Numerical Investigation of Segregation Evolution during the Vacuum Arc Remelting Process of Ni-Based Superalloy Ingots

Segregation defects greatly affect the service performance and working life of castings during the vacuum arc remelting (VAR) process. However, the corresponding research on the prediction of segregation defects is still not comprehensive. Through considering the influence of water-cooled crucible on the electromagnetic field inside an ingot, a full-scale model for the comprehensive prediction of freckles and macrosegregation defects during the VAR process is developed in this paper. The macroscopic solute transport phenomenon and the segregation behavior of Ni-5.8 wt% Al-15.2 wt% Ta alloy are predicted. The results indicate that the freckles are mainly concentrated in the lower region of the ingot. With the growth of the ingot, the solute enrichment channels gradually develop into solute enrichment regions, and the channel segregation evolves into macrosegregation. The Lorentz force mainly affects the flow pattern at the top of the molten pool, while the complex flow of multiple vortices is dominated by thermosolutal buoyancy. The maximum and minimum relative segregation ratio inside the ingot can reach 290% and −90%, respectively, and the positive segregation region accounts for about 79% of the total volume. This paper provides a new perspective for understanding the segregation behavior inside the ingot by studying the segregation evolution during the VAR process.

A Numerical Study on the Influence of an Axial Magnetic Field (AMF) on Vacuum Arc Remelting (VAR) Process

A comprehensive numerical model is proposed to study the influence of an axial magnetic field (AMF) on the solidification behavior of a Titanium-based (Ti–6Al–4V) vacuum arc remelting (VAR) ingot. Both static and time-varying AMF are examined. The proposed 2D axisymmetric swirl model includes calculating electromagnetic and thermal fields in the entire system composed of the electrode, vacuum plasma, ingot, and mold. A combination of vector potential formulation and induction equation is proposed to model the electromagnetic field accurately. Calculations of the flow in the melt pool and solidification of the ingot are also carried out. All governing equations are presented in cylindrical coordinate. The presence of a weak AMF, such as the earth magnetic field, can dramatically influence the flow pattern in the melt pool. The “Electro-vortex flow” is predicted ignoring AMF or in the presence of a time-varying AMF. However, the flow pattern is “Ekman pumping” in the presence of a static AMF. The amount of side-arcing has no influence on the pool depth in the presence of an AMF. Modeling results are validated against experiments.

Thermal Behavior of Ti-64 Primary Material in Electron Beam Melting Process

The Electron Beam Melting (EBM) process has emerged as either an alternative or a complement to vacuum arc remelting of titanium alloys, since it is capable of enhancing the removal of exogenous inclusions by dissolution or sedimentation. The melting of the primary material is a first step of this continuous process, which has not been studied so far and is investigated experimentally and numerically in the present study. Experiments have been set up in a 100 kW laboratory furnace with the aim of analyzing the effect of melting rate on surface temperature of Ti-64 bars. It was found that melting rate is nearly proportional to the EB power while the overheating temperature remains roughly independent of the melting rate and equal to about 100 °C. The emissivity of molten Ti-64 was found to be 0.22 at an average temperature of about 1760 °C at the tip of the bar. In parallel, a mathematical model of the thermal behavior of the material during melting has been developed. The simulations revealed valuable results about the melting rate, global heat balance and thermal gradient throughout the bar, which agreed with the experimental values to a good extent. The modeling confirms that the overheating temperature of the tip of the material is nearly independent of the melting rate.

Phase Transformations, Microstructure and Shape Memory Effect of NiTiAg Alloy with Different Atomic Percentages (at. % Ag) Manufactured by Casting Method

In this paper, shape memory alloys (SMAs) (NiTi-based) have been manufactured by casting with a different atomic percentage of a silver element (0, 1, 2 and 3 at. % Ag) using a Vacuum Arc Remelting (VAR) furnace. The silver element is added to the binary alloys due to its excellent properties such as (anti-corrosion, anti-bacterial and high electrical conductivity), which make these alloys using in wider applications. These alloys with different atomic percentages (Ni55Ti45Ag0, Ni55Ti44Ag1, Ni55Ti43Ag2 and Ni55Ti42Ag3) have been manufactured. The successful manufacturing process has been achieved and proved via examinations and tests. The FESEM microscopic examinations show that the silver element has been distributed uniformly and homogeneously in the NiTi matrix. Moreover, the emergence of austenite phase, martensite phase and little amount impurities. Regarding the XRD examination, showed that there is an increase in the number of peaks of Ag phase with an increase in the atomic percentage of the silver element, as well to emergence of phase (Ti2Ni) upon heating, phase (Ti 002) upon cooling, and phase (Ni4Ti3) is not desired. The starting and finishing of the phase transformations have been determined for all samples by the DSC test. The Shape Memory Effect (SME) for the alloy (Ni50Ti42Ag3) is measured to be about 89.99%.

Bio-Functionalization of a Novel Biocompatible High Entropy Alloy Used For Bone Implants

In this paper, a novel biocompatible alloy defined as FeMoTaTiZr was obtained and functionalized by hydroxyapatite-based coatings (HAP) in order to increase their biocompatibility, bioactivity, and resistance to corrosion for to be used as bone implants. To obtain the surface with antibacterial properties, the HAP coatings were doped with small amount of Zn. The alloy was prepared using the VAR (Vacuum Arc Remelting) equipment, while the coatings by RF magnetron sputtering method. The EDS analysis confirmed the presence of Ca and P in the case of all developed coatings, having Ca/P or Ca/(P+Zn) ratio of about 1.70 and 1.66, respectively. The XRD and ATR-FTIR investigations confirmed the presence of calcium phosphate phases. The roughness of uncoated substrates increased after coating with HAP, and it was considerably increased by the Zn addition. The electrochemical tests showed that the un-doped HAP exhibited good corrosion behavior, while Zn doped HAP coatings have a high dissolution rate in fetal bovine serum, being more proper as a biodegradable material.

Perspective Chapter: A Personal Overview of Casting Processes

Casting processes are reviewed from the point of view of the type of defects they produce and their consequential properties of the castings they produce, particularly resistance to fracture, and therefore, their reliability in service. The ingot casting of steels is criticized for unnecessary degradation of the steel. The fundamental problems of continuous casting of aluminum alloys and steels are seen to be lying in inattention to the details of the processes. Vacuum casting, particularly vacuum arc remelting, as currently executed, is seen to be fundamentally unreliable for any safety critical purposes, particularly its history of helicopter tragedies resulting from its use in helicopter drive trains.

Effects of nickel content on the microstructure, microhardness and corrosion behavior of high-entropy AlCoCrFeNix alloys

In this study the effect of three different nickel concentration on the microstructure, hardness and corrosion properties of high entropy alloys (HEAs) from AlCrFeCoNi system as an alternative material for medical instruments fabrication was investigated. The analyzed HEAs were AlCrFeCoNix obtained by vacuum arc remelting from high purity raw materials and having nickel atomic ratio x = 1.0, 1.4 and 1.8. The microscopy examination revealed the dendritic morphology for the reference alloy (AlCrFeCoNi) and that the extent of the interdendritic areas increased with the concentration of nickel while Cr was more segregated in the interdendritic areas than in dendrites. Hardness values decreased as the percentage of nickel increased due to the dissolution of the precipitates in a nickel-rich matrix and consequently the formation of continuous solid solutions. The corrosion properties of the synthesized HEAs were evaluated using a potentiodynamic polarization method. The alloys were immersed in Simulated Body Fluid during one week and the corrosion parameters were recorded. The low corrosion rates, low corrosion currents and high polarization resistance attest the good stability of these HEAs in simulated biological environment indicating their possible use for surgical and dental instruments.