Solidification rapid

The industrial technique now known as Rapid Solidifieation Proeessing (RSP) is unusual in that it owes its existenee largely to a researeh programme executed in one laboratory for purely scientifie reasons. The manifold industrial developments that followed were an unforeseen and weleome by-produet. 

It appears that there was an independent initiative in RSP by I.V. Salli in Russia in 1958 (Salli 1959), but it was not pursued. 

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Traditionally, production of metallic glasses requites rapid heat removal from the material (Fig. 2) which normally involves a combination of a cooling process that has a high heat-transfer coefficient at the interface of the Hquid and quenching medium, and a thin cross section in at least one-dimension. Besides rapid cooling, a variety of techniques are available to produce metallic glasses. Processes not dependent on rapid solidification include plastic deformation (38), mechanical alloying (7,8), and diffusional transformations (10). 

Using rapid solidification technology molten metal is quench cast at a cooling rate up to 10 °C/s as a continuous ribbon. This ribbon is subsequently pulverized to an amorphous powder. RST powders include aluminum alloys, nickel-based superalloys, and nanoscale powders. RST conditions can also exist in powder atomization. 

The majority of ah these classes, even noneutectic ahoys, have been processed successfuhy by rapid solidification technology. This technology provides a beneficial alternative in the form of a flexible ductile foh when materials that are inherently brittle are used. Examples are the nickel—boron—shicon ahoys and many others, when produced using conventional technology (5). 

Elimination. Since slag is less dense than the weld metal, it will float to the surface if unhindered by rapid solidification. Therefore, preheating the components to be welded or high weld heat input may prevent slag entrapment. 

Virtually every reference at the end of this chapter is to post-war publications, and the majority are to papers published during the past 15 years. This shows, clearly enough, that extreme materials are recent features of materials science and engineering (MSE), and there is every indication that the focus on materials of the kind discussed in this chapter will continue to develop. Individual approaches come and go - thus, rapid solidification processing, the oldest of the approaches discussed here, seems to have passed its apogee - while others go from strength to strength ... 

F. W. Froes and S. J. Savage, Processing of Structural Metals by Rapid Solidification,... 

Rapid solidification technology has been applied to several magnesium alloy systems and extruded material of some of these systems have exhibited excellent corrosion resistance. 

Das, Chang, Raybould High Performance Magnesium Alloys by Rapid Solidification Processing , Light Metal Age, Dec. 5-8 1986... 

The equilibrium, room temperature structure of pure cobalt is hep. The fee structure is stable at high temperatures (422 °C to 1495 °C) and has been retained at room temperature by rapid solidification techniques [101], X-ray diffraction analysis was used to probe the microstructure of bulk Co-Al alloy deposits containing up to 25 a/o Al and prepared from solutions of Co(II) in the 60.0 m/o AlCfi-EtMelmCl melt. Pure Co deposits had the hep structure no fee Co was observed in any of the deposits. The addition of aluminum to the deposit caused a decrease in the deposit grain size and an increase in the hep lattice volume. A further increase in the aluminum content resulted in amorphization of the deposit [44], Because the equilibrium... 

The phase distribution observed in the alloys deposited from AlCb-NaCl is very similar to that of Mn-Al alloys electrodeposited from the same chloroaluminate melt [126 129], Such similarity may also be found between the phase structure of Cr-Al and Mn-Al alloys produced by rapid solidification from the liquid [7, 124], These observations are coincident with the resemblance of the phase diagrams for Cr-Al and Mn-Al, which contain several intermetallic compounds with narrow compositional ranges [20], inhibition of the nucleation and growth of ordered, often low symmetry, intermetallic structures is commonly observed in non-equilibrium processing. Phase evolution is the result of a balance between the interface velocity and... 

This process, originally designated as RSR (rapid solidification rate), was developed by Pratt and Whitney Aircraft Group and first operated in the late 1975 for the production of rapidly solidified nickel-base superalloy powders.[185][186] The major objective of the process is to achieve extremely high cooling rates in the atomized droplets via convective cooling in helium gas jets (dynamic helium quenching effects). Over the past decade, this technique has also been applied to the production of specialty aluminum alloy, steel, copper alloy, beryllium alloy, molybdenum, titanium alloy and sili-cide powders. The reactive metals (molybdenum and titanium) and... 

For an alloy droplet, the post-recalescence solidification involves segregated solidification and eutectic solidification. 619 Droplet cooling in the region (1),(2) and (6) can be calculated directly with the above-described heat transfer model. The nucleation temperature (the achievable undercooling) and the solid fraction evolution during recalescence and post-recalescence solidification need to be determined additionally on the basis of the rapid solidification kinetics. 154 156 ... 

With the above-described heat transfer model and rapid solidification kinetic model, along with the related process parameters and thermophysical properties of atomization gases (Tables 2.6 and 2.7) and metals/alloys (Tables 2.8,2.9,2.10 and 2.11), the 2-D distributions of transient droplet temperatures, cooling rates, achievable undercoolings, and solid fractions in the spray can be calculated, once the initial droplet sizes, temperatures, and velocities are established by the modeling of the atomization stage, as discussed in the previous subsection. For the implementation of the heat transfer model and the rapid solidification kinetic model, finite difference methods or finite element methods may be used. To characterize the entire size distribution of droplets, some specific droplet sizes (forexample,.D0 16,Z>05, andZ)0 84) are to be considered in the calculations of the 2-D motion, cooling and solidification histories. 

It should be noted that it is difficult to obtain models that can accurately predict thermal contact resistance and rapid solidification parameters, in addition to the difficulties in obtaining thermophysical properties of liquid metals/alloys, especially refractory metals/al-loys. These make the precise numerical modeling of flattening processes of molten metal droplets extremely difficult. Therefore, experimental studies are required. However, the scaling of the experimental results for millimeter-sized droplets to micrometer-sized droplets under rapid solidification conditions seems to be questionable if not impossible,13901 while experimental studies of micrometer-sized droplets under rapid solidification conditions are very difficult, and only inconclusive, sparse and scattered data are available. 

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