The effect of cooling rate on microstructure and microsegregation of three commercially important magnesium alloys was investigated using Wedge (V-shaped) castings of AZ91D, AM60B, and AE44 alloys. Thermocouples were distributed to measure the cooling rate at six different locations of the wedge casts. Solute redistribution profiles were drawn based on the chemical composition analysis obtained by EDS/WDS analysis. Microstructural and morphological features such as dendrite arm spacing and secondary phase particle size were analyzed using both optical and scanning electron microscopes. Dendritic arm spacing and secondary phase particle size showed an increasing trend with decreasing cooling rate for the three alloys. Area percentage of secondary phase particles decreased with decreasing cooling rate for AE44 alloy. The trend was different for AZ91D and AM60B alloys, for both alloys, area percentage of β-Mg17Al12 increased with decreasing cooling rate up to location 4 and then decreased slightly. The tendency for microsegregation was more severe at slower cooling rates, possibly due to prolonged back diffusion. At slower cooling rate, the minimum concentration of aluminum at the dendritic core was lower compared to faster cooled locations. The segregation deviation parameter and the partition coefficient were calculated from the experimentally obtained data.
The microstructural details of fourteen Mg-Al-Sr alloys were investigated in the as-cast form by a combination of scanning electron microscopy/energy dispersive spectrometer (SEM/EDS) analysis and quantitative electron probe microanalysis (EPMA). The heat transfer method coupled with the DSC measurement has been utilized to determine the solidification curves of the alloys. The morphology and the chemical composition of the phases were characterized. The microstructure of the alloys is primarily dominated by (Mg) and (Al 4 Sr). In the present investigation, ternary solid solubility of three binary compounds extended into the ternary system has been reported and denoted as: (Al 4 Sr), (Mg 17 Sr 2 ) and (Mg 38 Sr 9 ). The (Al 4 Sr) phase is a substitutional solid solution represented by Mg x Al 4Àx Sr and has a plate-like structure. The maximum solubility of Al in Mg 17 Sr 2 was found to be 21.3 at%. It was also observed that Mg 38 Sr 9 dissolved 12.5 at% Al. r
Mechanical response of nano-based composites is generally influenced by interaction of filler and matrix at interface. Increasing filler-loading within the composite may cause spatial limitation toward best dispersion of filler, and since synthesizing a totally agglomerated-free nanocomposite is difficult, filler and matrix interaction needs to be perfectly modeled. A micromechanical model is developed in this study based on the common Halpin-Tsai theory to predict the elastic stiffness of vinyl ester/exfoliated graphite platelet nanocomposites. The model considers near-rational ideal (uniformly dispersed) mixed with clustered filler-network to simulate filler-distribution conditions. A filler-dispersion level based on the filler concentration has been proposed mathematically in this study. Predictions of the proposed model considering filler morphology were compared with the predictions of the Halpin-Tsai model and the experimentally obtained results as well. The proposed model shows better accuracy in terms of stiffness over predictions of the HalpinTsai model and appears in a very good agreement with the experimental results obtained for vinyl ester nanocomposites.
The use of wrought magnesium for automobile structural components is an important component of the mass reduction strategy for automobiles to improve their fuel efficiency. Compared to Direct chill casting, Twin Roll Casting (TRC) allows major reduction of hot rolling steps in the production of Mg sheet due to the thin thickness of the as-cast strip. This TRC route can substantially reduce the time and cost to produce Mg alloy sheet product. In this work, AZ31 magnesium alloy was casted to 5 and 6 mm thick strips under different process conditions. Microstructure of these strips was analyzed using optical microscopy, SEM and EPMA. TRC strip was annealed under two different conditions: 2 hours at 330 and 1 hour at 400°C. It has been found that heat treatment at 400°C for 1 hour reduces centerline segregation significantly. TRC strips were rolled down to 2 mm and annealed at 450°C for 2 minutes. The average grain size was 4-6 µm and mechanical properties were comparable with commercial AZ31 sheet.
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