et géosynthétiques) des mélanges sont déterminés. Le programme expérimental complet est présenté, il intéresse les sédiments marins à stabiliser ou solidifier. Les essais mécaniques de résistance et de durabilité (compression simple, traction indirecte, mouillage-séchage) ont été effectués sur échantillons cylindriques. L'analyse et l'interprétation des résultats ont permis de mieux cerner les différents facteurs influant sur la résistance à la compression et à la traction indirecte des mélanges traités avec des additions de liants hydrauliques et de liant pouzzolanique, puis avec des ajouts spécifiques de fumée de silice, de sable correcteur et de produits chimiques réactifs. Une phase innovante a porté sur l'utilisation de fibres déchets dans les mélanges. Ces fibres naturelle (lin) et artificielles (géosynthétiques) ont été proposées pour améliorer le comportement mécanique des mélanges de sédiments marins et/ou fine de carrière. En conclusion, pour les dosages économiques retenus et les mélanges étudiés, une application en sous couche routière est possible (classes S1à S5). La teneur en matière organique des sédiments marins a une forte influence sur l'efficacité des traitements des sédiments marins aux liants. Les renforts fibreux sont tout à fait prometteurs et l'idée de covaloriser deux déchets constitue une avancée dans la gestion durable et la valorisation des sédiments.