Revealing the nucleation kinetics of primary Si particles in hypereutectic Al–Si alloys under the influence of P inoculation
Source abstract
Abstract
Abstract A quantitative study on the kinetics of nucleation of primary Si particles (PSPs), especially under the effect of P inoculation, during isothermal melt solidification of hypereutectic Al–Si(–Cu) alloys has been realized for the first time by using a unique micro-focus in situ X-radiography method, which is impossible by synchrotron X-radiography or tomography methods. The nucleation undercooling and nucleation rate of PSPs have been measured. Besides, TP-1 type solidification test has been carried out. It is found that nucleation undercooling of PSPs is reduced, while nucleation rate and number density of PSPs is increased significantly by P inoculation. Moreover, the influence of cooling rate on the nucleation kinetics of PSPs in the P inoculated alloy was investigated in situ. It is observed that higher cooling rate has the influence of increasing the peak nucleation rate and extending the nucleation temperature ranges of PSPs, in terms of earlier nucleation at lower undercooling and nucleation stopping at higher undercooling, which results in higher number density of PSPs. The decrease in minimum nucleation undercooling with increasing cooling rate in the P inoculated alloy is unexpected, which has been attributed to the extremely slow growth rate of faceted Si crystal on AlP substrates under low undercooling.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Aluminum Alloy Microstructure Properties · Solidification and crystal growth phenomena · Aluminum Alloys Composites Properties
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (60)
Show source-provided references
1. Vijeesh V, Prabhu KN (2014) Review of microstructure evolution in hypereutectic Al–Si alloys and its effect on wear properties. Trans Indian Inst Met 67(1):1–1810.1007/s12666-013-0327-x ↗
2. Javidani M, Larouche D (2014) Application of cast Al–Si alloys in internal combustion engine components. Int Mater Rev 59(3):132–15810.1179/1743280413Y.0000000027 ↗
3. Tenekedjiev N, Gruzleski JE (1990) Hypereutectic aluminium-silicon casting alloys—a review. Cast Metals 3(2):96–10510.1080/09534962.1990.11819026 ↗
4. Chen Y, Hu Z, Xu Y, Wang J, Schützendübe P, Huang Y, Liu Y, Wang Z (2019) Microstructure evolution and interface structure of Al–40 wt% Si composites produced by high-energy ball milling. J Mater Sci Technol 35(4):512–51910.1016/j.jmst.2018.10.005 ↗
5. Fredriksson H, Hillert M, Lange N (1973) The modification of aluminum-silicon alloys by sodium. J Inst Met 101:285–299
6. Xu CL, Wang HY, Liu C, Jiang QC (2006) Growth of octahedral primary silicon in cast hypereutectic Al–Si alloys. J Cryst Growth 291(2):540–54710.1016/j.jcrysgro.2006.03.044 ↗
7. Xu CL, Jiang QC (2006) Morphologies of primary silicon in hypereutectic Al–Si alloys with melt overheating temperature and cooling rate. Mater Sci Eng, A 437(2):451–45510.1016/j.msea.2006.07.088 ↗
8. Atasoy OA, Yilmaz F, Elliott R (1984) Growth structures in aluminium-silicon alloys I. The coupled zone. J Cryst Growth 66(1):137–14610.1016/0022-0248(84)90084-8 ↗
9. Liang D, Bayraktar Y, Jones H (1995) Formation and segregation of primary silicon in Bridgman solidified Al–18.3 wt% Si alloy. Acta Metall Mater 43(2):579–58510.1016/0956-7151(94)00287-R ↗
10. Kasprzak W, Sahoo M, Sokolowski J, Yamagata H, Kurita H (2009) The effect of the melt temperature and the cooling rate on the microstructure of the Al–20% Si alloy used for monolithic engine blocks. Int J Metalcast 3(3):55–7110.1007/BF03355453 ↗
11. Ullah MW, Carlberg T (2011) Silicon crystal morphologies during solidification refining from Al–Si melts. J Cryst Growth 318(1):212–21810.1016/j.jcrysgro.2010.10.084 ↗
12. Wang W, Bian X, Qin J, Syliusarenko SI (2000) The atomic-structure changes in Al-16 pct Si alloy above the liquidus. Metall Mater Trans A 31(9):2163–216810.1007/s11661-000-0134-y ↗
13. Eskin GI, Eskin DG (2004) Some control mechanisms of spatial solidification in light alloys. Z Metall 95(8):682–69010.3139/146.018006 ↗
14. Kasprzak W, Sediako D, Walker M, Sahoo M, Swainson I (2011) Solidification analysis of an Al-19 Pct Si alloy using in situ neutron diffraction. Metall Mater Trans A 42(7):1854–186210.1007/s11661-011-0666-3 ↗
15. Sterner-Rainer R (1933) Aluminium silicon alloy with a phosphorus content of 0.001 to 0.1%. Google Patents
16. Ho CR, Cantor B (1995) Heterogeneous nucleation of solidification of Si in Al–Si and Al–Si–P alloys. Acta Metall Mater 43(8):3231–324610.1016/0956-7151(94)00480-6 ↗
17. Xu Y, Casari D, Du Q, Mathiesen RH, Arnberg L, Li Y (2017) Heterogeneous nucleation and grain growth of inoculated aluminium alloys: an integrated study by in situ X-radiography and numerical modelling. Acta Mater 140:224–23910.1016/j.actamat.2017.08.053 ↗
18. Xu Y, Casari D, Mathiesen RH, Li Y (2018) Revealing the heterogeneous nucleation behavior of equiaxed grains of inoculated Al alloys during directional solidification. Acta Mater 149:312–32510.1016/j.actamat.2018.02.058 ↗
19. Xu Y, Casari D, Mathiesen RH, Li Y (2019) Revealing the heterogeneous nucleation and growth behaviour of grains in inoculated aluminium alloys during solidification. Springer International Publishing, Cham, pp 1665–1675
20. Fan Z, Wang Y, Zhang Y, Qin T, Zhou XR, Thompson GE, Pennycook T, Hashimoto T (2015) Grain refining mechanism in the Al/Al–Ti–B system. Acta Mater 84:292–30410.1016/j.actamat.2014.10.055 ↗
21. Easton MA, Qian M, Prasad A, StJohn DH (2016) Recent advances in grain refinement of light metals and alloys. Curr Opin Solid State Mater Sci 20(1):13–2410.1016/j.cossms.2015.10.001 ↗
22. Greer AL (2016) Overview: application of heterogeneous nucleation in grain-refining of metals. J Chem Phys 145(21):21170410.1063/1.4968846 ↗
23. Murphy AG, Mathiesen RH, Houltz Y, Li J, Lockowandt C, Henriksson K, Zimmermann G, Melville N, Browne DJ (2016) XRMON-SOL: isothermal equiaxed solidification of a grain refined Al–20 wt%Cu alloy. J Cryst Growth 440:38–4610.1016/j.jcrysgro.2016.01.032 ↗
24. Liotti E, Arteta C, Zisserman A, Lui A, Lempitsky V, Grant PS (2018) Crystal nucleation in metallic alloys using x-ray radiography and machine learning. Sci Adv 4(4):eaar400410.1126/sciadv.aar4004 ↗
25. Olmedilla A, Založnik M, Combeau H (2019) Quantitative 3D mesoscopic modeling of grain interactions during equiaxed dendritic solidification in a thin sample. Acta Mater 173:249–26110.1016/j.actamat.2019.05.019 ↗
26. Wang Y, Fang CM, Zhou L, Hashimoto T, Zhou X, Ramasse QM, Fan Z (2019) Mechanism for Zr poisoning of Al-Ti-B based grain refiners. Acta Mater 164:428–43910.1016/j.actamat.2018.10.056 ↗
27. Kyffin WJ, Rainforth WM, Jones H (2001) Effect of treatment variables on size refinement by phosphide inoculants of primary silicon in hypereutectic Al–Si alloys. Mater Sci Technol 17(8):901–90510.1179/026708301101510870 ↗
28. Yu W, Zhang Y, Jiang A, Yan T, Du H, Tian Y, Lin X, Zheng H, Tian X (2017) Multi-step nucleation in Al–Si liquids catalyzed by a Ni–Si master alloy. Mater Des 132:385–39110.1016/j.matdes.2017.07.019 ↗
29. Kyffin WJ, Rainforth WM, Jones H (2001) Effect of phosphorus additions on the spacing between primary silicon particles in a Bridgman solidified hypereutectic Al–Si alloy. J Mater Sci 36(11):2667–2672. https://doi.org/10.1023/A:101790462773310.1023/A:1017904627733 ↗
30. Zhang Z-H, Bian X-F, Wang Y, Liu X (2001) Refinement and thermal analysis of hypereutectic Al–25% Si alloy. Trans Nonferrous Met Soc China 11(3):374–377
31. Wang R-Y, Lu W-H, Hogan LM (1995) Twin related silicon crystals in Al–Si alloys and their growth mechanism. Mater Sci Technol 11(5):441–44910.1179/mst.1995.11.5.441 ↗
32. Mathiesen RH, Arnberg L, Li Y, Meier V, Schaffer PL, Snigireva I, Snigirev A, Dahle AK (2011) X-ray videomicroscopy studies of eutectic Al–Si solidification in Al–Si–Cu. Metall Mater Trans A 42(1):170–18010.1007/s11661-010-0443-8 ↗
33. Shahani AJ, Gulsoy EB, Poulsen SO, Xiao X, Voorhees PW (2016) Twin-mediated crystal growth: an enigma resolved. Sci Rep 6:2865110.1038/srep28651 ↗
34. Shahani AJ, Xiao X, Skinner K, Peters M, Voorhees PW (2016) Ostwald ripening of faceted Si particles in an Al–Si–Cu melt. Mater Sci Eng, A 673:307–32010.1016/j.msea.2016.06.077 ↗
35. Mirihanage WU, Browne DJ (2011) As-cast grain size distribution prediction for grain refined castings via simulating free equiaxed dendrite transport during solidification. Int Found Res 63(1):28–33
36. Hall RN, Racette JH (1964) Diffusion and solubility of copper in extrinsic and intrinsic germanium, silicon, and gallium Arsenide. J Appl Phys 35(2):379–39710.1063/1.1713322 ↗
37. Dorward R, Kirkaldy J (1968) Thermodynamic properties of copper and gold in silicon and germanium. Trans Met Soc AIME 242(10):2055–2061
38. Darlapudi A, Felberbaum M, Mathiesen RH, Dahle AK (2016) The influence of Cu on eutectic nucleation and morphology in hypoeutectic Al–Si alloys. Springer International Publishing, Cham, pp 1475–1482
39. Zuo M, Liu XF (2011) Series of Al–P master alloy and excellent refining performance on hypereutectic A390 alloys. In: Advanced materials research. Trans Tech Publ, pp 613–61610.4028/www.scientific.net/AMR.306-307.613 ↗
40. Qiao H, Zhu X, Gao T, Wu Y, Liu X (2015) Influence of deformation on the microstructure and low-temperature refining behavior of Al–35P master alloy. J Mater Sci Technol 31(4):391–39610.1016/j.jmst.2014.09.010 ↗
41. Murphy AG, Mirihanage WU, Browne DJ, Mathiesen RH (2015) Equiaxed dendritic solidification and grain refiner potency characterised through in situ X-radiography. Acta Mater 95:83–8910.1016/j.actamat.2015.04.060 ↗
42. Murphy AG, Browne DJ, Mirihanage WU, Mathiesen RH (2013) Combined in situ X-ray radiographic observations and post-solidification metallographic characterisation of eutectic transformations in Al–Cu alloy systems. Acta Mater 61(12):4559–457110.1016/j.actamat.2013.04.024 ↗
43. Bjurenstedt A, Casari D, Seifeddine S, Mathiesen RH, Dahle AK (2017) In-situ study of morphology and growth of primary α-Al(FeMnCr)Si intermetallics in an Al–Si alloy. Acta Mater 130:1–910.1016/j.actamat.2017.03.026 ↗
44. Casari D, Mirihanage WU, Falch KV, Ringdalen IG, Friis J, Schmid-Fetzer R, Zhao D, Li Y, Sillekens WH, Mathiesen RH (2016) α-Mg primary phase formation and dendritic morphology transition in solidification of a Mg–Nd–Gd–Zn–Zr casting alloy. Acta Mater 116:177–18710.1016/j.actamat.2016.06.035 ↗
45. Xu Y, Deng Y, Casari D, Mathiesen RH, Li Y (2020) In-situ X-radiographic study of nucleation and growth behaviour of primary silicon particles during solidification of a hypereutectic Al–Si alloy. J Alloy Compd 832:15494810.1016/j.jallcom.2020.154948 ↗
46. Xu Y, Deng Y, Casari D, Mathiesen RH, Liu X, Li Y (2020) Growth kinetics of primary Si particles in hypereutectic Al–Si alloys under the influence of P inoculation: experiments and modelling. J Alloys Compd. https://doi.org/10.1016/j.jallcom.2020.15532310.1016/j.jallcom.2020.155323 ↗
47. Kurz W, Fisher DJ (1998) Fundamentals of solidification, 4th edn. Trans Tech Publication LTD, Stafa-Zurich10.4028/www.scientific.net/RC.35 ↗
48. Men H, Jiang B, Fan Z (2010) Mechanisms of grain refinement by intensive shearing of AZ91 alloy melt. Acta Mater 58(19):6526–653410.1016/j.actamat.2010.08.016 ↗
49. Yu W, Zhang Y, Jiang A, Yan T, Tian Y, Zheng H, Lin X, Tian X (2017) Promoted nucleation of potent substrates assisted with Al–10Si–2Fe master alloy in Al–Si alloys. Mater Lett 207:93–9510.1016/j.matlet.2017.06.128 ↗
50. Liang S-M, Schmid-Fetzer R (2013) Thermodynamic assessment of the Al–P system based on original experimental data. Calphad 42:76–8510.1016/j.calphad.2013.07.001 ↗
51. Liang S-M, Schmid-Fetzer R (2014) Phosphorus in Al–Si cast alloys: thermodynamic prediction of the AlP and eutectic (Si) solidification sequence validated by microstructure and nucleation undercooling data. Acta Mater 72:41–5610.1016/j.actamat.2014.02.042 ↗
52. Nogita K, McDonald SD, Tsujimoto K, Yasuda K, Dahle AK (2004) Aluminium phosphide as a eutectic grain nucleus in hypoeutectic Al–Si alloys. Microscopy 53(4):361–36910.1093/jmicro/dfh048 ↗
53. Dahle AK, Nogita K, McDonald SD, Dinnis C, Lu L (2005) Eutectic modification and microstructure development in Al–Si Alloys. Mater Sci Eng, A 413–414:243–24810.1016/j.msea.2005.09.055 ↗
54. Quested TE, Greer AL (2005) Grain refinement of Al alloys: mechanisms determining as-cast grain size in directional solidification. Acta Mater 53(17):4643–465310.1016/j.actamat.2005.06.018 ↗
55. Shu D, Sun B, Mi J, Grant PS (2011) A quantitative study of solute diffusion field effects on heterogeneous nucleation and the grain size of alloys. Acta Mater 59(5):2135–214410.1016/j.actamat.2010.12.014 ↗
56. StJohn DH, Qian M, Easton MA, Cao P (2011) The interdependence theory: the relationship between grain formation and nucleant selection. Acta Mater 59(12):4907–492110.1016/j.actamat.2011.04.035 ↗
57. Du Q, Li YJ (2014) An extension of the Kampmann–Wagner numerical model towards as-cast grain size prediction of multicomponent aluminum alloys. Acta Mater 71:380–38910.1016/j.actamat.2014.03.028 ↗
58. Quested TE, Greer AL (2005) Athermal heterogeneous nucleation of solidification. Acta Mater 53(9):2683–269210.1016/j.actamat.2005.02.028 ↗
59. Greer AL, Bunn AM, Tronche A, Evans PV, Bristow DJ (2000) Modelling of inoculation of metallic melts: application to grain refinement of aluminium by Al–Ti–B. Acta Mater 48(11):2823–283510.1016/S1359-6454(00)00094-X ↗
60. Qian M (2007) Heterogeneous nucleation on potent spherical substrates during solidification. Acta Mater 55(3):943–95310.1016/j.actamat.2006.09.016 ↗