Alloys, Volume 1, Issue 3 (December 2022) – 6 articles

FeSiCr alloys are used as soft magnetic materials for power multilayer inductors. The alloys are typically annealed at intermediate temperatures in air during inductor fabrication to form an insulating chromium oxide layer around the alloy particles. The variation of the annealing temperature between 700 °C and 900 °C in air, and, for the first time, the variation of the oxygen partial pressure during annealing at 900 °C are studied, and their effects on the alloy’s oxidation behavior, phase formation, insulation resistance, and permeability are demonstrated. The chromium oxide content increases up to about 12 wt% with annealing temperature in air, whereas it decreases to 8.2 wt% after annealing at 900 °C and 0.001% O₂. The observed mass changes during annealing confirm the various tendencies towards oxidation. This oxidation behavior is reflected in an increase in the insulation resistance with annealing temperature or in a resistance reduction with decreasing oxygen partial pressure. The permeability decreases from µ = 22 after annealing at 700 °C to µ = 18.5 at 900 °C in air. The reduction of p_O2 during annealing at 900 °C leads to an increase in permeability up to µ = 22.5 at p_O2 = 0.001% O₂. The results can be used to design cofiring strategies using reduced oxygen partial pressure for new composite multilayer inductive components consisting of FeSiCr- and ferrite layers in combination with silver metallization. Full article

The demand for high-strength aluminum alloys for the laser powder bed fusion (LPBF) process is still growing. However, to date, the crack susceptibility of conventional alloys as well as the high prices for specially developed alloys are the main obstacles for the use of high-strength aluminum alloys for LPBF. In this paper, crack-free LPBF samples with a relative density >99.9% were processed from AlMgSi1Zr (6182 series alloy) powder, to which 0.5 wt.-% Zr and 0.5 wt.-% Ti were added via mechanical mixing. No hot cracks were found in the µCT scans. Moreover, a fully equiaxed microstructure with a mean size of the α-Al grains of 1.2 µm was observed in the as-built parts. Al₃(Zr,Ti) particles were observed, acting as efficient heterogeneous grain refiners for α-Al by building a semi-coherent interface. Unmolten Ti and Zr particles with sizes up to 80 µm were found in the α-Al phase. The resulting fine-grained microstructure led to a tensile strength of 329 ± 4 MPa and a total elongation at a break of 11.4 ± 0.9% after solution heat treatment, quenching in water, and subsequent artificial ageing. Full article

Additive manufacturing (AM) techniques such as laser powder bed fusion (L-PBF) are rapidly growing due to the inherent design freedom and possibilities to produce components not available with other techniques. This could be utilized in, e.g., the design of new types of heat exchangers in ferritic stainless steels often used for high-temperature applications. Ferritic stainless steels are, however, difficult to weld and could therefore imply obstacles when produced by AM. When establishing the AM-produced alloy in new applications, it is therefore important to increase the understanding of the mechanical properties and high-temperature creep resistance in relation to the unique microstructure and printability. In this study, we have investigated the microstructure of Cr-rich SS446 ferritic stainless steel produced by L-PBF by microscopical and crystallographic techniques. The properties were compared to the conventionally produced tubes. The rapid cooling and reheating during the application of the subsequent powder layers during L-PBF introduces an intriguing microstructure consisting of a ferritic matrix with precipitation of austenite showing a Kurdjumov–Sachs orientation relationship. Characteristic dislocation networks were observed in the L-PBF samples and contributed to the good mechanical properties in the as-built state (more than twice the yield strength of the conventionally produced tube). Furthermore, the creep resistance at 800 °C was superior to the conventionally produced component, suggesting that L-PBF-produced SS446 possesses many advantages regarding production as compared to the conventional route. Full article

In this work, the structural, magnetic, thermal, and transport properties of the arc-melted polycrystalline Heusler alloy Co₂Ti_1.5Sn_0.5 are investigated. The alloy crystallizes in an L2₁ structure with a space group of Fm-3m. The magnetic properties of the alloy depict its antiferromagnetic nature and the alloy exhibits magnetic ordering around Neel Temperature T_N = 8.5 K. The effective magnetic moment value obtained from the Curie –Weiss law suggests that the cobalt atom in the alloy is in the low-spin state. From the heat capacity studies, the Sommerfeld coefficient and Debye temperature were determined. In addition, electrical resistivity shows a linear response with increasing temperature, indicating the metallic nature of the alloy. Full article

The defect evolution associated with an anomalous work hardening behavior of a single crystalline quaternary Co-Al-W-Ta superalloy at 950 °C was investigated by transmission electron microscopy. As plastic deformation is initially confined to the γ matrix channels, a plateau arises in the stress-strain curve after yielding. At about 1% plastic strain, extensive shearing of the γ′ precipitates under superlattice stacking fault formation occurs leading to extreme work hardening rates up to 12 GPa and a total increase in stress of about 200 MPa. Additional investigations on the temperature and strain-rate dependence of the anomalous work hardening behavior reveal the significance of diffusion and segregation processes on the stress-strain curve and the work hardening behavior. Full article

Titanium alloys are ideal for a great range of engineering applications; however, their high manufacturing costs hinder their widespread use. This study investigates the relationship between the processing and properties of representative Ti-based materials manufactured via powder metallurgy in order to reduce the manufacturing costs. This is possible as powder metallurgy techniques are near-net shape processes with high yield of material. It is found that the relative density increases with the sintering temperature, and it is slightly higher for longer processing times, reaching values in the 94–97% range. Moreover, homogeneous microstructures are obtained for all the conditions investigated, achieving an equiaxed microstructure for Ti and the typical lamellar structure for the Ti-6Al-7Nb alloy. However, the increment of the temperature also leads to a higher amount of interstitial pick-up, with a maximum increment of 0.21 wt.% and 0.028 wt.% for oxygen and nitrogen, respectively. The highest properties achieved for Ti and Ti-6Al-7Nb are 272 HV (hardness), 17.9 W/m·K (thermal conductivity), and 62.7 μohm·cm (electrical resistivity) and 336 HV, 6.9 W/m·K, and 180 μohm·cm, respectively. Full article