Electrospark deposition (ESD) was applied to AlZr binary system in order to study the possible change of solidification structure from the stable D0 23 tetragonal equilibrium phases to the cubic L1 2 , when high cooling rates and undercooling conditions are involved. The results show that a supersaturated solid solution was formed for the alloy containing 0.5 at%Zr, while a two-region layered structure was developed for the alloys with 11.5 at%Zr. These layers are composed of refined equiaxed grains, with a smaller particle size distribution for the region where the L1 2 precipitates were present.
Electrospark deposition (ESD) was studied to investigate the possibility of forming non-equilibrium microstructures in Al alloy systems. The results have demonstrated that the level of supersaturation is system-dependent. The Al-10 wt% Mg system exhibited a complete supersaturation, while the Al-Si system had a supersaturation level reaching about 1wt%. The ESD process was also used to demonstrate the possibility of forming metastable intermetallics in the Al-Ni system, such as the Al 9 Ni 2. When comparing the present results with the literature of rapid solidification of these alloys using other processes, the discrepancy between the extent of non-equilibrium microstructure obtained is believed to be associated with the formation and duration of the weld pool prior to solidification.
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