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Process optimization for the selective laser melting (SLM) of the Fe-10Cu alloy was performed to obtain defect-free parts based on the energy density for thermodynamically complete melting. A microstructural study was conducted for the corresponding energy densities that focused on identifying defect formation mechanisms. A range of defects formed via by diverse mechanisms, such as lack of fusion, balling, shrinkage and the key-hole effect, were characterized, including mixed zones. The process range in which these defects were not formed could be suggested as the optimal conditions for SLM of the Fe-10Cu alloy. In this study, a laser power below 320 W, a scan speed below 1523 mm/s and an energy density under 15.56 J/mm3 were indicated to be the optimum process conditions for SLM of Fe-10Cu alloy to avoid micro-cracks from shrinkage, balling and rounded pores from the key-hole phenomenon.

The mechanism of extrusion and intrusion formation in Co–Cr–Mo–N alloys during fatigue deformation was investigated. In particular, we focused on the role of the strain-induced martensitic transformation (SIMT), which is the transformation of the metastable γ face-centered cubic (fcc) phase into a stable e hexagonal close-packed (hcp) phase at room temperature because of the gliding of Shockley partial dislocations in the γ-phase matrix. We found that the SIMT also plays a crucial role in the formation of extrusions and intrusions. Further, the morphology of the extrusions and intrusions formed in the Co–Cr–Mo–N alloy specimens was very different from that seen in other fcc alloys. The extrusions and intrusions were formed by the gliding of perfect dislocations with a Burgers vector of perfect dislocation on the basal plane of the e-hcp phase. This suggests that the e-phases introduced by the SIMT can deform readily.

Surface relief formation of a biomedical Co–Cr–Mo–N (CCMN) alloy under tension/compression cyclic deformation has been investigated by in situ optical microscopy, atomic force microscopy and electron backscattering diffraction analysis. The formation of slip traces exhibited tension/compression asymmetry, resulting in unique surface reliefs. This is attributed to the motion of isolated Shockley partial dislocations in the metastable γ-face-centered cubic phase, in which the stacking fault energy is negative.

The influence of aging treatment on the microstructure, mechanical and electrical properties of Cu-Be alloy for connector material applications was investigated. The properties of mechanical strength and electrical conductivity were found to increase with increasing aging temperature. By the way, SEM/EDS and TEM analysis exhibited that beryllides precipitation (CoBe and NiBe) with a size of 50 nm were distributed in grains. It was, therefore concluded that these beryllide precipitates improved the mechanical strength and also it was favor in increasing of electrical conductivity.

The deformation mode of polycrystalline Co–27Cr–5Mo (in mass%) alloy consisting of the hexagonal close-packed e phase was examined. Basal 〈a〉 and prismatic 〈a〉 slips were the dominant deformation modes. The activation of these 〈a〉 slips is strongly dependent on Schmid factor, which indicates that the values of critical resolved shear stress for basal 〈a〉 slip and prismatic 〈a〉 slip are similar. For tensile strains up to 10%, the frequent occurrence of deformation twins could not be confirmed by electron backscattered diffraction analysis.

Eco-friendly grain refinement of A3003 alloy was studied by addition of non-toxic Al-Ti alloy because of toxic-fluorine in Al-Ti-B alloys which used as a representative grain refiner for aluminum and its alloys. TiAl3 phase in Al-Ti alloy bring to decrease grain size of A3003 alloy. But, grain growth occurred with prolonged holding time due to the solution of Ti into aluminum matrix. In contrast, lasting grain refinement of A3003 alloy was occurred in graphite crucible. It can be mentioned that carbon comes from graphite crucible was combined with Ti solute in aluminum melt and then TiC acts as a heterogeneous nucleation for A3003 alloy.

To develop Cu alloy with tensile strength of 800 MPa and electrical conductivity of 80 %IACS (International Annealed Copper Standard), the variation of mechanical strength and electrical conductivity in Cu-Ag alloy during fabrication processes including casting, solid solution and ageing treatment were investigated. Solid solution hardening leads to a large drop in electrical conductivity of Cu-Ag alloys due to super-saturation of Ag solute in Cu matrix. Ageing hardening gives rise to enhance both of the mechanical strength and the electrical conductivity. Therefore, it can be mentioned that the electrical conductivity of Cu-Ag alloys was affected dominantly by Ag solute in Cu matrix.

The anisotropy in mechanical strength and electrical conductivity in Cu-Ag alloy during cold rolling were investigated. The anisotropy in tensile strength and electrical conductivity was significant with increasing Ag content in Cu-Ag alloy. The cold rolled Cu-Ag alloys with higher Ag content have filamentary structure, which is composed of elongated eutectic phase and Cu matrix. In addition, the eutectic phase in Cu-Ag alloys with higher Ag content has a strong α-fiber texture. It can be mentioned that the eutectic phase in filamentary structure is promotes the anisotropy of electrical conductivity of Cu-Ag alloys. This strong a-fiber texture of eutectic phase was decreased by annealing process (300 OC for 1h), and the anisotropy in strength and conductivity was decreased.

The influence of extrusion temperature and Ti content was investigated by observing the microstructure and determining the mechanical strength of A3003 alloy tube. The A3003 alloy was modified by inoculation in terms of addition of Ti and then extruded at the various extrusion temperatures. In case of A3003 alloy tube without addition of Ti, the yield strength was slightly improved with decreasing extrusion temperature. On the other hand, the yield strength was improved markedly in A3003 alloy tube with small addition of Ti, and also ductility was slightly reduced. Grain size distribution from observing the microstructure was different with addition of Ti. Coarse grains were formed on the outer and inner parts of the alloy tube without addition of Ti, whereas the finer grains were uniformly distributed in the alloy tube with addition of Ti. Thus the microstructure and mechanical strength of A3003 alloy tube could be controlled by addition of Ti. Threefore, optimum Ti content and extrusion temperature to fabricate high yield strength and ductility A3003 alloy tube (σy=60 MPa, ε=30%) for eco-friendly refrigerant application are above 0.05wt.Ti and below 480 °C, respectively. Introduction

The influence of annealing atmosphere on mechanical and wear properties of free-cutting phosphor bronze alloy was investigated. After annealing in vacuum, the mechanical properties of the alloy decreases due to vaporization of alloying element. In addition, the softening of matrix induces decreasing the wear resistance dramatically. In contrast, high mechanical properties were observed in the alloy annealed in air and in nitrogen atmosphere. In particular, a large smearing of lead in the alloy annealed in air atmosphere was observed and was affected on the enhancement of wear resistance. Consequently, annealing in vacuum atmosphere is not suitable for high mechanical properties and wear resistance.

The microstructures and mechanical properties of unidirectional deformation structured Al alloy during ECAP with various deformation routes were investigated. In order to fabricate unidirectional deformation structure for Al alloy, hot extrusion was carried out. It was found that the deformation route A in ECAP routes is the dominant route for the grain refinement and strengthening. In deformation route A, the high strength ultra-fine grained Al alloy with a grain size of ~ 200 nm was obtained due to the accumulation of consecutive strain process. In contrast, the strength of ECAP’ed Al alloy produced via deformation route C was greatly increased after one pass because the grains were strained and cancelled each pass. By contrast, the equiaxed grains were obtained in deformation route BC because the sample was rotated 90 O in the same sense in each pass. The deformation route BC was superior to the deformation route C because the deformation route BC was more favorable than the deformation route C in the accumulation of consecutive strain. It is also found that unidirectional deformation structured Al alloy via hot extrusion shows similar grain refinement tendency with equiaxed structured Al alloy during ECAP processing.

In accordance with environmental regulations on refrigeration technology, the commercial A1100 alloy condenser tube that has widely been used in CFC and HCFC refrigerant systems and operated at a low working pressure (10–30 bar) was inappropriate to the eco-friendly CO 2 refrigerant systems which possess a high working pressure (60–80 bar) due to the low mechanical properties. As a result, the stiffness of the conventional 1000 series alloys might not be appropriate in this requirement. The present study is mainly aimed at developing condenser tube material such as A3003 alloy for the application of eco-friendly refrigerants with higher working pressure rather than for conventional CFC and HCFC refrigerants. The mechanical properties and pressurized strength of condenser tube are greatly affected by the coarse grains, which grow during the brazing process. According to the pressurized testing, A3003 alloy is more suitable than A1100 alloy when the condenser tube is applied to eco-friendly refrigerants usage because A3003 alloy can be durable in a heat exchanger which requires high working pressure.

Free-cutting phosphor bronze alloy (ASTM C54400) was used as a material for automotive parts and industrial valve parts for its high strength, machinability and excellent corrosion resistance. To obtain desired mechanical strength of the alloy, the process parameters including continuous casting speed, reduction in area and annealing temperature have to be controlled. In this study, we investigated the effect of annealing on the mechanical property and machinability of free-cutting phosphor bronze alloy fabricated by continuous casting with different casting speeds of 80, 100, and 120 m/min, respectively. After annealing, the tensile strength of the alloy decreased with increasing annealing time owing to the occurrence of recrystallization and grain growth. In the cast and swaged alloy produced at casting speed of 120 m/min, the grain growth occurred rapidly. In contrast, in the alloy produced at the casting speed of 80 m/min, the grains growth rate was low. Furthermore, the effect of Pb particle in the alloy on machinability was also investigated by using a tool dynamometer installed force sensor.

The strength of aluminum alloys was improved by a severe deformation process while the decrease of elongation leads to the defect. Modification of A3003 alloy was attempted in order to develop a high strength and high formability Al alloy tube for the application of air-conditioning systems in transportation, such as passenger planes and automobiles. An A3003 alloy was modified by Ti addition, grain refiner. As a result of modification, the modified A3003 alloy was able to suitably satisfy the mechanical strength requirements, including elongation. Grain size and secondary dendrite arm spacing of A3003 alloy decreased by as much as 50 % by Ti addition. The finer grains were uniformly distributed in the modified A3003 alloy billet. The yield strength of the modified A3003 alloy was improved by 30 % without decreasing elongation.

Melt extrusion is a new fabrication process with the characteristics of both casting and extrusion. In this process, a metallic melt which is poured and solidified up to semisolid state in the container can be directly extruded through the die exit to form a product of bar shape without other intermediate processes. The effects of various process parameters, such as melt temperature and extrusion ratio, on the extrusion behavior of Al-Cu alloys in the semisolid state were investigated. Mechanical properties of the melt extruded Al-Cu alloy were measured and its characteristics are compared with the microstructure and copper contents in the alloy. Al-Cu alloys were successfully extruded after squeezing out of liquid during the melt extrusion with smaller force (60 Mpa) compared to the solid extrusion. Al-Cu alloys bar with the mean grain size of 200 μm was fabricated by melt extrusion; however, the mechanical properties have nothing to do with the extrusion ratio. The squeezing out of liquid was get lead to the segregation of the alloys and was affect on the mechanical properties.

Melt extrusion is a new fabrication process with the characteristics of both casting and extrusion. In this process, a metallic melt which is poured and solidified up to semisolid state in the container can be directly extruded through the die exit to form a product of bar shape without other intermediate processes. The aging behavior of Al-Cu alloys in the semisolid state was investigated. And the microstructure and mechanical properties of the melt extruded Al-Cu alloy bar were measured and its characteristics are compared with those of a hot extruded Al-Cu alloy bar. Al-Cu alloys were successfully extruded after squeezing out of liquid during melt extrusion with smaller force compared to the solid extrusion. Al-Cu alloys bar with the mean grain size of up to 200 μm was fabricated by melt extrusion process. And the mechanical properties of the melt extruded Al-Cu alloy bar were improved after the T6 treatment.

In the present study, in order to find out an grain refinement mechanism, 0.1wt.% Al-10wt.%Ti master alloy was added into A3003 alloy melt contained in graphite crucible and in alumina crucible, and then the melt holding time at 750°C was systematically changed from 1 min up to 120 min. It is interesting to note that the grain refinement and fading phenomena remarkably depend on the crucible material. The fading effect in the specimens using alumina crucible can be explained as the result of TiAl3 phase dissolution into molten aluminium matrix. In the specimens using graphite crucible, the grain refinement was occurred gradually with increasing holding time. It was suggest that the continuous grain refinement is due to transition of refinement mechanism from TiAl3 phase to TiC phase. It can be mentioned that the TiC formed from titanium and carbon solute in the aluminium melt, which came from the Al-10Ti alloy and the graphite crucible.