The study of microstructures for the accurate control of material properties is of industrial relevance. Identification and characterization of microstructural properties by manual measurement are often slow, labour intensive, and have a lack of repeatability. In the present work, the intermetallic phase ratio and grain size in the microstructure of known Mg-Sn-Al alloys were measured by computer vision (CV) technology. New Mg (Magnesium) alloys with different alloying element contents were selected as the work materials. Mg alloys (Mg-Al-Sn) were produced using the hot-pressing powder metallurgy technique. The alloys were sintered at 620 °C under 50 MPa pressure in an argon gas atmosphere. Scanning electron microscopy (SEM) images were taken for all the fabricated alloys (three alloys: Mg-7Al-5Sn, Mg-8Al-5Sn, Mg-9Al-5Sn). From the SEM images, the grain size was counted manually and automatically with the application of CV technology. The obtained results were evaluated by correcting automated grain counting procedures with manual measurements. The accuracy of the automated counting technique for determining the grain count exceeded 92% compared to the manual counting procedure. In addition, ASTM (American Society for Testing and Materials) grain sizes were accurately calculated (approximately 99% accuracy) according to the determined grain counts in the SEM images. Hence, a successful approach was proposed by calculating the ASTM grain sizes of each alloy with respect to manual and automated counting methods. The intermetallic phases (Mg17Al12 and Mg2Sn) were also detected by theoretical calculations and automated measurements. The accuracy of automated measurements for Mg17Al12 and Mg2Sn intermetallic phases were over 95% and 97%, respectively. The proposed automatic image processing technique can be used as a tool to track and analyse the grain and intermetallic phases of the microstructure of other alloys such as AZ31 and AZ91 magnesium alloys, aluminium, titanium, and Co alloys.
PurposeMetal foams are a structural and functional composite materials that have received wide attention due to their specific structures and properties. The aim of this study is to investigate the mechanical properties of syntactic foam by using expanded silica gel with the spacer technique.Design/methodology/approachIn this research paper, the vacuum casting production method was used to produce metal syntactic foams including AlSi12 and AlSi8Cu3 matrix and expanded silica gel fillers with diameters of 2–4.75 mm and 4.75–5.6 mm.FindingsAs a result of the study, it was observed that as the foam densities increased, the compressive strength values of the samples increased due to the increasing volume fraction of the metallic matrix. Samples with the AlSi12 matrix showed higher compressive strength than samples with the AlSi8Cu3 matrix.Originality/valueThe originality of the study is the comparison of two different main matrix alloys (AlSi12 and AlSi8Cu3) and different pores using expanded silica gel.
This research focuses on the fabrication and characterization of TAZ532-xNb composites, employing high-purity, micron-sized powders of Mg, Sn, Al, Zn, Mn, and Nb as the raw materials. These powders were subjected to a paraffin coating process aimed at mitigating oxidation. The formation of composites was achieved via hot pressing and was followed by surface preparation and analysis using scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS). An X-ray diffraction (XRD) study was conducted to identify the microstructural phases. Quantitative assessments including the theoretical density, actual density, and relative density were computed, and their fluctuations in relation to the increasing Nb reinforcement ratio were scrutinized. Furthermore, the mechanical attributes of the composites, such as hardness and tensile strength, were assessed via experimental procedures. The absence of oxygen-related peaks in the XRD patterns endorsed the successful execution of the paraffin coating technique and protective gas atmosphere during sintering. The detection of α-Mg, Mg2Sn, MgZn, Mg17Al12, and Nb phases within the Nb-reinforced composite patterns authenticated the formation of the intended phases. Notably, the relative density values of the composites surpassed 95%, indicating efficient sintering. SEM results disclosed a densely packed microstructure, with Nb reinforcement particles evenly distributed along the grain boundaries, devoid of particle clustering or significant grain growth. These composites manifested exceptional wetting characteristics, which can be attributed to the employment of Mg alloy as the matrix material. EDS data confirmed the proportions of Nb within the composites, aligning with the quantities incorporated during fabrication. The composites showcased an increase in microhardness values with the escalating Nb reinforcement ratio, credited to the harder constitution of Nb particles in comparison to the matrix alloy. Concurrently, tensile strength showed a significant improvement with the increment in Nb reinforcement, while elongation values peaked at a specific Nb reinforcement level. The positive evolution of tensile strength properties was ascribed to the escalated Nb reinforcement ratio, grain size, and consequent higher sample densities.
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