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Special Issue "Casting Alloy Design and Characterization"

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A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Casting, Forming and Heat Treatment".

Deadline for manuscript submissions: 29 February 2024 | Viewed by 8831

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Special Issue Editors

Dr. Carlos Alexandre Dos Santos

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Guest Editor

School of Technology, Pontifícia Universidade Católica do Rio Grande do Sul, 90619-900 Porto Alegre, Brazil
Interests: materials science and engineering; solidification; material testing; wear; manufacturing processes

Dr. Eleani Maria Da Costa

E-Mail Website
Guest Editor

Special Issue Information

Dear Colleagues,

Metal casting processes normally used in the foundry industry (e.g., gravity or pressure casting) are subjected to a wide range of operational parameters. Consequently, a variety of solidification microstructures are formed, directly affecting mechanical, physical and chemical properties, strength–ductility response, corrosion and wear resistance, electrical conductivity, and others. In general, aspects such as the phase and microconstituents present, grain size, macrostructure morphology, porosity, and alloying segregation are responsible for defining the main properties of the final casting. Since there is a close correlation between solidification conditions, microstructure and properties, the effects of solidification conditions and alloying elements on microstructure design and the resulting properties in cast alloys have stimulated new research interest. In addition, it is fundamental to understand the influence of these characteristics on subsequent manufacturing processes such as heat treatment, forming, welding and machining.

The possibility of replacing wrought alloys with cast alloys, with associated cost reduction and improved mechanical properties, has motivated the modern industry to design new alloys by adding new elements or by using additive manufacturing techniques. Thus, this Special Issue aims to collect research articles focused on the design and characterization of cast alloys, especially on the interrelationship between solidification, microstructure and properties; both experimental and theoretical research are welcome.

The scope of the Special Issue includes, but is not limited to, the following technical topics:

Casting processes and novel techniques;
Solidification: experimental and theoretical studies;
Microstructures and properties characterization;
Numerical and analytical simulations;
Heat and mass transfer;
Processing-structure-property relations;
Industrial applications.

Dr. Carlos Alexandre Dos Santos
Dr. Eleani Maria Da Costa
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

casting
solidification
microstructures
properties
characterization
casting design

Published Papers (7 papers)

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Editorial

Jump to: Research, Review

4 pages, 347 KiB

Open AccessEditorial

Casting Alloy Design and Characterization

Eleani Maria Da Costa

and

Carlos Alexandre Dos Santos

Metals 2022, 12(7), 1228; https://doi.org/10.3390/met12071228 - 20 Jul 2022

Cited by 1 | Viewed by 949

Abstract

Metal casting processes routinely used in the foundry industry (e.g., gravity or pressure casting) are subject to a wide range of operational parameters. Since there is a close correlation between solidification conditions, microstructure, and properties, the effects of the solidification thermal parameters and alloying elements on microstructure designs and the resulting properties in cast alloys have stimulated new research interest. Thus, this Special Issue aims to collect research articles focused on the design and characterization of cast alloys, especially on the interrelationship between solidification, microstructure, and properties; both experimental and theoretical research are welcome for contribution. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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Research

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18 pages, 6060 KiB

Open AccessArticle

Electrical Equivalent Circuit Model Prediction of High-Entropy Alloy Behavior in Aggressive Media

Jose Cabrera-Peña

Santiago Jose Brito-Garcia

Julia Claudia Mirza-Rosca

and

Gustavo M. Callico

Metals 2023, 13(7), 1204; https://doi.org/10.3390/met13071204 - 29 Jun 2023

Viewed by 526

Abstract

Due to the optimistic outcomes of the research on high-entropy alloys, new designs of these alloys are being encouraged. We studied the high-entropy CoCrFeMoNi alloy and the CoCrFeMoNi alloy doped with Zr. In order to choose the best electrical equivalent circuit for the prediction of the behavior of these high-entropy alloys at various potentials in artificial seawater, electrochemical impedance spectroscopy (EIS) measurements were conducted on samples with and without Zr-doped CoCrFeMoNi. At various potential levels, the impedance spectra were measured between −1.0 and +0.8 V vs. SCE. The study consists of a preliminary section with microstructure by metallography, open-circuit potential, and linear polarization curves by direct-current tests followed by visual analysis of the impedance spectra, and, finally, the selection of an equivalent electrical circuit model to fit the experimental data. By leveraging the advantages of EIS analysis, the information is essential for materials development, corrosion-mitigation strategies, and the successful implementation of these alloys in practical applications. It is important to note that selecting an equivalent circuit is often an iterative and subjective process, as it involves a balance between model complexity and the ability to accurately represent the system’s behavior. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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22 pages, 10044 KiB

Open AccessArticle

Microstructure, Hardness, and Linear Reciprocating Sliding Wear Response of Directionally Solidified Al–(2.5, 3.5, 4.5)Cu–(0.25, 0.50)Cr Alloys

and

Metals 2023, 13(7), 1178; https://doi.org/10.3390/met13071178 - 24 Jun 2023

Viewed by 585

Abstract

Aluminum alloys containing transition metal alloying elements have attracted interest from researchers. The effect of Cr additions of 0.25 and 0.50% on the thermal profile, microstructure, hardness, and linear reciprocating sliding wear response of as-cast hypoeutectic Al–Cu alloys with 2.5, 3.5, and 4.5% Cu (wt.%) was investigated. The binary Al–Cu and ternary Al–Cu–Cr alloys were directionally solidified under upward non-steady state heat transfer conditions using a dedicated solidification apparatus. Thermal analysis based on differential thermal analysis (DTA) and cooling curve profiles was performed to determine solidification thermal parameters such as Liquidus temperature (T_L), transformation enthalpy (ΔH), and liquid cooling rate (Ṫ_L). Samples extracted from the solidified ingots were submitted to optical microscopy, hardness measurement, and linear reciprocating sliding wear test using a high-frequency reciprocating rig (HFRR). The results showed a decrease at the beginning of solidification (T_L) and of the transformation enthalpy (ΔH) when both alloy Cu and Cr contents increased, with a higher influence of Cu. The addition of Cu decreased cooling rates, whereas the increase in the alloy Cr concentration showed an opposite behavior, increasing cooling rates. The refinement of the primary dendrite arm spacing (λ₁), as a consequence of the increase in alloying elements and solidification cooling rates, enhanced the hardness of the alloys, with the maximum value of 58 HB achieved in the ternary Al–4.5Cu–0.50Cr alloy. The wear tests indicated a better response to wear associated with microstructure refinement for the alloys with 2.5% Cu, for both Cr contents, an almost constant behavior for the 3.5% Cu alloys, and an opposite performance for the alloys with 4.5% Cu alloys that showed better wear resistance with coarsening of the λ₁ and with the increase in the amount of the eutectic microconstituent. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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14 pages, 8171 KiB

Open AccessArticle

Novel Cast and Wrought Al-3Zn-3Mg-3Cu-Zr-Y(Er) Alloys with Improved Heat Resistance

and

Metals 2023, 13(5), 909; https://doi.org/10.3390/met13050909 - 08 May 2023

Cited by 2 | Viewed by 986

Abstract

The main weaknesses of commercial high-strength Al-Zn-Mg-Cu-based alloys are the low casting properties, corrosion and heat resistance. Al-Zn-Mg-Cu-based alloys with Zn/Mg ratio equal to 1 combine good strength, corrosion and heat resistance. Al alloys with atomic ratio Cu/Y(Er) equal to 4 have a narrow solidification range and high solidus temperature. Two basic principles were taken into consideration to develop novel heat-resistant Al-Zn-Mg-Cu-based alloys with improved casting properties: 1—mass ratio of Zn/Mg = 1, and 2—atomic ratio of Cu/Y(Er) = 4. The microstructure, phase transformation and tensile properties of the novel cast and wrought Al–3Zn–3Mg–3Cu–0.2Zr–Y(Er) alloys were investigated. The structure and phase composition were investigated via thermodynamic calculation, optical and scanning electron microscopy and X-ray diffraction methods. A two-step solution treatment with higher temperature in the second step provides a microstructure with better elongation, making possible to increase the hot rolling temperature of the Y or Er-containing alloys. The yield strength (YS) of the alloys decreased insignificantly from 270 to 290 MPa at room temperature to 225 to 260 MPa at 200 °C after casting, solution treatment, water quenching and aging. A better combination of the YS = 291–345 MPa and elongation (El.) (11–14.8%) was achieved in the Al3Zn3Mg3CuY and Al3Zn3Mg3CuEr alloys after solution treatment, rolling, recrystallization annealing, water quenching and aging compared with the Al3Zn3Mg3Cu alloy with YS = 245–340 MPa and El. = 6.8–12.5%. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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18 pages, 9013 KiB

Open AccessArticle

Influence of Minor Additions of Be on the Eutectic Modification of an Al-33wt.%Cu Alloy Solidified under Transient Conditions

Adilson Vitor Rodrigues

and

Metals 2023, 13(1), 94; https://doi.org/10.3390/met13010094 - 02 Jan 2023

Cited by 1 | Viewed by 980

Abstract

Al-based alloys are often selected for use in various engineering applications as well as in the aircraft and aerospace industry. The improvement of their performances under severe conditions have required the use of alloying elements. In the present work, Be is added to the eutectic Al-33 wt.%Cu alloy with a view to investigating the resulting effects on microstructural features and hardness. A directional solidification technique is used, yielding a wide range of solidification cooling rates. This permits microstructural features to be investigated with emphasis on the role of Be on the eutectic morphology. The directionally solidified microstructures are formed by eutectic colonies for the Al-33 wt.%Cu alloy, however, with additions of both 0.05 and 0.5 wt.% Be, the original cell-like morphology is transformed into a trefoil-like morphology. This together with the α-Al dendritic pattern characterize the microstructure of the Al-33Cu-Be alloys examined. Solidification growth laws are experimentally derived relating dendritic and eutectic colony spacings to solidification cooling rates and growth rates. The length scale of such spacings is shown not to affect the Vickers hardness of the Al-33Cu-Be alloys examined; however, the additions of Be are shown to improve the brittle behavior of the Al-33 wt.%Cu alloy. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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14 pages, 5164 KiB

Open AccessArticle

Phase Prediction, Microstructure and Mechanical Properties of Fe–Mn–Ni–Cr–Al–Si High Entropy Alloys

and

Metals 2022, 12(7), 1164; https://doi.org/10.3390/met12071164 - 08 Jul 2022

Cited by 4 | Viewed by 1902

Abstract

The selection of high-entropy alloys (HEAs), which are relatively lightweight and have unique mechanical properties, remains a substantial challenge. In this study, six new HEAs were designed from the relatively low-cost Fe–Mn–Ni–Cr–Al–Si system using Thermo-Calc software, and then manufactured using a casting process. The effects of the atomic ratio of the alloying elements on the microstructures and mechanical properties of these alloys in the as-cast condition were systematically investigated. Brittle body-centered cubic BCC/B2 and silicide phases were found in relatively large amounts in the form of dendritic structure within large equiaxed grains with fine needle-shaped phases in the Fe₃₀Mn₁₅Ni₂₀Cr₁₅Al₁₀Si₁₀ and Fe₃₅Mn₁₅Ni₂₀Cr₁₅Al₁₀Si₅ alloys, in addition to the face-centered cubic (FCC) phase. When the contents of Mn and Ni were increased in the Fe₃₅Mn₂₅Ni₁₅Cr₁₅Al₅Si₅ and Fe₃₅Mn₂₀Ni₂₀Cr₁₅Al₅Si₅ alloys, the amounts of brittle phases were reduced; however, the ductile FCC phase is not significant. The FCC phase amount, which appeared as a honeycombed structure, was more than enough when the Si content was decreased to 3%. Broad relationships between the chemical composition of the alloys, especially the Si content, and the hardness and compression properties’ measurements were established. As the Si content decreased, both the hardness and compression properties of the resulting alloy also decreased. The experimental observation of the six HEAs matched the equilibrium phases predicted by the Thermo-Calc calculations. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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Review

Jump to: Editorial, Research

28 pages, 5454 KiB

Open AccessReview

Technological Insights into the Evolution of Bronze Bell Metal Casting on the Korean Peninsula

and

Metals 2022, 12(11), 1776; https://doi.org/10.3390/met12111776 - 22 Oct 2022

Cited by 2 | Viewed by 2259

Abstract

Bronze cast bells have been designed and developed for hundreds of years, with the worldwide spread of several faiths and religions such as Buddhism, Catholicism, and Protestantism. The exceptional ringtones of bronze bell metals have scientific healing and cultural importance. In this review article, we highlight the evolution of bronze bell metal over the decades, its composition, and the complex fabrication technologies used to date. Furthermore, we overview ancient and modern casting alloy technology, especially bronze bell castings in Asia. The bell shape, materials, and alloy casting technology have undergone dramatic change over the years. For comparison, we include different bronze cast bells and their characteristics produced from the Middle Ages to the present times. Based on the data obtained from the bell casting technology surrounding the Korean Peninsula, the major trends in the evolution of bronze bell castings and long-standing traditions of mold materials and alloys are described. In the present review, the effects of different elements on bell materials are qualitatively overviewed, with an assessment of the material and casting properties, service life, and bell sound. We also highlight the challenges of conventional bronze casting and possible solutions for future investment castings and rapid prototyping of bronze bells. Full article

(This article belongs to the Special Issue Casting Alloy Design and Characterization)

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