Casting

Abstract: We report on the properties of one example of a new family of metallic alloys which exhibit excellent glass forming ability. The critical cooling rate to retain the glassy phase is of the order of 10 K/s or less. Large samples in the form of rods ranging up to 14 mm in diameter have been prepared by casting in silica containers. The undercooled liquid alloy has been studied over a wide range of temperatures between the glass transition temperature and the thermodynamic melting point of the equilibrium crystalline alloy using scanning calorimetry. Crystallization of the material has been studied. Some characteristic properties of the new material are presented. The origins of exceptional glass forming ability of these new alloys are discussed.

Abstract: Metal-based additive manufacturing, or three-dimensional (3D) printing, is a potentially disruptive technology across multiple industries, including the aerospace, biomedical and automotive industries. Building up metal components layer by layer increases design freedom and manufacturing flexibility, thereby enabling complex geometries, increased product customization and shorter time to market, while eliminating traditional economy-of-scale constraints. However, currently only a few alloys, the most relevant being AlSi10Mg, TiAl6V4, CoCr and Inconel 718, can be reliably printed; the vast majority of the more than 5,500 alloys in use today cannot be additively manufactured because the melting and solidification dynamics during the printing process lead to intolerable microstructures with large columnar grains and periodic cracks. Here we demonstrate that these issues can be resolved by introducing nanoparticles of nucleants that control solidification during additive manufacturing. We selected the nucleants on the basis of crystallographic information and assembled them onto 7075 and 6061 series aluminium alloy powders. After functionalization with the nucleants, we found that these high-strength aluminium alloys, which were previously incompatible with additive manufacturing, could be processed successfully using selective laser melting. Crack-free, equiaxed (that is, with grains roughly equal in length, width and height), fine-grained microstructures were achieved, resulting in material strengths comparable to that of wrought material. Our approach to metal-based additive manufacturing is applicable to a wide range of alloys and can be implemented using a range of additive machines. It thus provides a foundation for broad industrial applicability, including where electron-beam melting or directed-energy-deposition techniques are used instead of selective laser melting, and will enable additive manufacturing of other alloy systems, such as non-weldable nickel superalloys and intermetallics. Furthermore, this technology could be used in conventional processing such as in joining, casting and injection moulding, in which solidification cracking and hot tearing are also common issues.

Abstract: Solidification, in the sense used in this context, is the process by which a liquid is transformed into a crystalline solid. In crystal growth the solid that forms first is solvent rich as distinct from crystallisation, in which the crystals that are formed are solute rich. It is not always possible to make a clear distinction. Solidification is important as the process employed in the widely used process of casting, in all its forms from large ingots of steel to small crystals of silicon. While in principle it would seem simple to convert a homogeneous liquid into an equally homogeneous perfect crystal, this is extremely difficult, if not impossible to achieve in practice. Thorough understanding requires that the process be studied at various levels, which can be conveniently described as the angstrom level, the micron level and the centimetre level.