The melting, evaporation and oxidation behaviors as well as the solidification phenomena of tungsten and molybdenum in induction plasma were studied. Scanning electron microscopy was used to examine the morphology and...The melting, evaporation and oxidation behaviors as well as the solidification phenomena of tungsten and molybdenum in induction plasma were studied. Scanning electron microscopy was used to examine the morphology and the cross section of plasma-processed powders. X-ray diffraction was used to analyze the oxides formed on the particle surface of these two metals. The influence of spray chamber pressure on the spheroidization and oxidation phenomena was discussed. The results show that fewer Mo particles than W particles are spheroidized at the same powder feed rate under the same plasma spray condition although molybdenum has a lower melting point. A small fraction of tungsten is evaporized and condensed either on the surface of tungsten particles nearby or on the wall of spray chamber. Tungsten oxides were found in tungsten powder processed under soft vacuum condition. Extremely large grains form inside some spheroidized particles of tungsten powder.展开更多
Experimental studies on the melting process of titanium aluminum alloy have been pursued from the viewpoint of contamination.TiAl alloys were prepared with vacuum induction melting （VIM） in calcia crucibles at 1873 ...Experimental studies on the melting process of titanium aluminum alloy have been pursued from the viewpoint of contamination.TiAl alloys were prepared with vacuum induction melting （VIM） in calcia crucibles at 1873 K and 1923 K in order to determine the behavior of the oxygen content as a function of temperature,time and frequency of power.The experiment results showed that alloys were uncontaminated except for the increasing of oxygen content which was introduced from the reaction CaO（s）=Ca（in TiAl）＋O（in TiAl）,and the standard Gibbs energy of the reaction was determined to be △G0 =274000 102.8T（J/mol）.Oxygen content increased slowly with the melting time by about 50×10-6 wt pct/min,and decreased with induction melting frequency.Lower superheat and higher melting frequency can be used to reduce oxygen content increasing rate.展开更多
This study documents laboratory-scale observation of the interactions between the Ni-based superalloy FGH4096 and refractories.Three different crucibles were tested—MgO,Al2O3,and MgO–spinel.We studied the variations...This study documents laboratory-scale observation of the interactions between the Ni-based superalloy FGH4096 and refractories.Three different crucibles were tested—MgO,Al2O3,and MgO–spinel.We studied the variations in the compositions of the inclusions and the alloy–crucible interface with the reaction time using scanning electron microscopy equipped with energy dispersive X-ray spectroscopy and Xray diffraction.The results showed that the MgO and MgO–spinel crucibles form MgO-containing inclusions(Al–Mg oxides and Al–Mg–Ti oxides),whereas the inclusions formed when using the Al2O3 crucible are Al2O3 and Al–Ti oxides.We observed a new MgAl2O4 phase at the inner wall of the MgO crucible,with the alloy melted in the MgO crucible exhibiting fewer inclusions.No new phase occurred at the inner wall of the Al2O3 crucible.We discuss the mechanism of interaction between the refractories and the Ni-based superalloy.Physical erosion was found to predominate in the Al2O3 crucible,whereas dissolution and chemical reactions dominated in the MgO crucible.No reaction was observed between three crucibles and the Ti of the melt although the Ti content(3.8wt%)was higher than that of Al(2.1wt%).展开更多
The variation law of inclusions type and size in the vacuum induction melting process and ingot of Ni-based superalloy containing 70%return material was studied by industrial test sampling,and the mechanism of inclusi...The variation law of inclusions type and size in the vacuum induction melting process and ingot of Ni-based superalloy containing 70%return material was studied by industrial test sampling,and the mechanism of inclusions formation was analyzed with thermodynamic calculations.The results show that there are mainly two types of composite inclusions in the vacuum induction melting of Ni-based superalloys,which are nitride-and oxide-based composite inclusions,like Al_(2)O_(3)-SiO_(2)-Cr_(2)O_(3),TiN-(Mo,Nb)C,etc.The type and proportion of inclusions from the center to the edge of the vacuum induction ingot did not change significantly.The number density of inclusions from the center to the edge of the ingot varied less,and the size of inclusions became smaller from the center to the edge.In addition,thermodynamic calculations show that oxides(M_(2)O_(3))are present in the liquid phase and mainly contain Al,Ti,Cr,Fe and O elements.The nitride consists mainly of Ti and N and contains small amounts of Cr,C,Nb,and Mo elements.This is consistent with the results of industrial tests.As the temperature decreases,the precipitation phases such as M_(2)O_(3),MN,γ,MC,δ,γ'andμphases are gradually precipitated,where oxides and nitrides are present in the liquid phase.The contents of O and N elements are the main influencing factors for the inclusions content and precipitation temperature;when the nitrogen content is reduced to below 0.0015%,it can make MN precipitate below the liquid-phase line.展开更多
Electricity is an efficient form of energy,and the growing interest in electricity-assisted manufacturing is motivated by its inherent energy saving and reduced environmental impact.Beyond this,Electromagnetic Process...Electricity is an efficient form of energy,and the growing interest in electricity-assisted manufacturing is motivated by its inherent energy saving and reduced environmental impact.Beyond this,Electromagnetic Processing of Materials(EPM)allows the fabrication of materials with new compositions,metastable phases and nanograined microstructures that cannot be obtained using conventional heating processes using furnaces.This review covers EPM for the manufacture of ceramic and metal bulk components,with a specific focus on the effects of electric fields and electromagnetic radiations on processing in a wide spectrum of frequencies ranging from DC(f=0 Hz)to visible light(f=10^(14)–10^(15)Hz).The manuscript is divided into two parts.The first part provides a comprehensive overview of the interactions between matter and electric field/current,including heating phenomena(resistive Joule,induction,dielectric heating,electric arcs)and athermal effects(electromigration,electroplasticity,electrochemical reactions,ponderomotive force and others).The second part is focused on the technological application of the techniques,covering heat treatments,joining,sintering and forming.Seven distinct physical phenomena are involved in EPM:resistive Joule and induction heating,electrochemical reactions,electroplasticity,electric arcs and electromagnetic heating based on radio and microwave frequencies(mainly used for heating dielectric materials;i.e.,dielectric heating)or on the IR/visible light(IR heating and lasers).展开更多
The Y2O3 crucibles were introduced in the study as an alternative to the traditional ceramic ones in vacuum induction melting of multi-component Nb-16Si-22Ti-2AI-2Hf-17Cr （at.%） alloys, to reveal the possible intera...The Y2O3 crucibles were introduced in the study as an alternative to the traditional ceramic ones in vacuum induction melting of multi-component Nb-16Si-22Ti-2AI-2Hf-17Cr （at.%） alloys, to reveal the possible interactions between the alloy melt and the refractory crucible. Multiple melting time lengths and two cooling schemes were designed and used for the experiments. The chemical composition and microstructure of the tested alloy and the melt-crucible interaction were investigated and evaluated. In the experiments,Y2O3 crucible displays good physical-chemical compatibility. The results indicate that the increment of O element in the as-cast ingot iS： 0.03at.%-0.04at.% （72-97 ppm） and the increment of Y element is very insignificant. The key features of the alloy melt interacting with Y2O3 ceramics are analyzed and concluded in the paper. As a result of the dissolution reactiofi xY2O3 （in molten alloy） ＋ （1-x）HfO2 （impurity） →,Hf1-xY2xO2-x, a continuous double-layer solid film consisted of HfO2 solid solution （-2 pm） and pure HfO2 （-5μm） is formed on the surface of the test ingot after cooled down in the crucible. The experimental results show that theY2O3 crucible is applicable to the vacuum induction melting of Nb＇ Si based alloys.展开更多
The developing of large size superalloy vacuum induction melting(VIM)ingots is limited owing to hot cracking,The hot cracking behavior of the large size GH4742 superalloy VIM ingot was investigated via experiment and ...The developing of large size superalloy vacuum induction melting(VIM)ingots is limited owing to hot cracking,The hot cracking behavior of the large size GH4742 superalloy VIM ingot was investigated via experiment and simulation.The microstructure was examined by optical microscopy,and element segregation was investigated by electron probe microanalysis.The solidification temperature range and yield strength at high temperature(YSHT)were calculated by JMatPro software.The results show that the variations of microstructure and element segregation in different locations are caused by different cooling rates.Moreover,the larger secondary dendrite arm spacing and serious element segregation of Nb accelerate hot cracking of the VIM ingot.In addition,the solidification temperature range is wider,and YSHT is lower in center than at edge of the ingot.Therefore,the hot cracking susceptibility is the highest in the center of the GH4742 superalloy VIM ingot.The critical criterion of element segregation for hot cracking is that the partition coeffcient of Nb should be larger than 0.5.展开更多
A wide range of industrial metallurgical heating and melting processes are carried out using electrothermal and electromagnetic technologies.The application of electromagnetic processing offers many advantages from te...A wide range of industrial metallurgical heating and melting processes are carried out using electrothermal and electromagnetic technologies.The application of electromagnetic processing offers many advantages from technological, ecological and economical point of view.Although the technology level of the electromagnetic heating and melting installations and processes used in the industry today is very high,there are still potentials for improvement and optimization.In this paper recent applications and future development trends for efficient use of electromagnetic processing technologies in metallurgical and non-metallic material processes are described along selected examples in the field of heating for melting,forging,joining and solidification.展开更多
文摘The melting, evaporation and oxidation behaviors as well as the solidification phenomena of tungsten and molybdenum in induction plasma were studied. Scanning electron microscopy was used to examine the morphology and the cross section of plasma-processed powders. X-ray diffraction was used to analyze the oxides formed on the particle surface of these two metals. The influence of spray chamber pressure on the spheroidization and oxidation phenomena was discussed. The results show that fewer Mo particles than W particles are spheroidized at the same powder feed rate under the same plasma spray condition although molybdenum has a lower melting point. A small fraction of tungsten is evaporized and condensed either on the surface of tungsten particles nearby or on the wall of spray chamber. Tungsten oxides were found in tungsten powder processed under soft vacuum condition. Extremely large grains form inside some spheroidized particles of tungsten powder.
文摘Experimental studies on the melting process of titanium aluminum alloy have been pursued from the viewpoint of contamination.TiAl alloys were prepared with vacuum induction melting （VIM） in calcia crucibles at 1873 K and 1923 K in order to determine the behavior of the oxygen content as a function of temperature,time and frequency of power.The experiment results showed that alloys were uncontaminated except for the increasing of oxygen content which was introduced from the reaction CaO（s）=Ca（in TiAl）＋O（in TiAl）,and the standard Gibbs energy of the reaction was determined to be △G0 =274000 102.8T（J/mol）.Oxygen content increased slowly with the melting time by about 50×10-6 wt pct/min,and decreased with induction melting frequency.Lower superheat and higher melting frequency can be used to reduce oxygen content increasing rate.
基金This work is financially supported by the Natural Science Foundation of China(No.51974029)the Natural Science and Technology Major Project(No.2017-VI-0014-0086)and Fundamental Research Funds for the Central Universities(Nos.FRF-AT-19-013 and FRF-NP-19-003).
文摘This study documents laboratory-scale observation of the interactions between the Ni-based superalloy FGH4096 and refractories.Three different crucibles were tested—MgO,Al2O3,and MgO–spinel.We studied the variations in the compositions of the inclusions and the alloy–crucible interface with the reaction time using scanning electron microscopy equipped with energy dispersive X-ray spectroscopy and Xray diffraction.The results showed that the MgO and MgO–spinel crucibles form MgO-containing inclusions(Al–Mg oxides and Al–Mg–Ti oxides),whereas the inclusions formed when using the Al2O3 crucible are Al2O3 and Al–Ti oxides.We observed a new MgAl2O4 phase at the inner wall of the MgO crucible,with the alloy melted in the MgO crucible exhibiting fewer inclusions.No new phase occurred at the inner wall of the Al2O3 crucible.We discuss the mechanism of interaction between the refractories and the Ni-based superalloy.Physical erosion was found to predominate in the Al2O3 crucible,whereas dissolution and chemical reactions dominated in the MgO crucible.No reaction was observed between three crucibles and the Ti of the melt although the Ti content(3.8wt%)was higher than that of Al(2.1wt%).
基金supported by the National Key R&D Program of China(2021YFB3700402)National Natural Science Foundation of China(51974020,52104318 and 52074030).
文摘The variation law of inclusions type and size in the vacuum induction melting process and ingot of Ni-based superalloy containing 70%return material was studied by industrial test sampling,and the mechanism of inclusions formation was analyzed with thermodynamic calculations.The results show that there are mainly two types of composite inclusions in the vacuum induction melting of Ni-based superalloys,which are nitride-and oxide-based composite inclusions,like Al_(2)O_(3)-SiO_(2)-Cr_(2)O_(3),TiN-(Mo,Nb)C,etc.The type and proportion of inclusions from the center to the edge of the vacuum induction ingot did not change significantly.The number density of inclusions from the center to the edge of the ingot varied less,and the size of inclusions became smaller from the center to the edge.In addition,thermodynamic calculations show that oxides(M_(2)O_(3))are present in the liquid phase and mainly contain Al,Ti,Cr,Fe and O elements.The nitride consists mainly of Ti and N and contains small amounts of Cr,C,Nb,and Mo elements.This is consistent with the results of industrial tests.As the temperature decreases,the precipitation phases such as M_(2)O_(3),MN,γ,MC,δ,γ'andμphases are gradually precipitated,where oxides and nitrides are present in the liquid phase.The contents of O and N elements are the main influencing factors for the inclusions content and precipitation temperature;when the nitrogen content is reduced to below 0.0015%,it can make MN precipitate below the liquid-phase line.
基金the Thousand Talents Program of China and Sichuan Province。
文摘Electricity is an efficient form of energy,and the growing interest in electricity-assisted manufacturing is motivated by its inherent energy saving and reduced environmental impact.Beyond this,Electromagnetic Processing of Materials(EPM)allows the fabrication of materials with new compositions,metastable phases and nanograined microstructures that cannot be obtained using conventional heating processes using furnaces.This review covers EPM for the manufacture of ceramic and metal bulk components,with a specific focus on the effects of electric fields and electromagnetic radiations on processing in a wide spectrum of frequencies ranging from DC(f=0 Hz)to visible light(f=10^(14)–10^(15)Hz).The manuscript is divided into two parts.The first part provides a comprehensive overview of the interactions between matter and electric field/current,including heating phenomena(resistive Joule,induction,dielectric heating,electric arcs)and athermal effects(electromigration,electroplasticity,electrochemical reactions,ponderomotive force and others).The second part is focused on the technological application of the techniques,covering heat treatments,joining,sintering and forming.Seven distinct physical phenomena are involved in EPM:resistive Joule and induction heating,electrochemical reactions,electroplasticity,electric arcs and electromagnetic heating based on radio and microwave frequencies(mainly used for heating dielectric materials;i.e.,dielectric heating)or on the IR/visible light(IR heating and lasers).
文摘The Y2O3 crucibles were introduced in the study as an alternative to the traditional ceramic ones in vacuum induction melting of multi-component Nb-16Si-22Ti-2AI-2Hf-17Cr （at.%） alloys, to reveal the possible interactions between the alloy melt and the refractory crucible. Multiple melting time lengths and two cooling schemes were designed and used for the experiments. The chemical composition and microstructure of the tested alloy and the melt-crucible interaction were investigated and evaluated. In the experiments,Y2O3 crucible displays good physical-chemical compatibility. The results indicate that the increment of O element in the as-cast ingot iS： 0.03at.%-0.04at.% （72-97 ppm） and the increment of Y element is very insignificant. The key features of the alloy melt interacting with Y2O3 ceramics are analyzed and concluded in the paper. As a result of the dissolution reactiofi xY2O3 （in molten alloy） ＋ （1-x）HfO2 （impurity） →,Hf1-xY2xO2-x, a continuous double-layer solid film consisted of HfO2 solid solution （-2 pm） and pure HfO2 （-5μm） is formed on the surface of the test ingot after cooled down in the crucible. The experimental results show that theY2O3 crucible is applicable to the vacuum induction melting of Nb＇ Si based alloys.
基金supported by the National Natural Science Foundation of China(Nos.Ui708253 and 51571052)。
文摘The developing of large size superalloy vacuum induction melting(VIM)ingots is limited owing to hot cracking,The hot cracking behavior of the large size GH4742 superalloy VIM ingot was investigated via experiment and simulation.The microstructure was examined by optical microscopy,and element segregation was investigated by electron probe microanalysis.The solidification temperature range and yield strength at high temperature(YSHT)were calculated by JMatPro software.The results show that the variations of microstructure and element segregation in different locations are caused by different cooling rates.Moreover,the larger secondary dendrite arm spacing and serious element segregation of Nb accelerate hot cracking of the VIM ingot.In addition,the solidification temperature range is wider,and YSHT is lower in center than at edge of the ingot.Therefore,the hot cracking susceptibility is the highest in the center of the GH4742 superalloy VIM ingot.The critical criterion of element segregation for hot cracking is that the partition coeffcient of Nb should be larger than 0.5.
文摘A wide range of industrial metallurgical heating and melting processes are carried out using electrothermal and electromagnetic technologies.The application of electromagnetic processing offers many advantages from technological, ecological and economical point of view.Although the technology level of the electromagnetic heating and melting installations and processes used in the industry today is very high,there are still potentials for improvement and optimization.In this paper recent applications and future development trends for efficient use of electromagnetic processing technologies in metallurgical and non-metallic material processes are described along selected examples in the field of heating for melting,forging,joining and solidification.
