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This study investigated the microstructural constituents and forming properties of alloy Al-1.4 wt.% Fe with different additions of Ce and/or La. The addition of rare earth (RE) elements to aluminum alloys improves their microstructures in their as-cast and heat-treated states. RE additions and appropriate heat treatment also improve their mechanical properties. The influence of the homogenization process on the microstructure and forming properties of Al-1.4 wt.% Fe alloy with various additions of Ce and/or La was investigated. When homogenizing the Al-1.4 wt.% Fe alloy at 580 °C, the majority of the homogenization process is completed after 6 h; at 600 °C, after about 5 h; and at 620 °C, after about 4 h. In the micro-alloyed Al-1.4 wt.%–Fe alloy, α-Al, stable Al13Fe4 phases in an agglomerated form, La-containing phases in a spherical form, and Ce-containing phases in a rod-shaped form are present after homogenization. The addition of La was shown to be advantageous as a micro-addition to Al–Fe alloys. Its forming properties show that the combination of Ce and La is the most favorable addition, whereby the homogenization process is fully optimized.

The tool used in die casting or hot forming is subjected to thermal and mechanical stress, resulting in damage and cracking due to thermal fatigue and melt flow. This reduces the profitability and efficiency of production, as the products may not meet the required dimensions and mechanical properties. Understanding the interaction between tool steel and molten aluminium alloy is critical to extending tool life. AlCrN protective coatings on tool surfaces can improve corrosion resistance, thermal fatigue and wear resistance.The present work was carried out to predict the effect of the AlCrN protective coating on the interaction kinetics between H11 tool steel and molten aluminium alloy Al99.7. The AlCrN protective coating on the H11 tool steel sample served its purpose and slowed down the interaction between the aluminium melt from Al99.7 and the H11 tool steel, as the DSC curve of the sample that had the AlCrN protective coating applied flattened out faster, indicating the cessation of dissolution in the material at all investigated temperatures. Measurements of the thicknesses of the interaction layers also confirmed these results, whereas the thickness of the composite layer was almost the same at both experimental temperatures, 670 °C and 700 °C, respectively, without an AlCrN protective coating; the temperature has no effect on this layer and the types of interaction layers did not differ from each other.

Seventeen new experimental filler metals from eight different alloy systems based on Fe–P–X and Mn–Fe–P–X (X = B, C, Si in various combinations) were created and experimented with. DSC analyses were performed to determine the solidus and liquidus temperatures and the melting ranges. Hardness measurements of the alloys were performed in the as-cast state. The alloys contain primary and eutectic intermetallic compounds that make them very hard with average hardness values ranging from 590 HV10 to 876 HV10. The wettability was determined at 1000 °C, 1040 °C and 1080 °C on C22 non-alloy steel and 15CrNiS6 low-alloy steel in Ar 4.6 and 78 vol% H2-22 vol% N2 atmospheres. The results show good wettability at T = 1080 °C in both atmospheres, as the contact angles were mostly ≤30°. Thirteen alloys exhibit very good wettability with average contact angles of ≤15.5°. Nine alloys exhibit excellent wettability with their average contact angles being ≤10°. Wettability improves at higher temperatures. The liquid alloys are reactive to solid steels and form a diffusion joint. Diffusion of P, B, C, and Si from the filler metal into the base material dealloys the composition of the melt near the joint interface. For the same reason, a continuous layer of solid solution forms on the joint interface. When brazing with filler metals rich in carbon, strong carburisation of steels can be observed near the joint.

The objective of grain refining is to reduce the size of the primary solidified crystal grains in aluminum alloys, thereby eliminating large columnar grains. Excellent grain refining results can be achieved only when the grain refining agent is of excellent quality, i.e., the number of Al3Ti and TiB2 particles must be appropriate, the shape and size distribution of the particles must be suitable, the Ti/B ratio must be appropriate, and so on. To evaluate the quality of grain refiners, the electric resistivity was measured on four different grain refiners. The obtained results were supported by differential scanning calorimetry analyses and microstructure analyses. It was found that the quality of a grain refiner can be assessed by measurements of electrical resistance. The lowest electrical resistivity was measured for grain refiner B (Al-3Ti-1B), which had the lowest impurity content and the most suitable number and size distribution of TiB2 and Al3Ti particles, as well as the most optimal Ti/B ratio, namely, 3.6. A larger number and size of TiB2 and Al3Ti particles, as well as elements such as Fe and Si, and also inclusions, which were also confirmed by DSC analyses, cause a higher electrical resistivity due to a stronger scattering of electrons through the matrix.

Lightweight Fe-Mn-Al-Ni-C steels are an attractive material, due to the combination of low density, high elongation, and yield strength. However, the high Al content is also interesting from the point of view of high-temperature resistance. High-temperature resistance is important for high-temperature applications and oxidation during heat treatment. Oxidation tests at 700, 800 and 900 °C were carried out to investigate the oxidation rates. Oxidation at 700 °C resulted in slight decarburisation, which was reflected in a slight weight loss in the thermogravimetric analysis. In contrast, the weight in the thermogravimetric analysis increased at 800 and 900 °C and the kinetics followed a parabolic law. The higher the temperature, the more weight is gained and the thicker the oxide layer becomes. The oxidation layer at 800 and 900 °C consisted mainly of hematite and magnetite, with minor amounts of wüstite, alumina and hercynite. Preferential oxidation of austenite was also observed, as it has an increased Mn content. In addition, ferrite had an increased content of Al and Ni, which provide additional oxidation resistance.

This paper presents the results of a study of the influence of water and the commercial inhibitor VCI 379/611 on the corrosion behaviour of HTCS-130 hot work tool steel. Using the thermodynamic program Thermo-Calc, phase equilibria were determined according to the choice of calculation conditions and the known chemical composition of tool steels. From the obtained projections, it is possible to observe the secretion of individual phases at certain temperatures. To obtain insight into the corrosion resistance of steel, the following electrochemical methods were used: open circuit potential measurement; electrochemical impedance spectroscopy; and Tafel extrapolation. Metallographic tests were performed on a sample previously etched in nital to identify the microstructure of the steel. Using an optical microscope, the sample surface was analysed after each measurement. Images of the sample surface subjected to water without inhibitors indicate the occurrence of pitting corrosion. The presence of tungsten and molybdenum carbides was identified by scanning electron microscopy and energy dispersion spectroscopy. It was found that the corrosion process is more pronounced in the area of the metal base while in the areas of excreted carbides, weaker corrosion activity was observed.

The influence of the nickel content and cooling rate on niobium nitride precipitation in as-cast stainless steels were analysed. Niobium microalloying is important for mechanical properties and the prevention of intergranular corrosion in stainless steels. However, coarse precipitates can negatively affect steel properties. The precipitation of NbN depends on thermodynamic conditions, which are dictated by the chemical composition and temperature. The thermodynamic computations were used to estimate niobium nitride precipitation. Additionally, segregation models were used to predict precipitation. Three steel batches with different nickel contents (9 wt.%, 4.7 wt.%, and 0.16 wt.%) were prepared in an induction furnace and cast into sand moulds. The polished and etched samples were examined with an optical microscope, followed by a more detailed examination using a scanning electron microscope. An automatic scanning electron microscope analysis of the niobium particles was performed to obtain particle number and size distribution. Primary niobium carbonitrides, eutectic phases, and heterogenous nucleations on MnS inclusions were observed. As the proportion of nickel in the solution decreased, the solubility of nitrogen in the melt increased, which is manifested by a lower formation of primary and eutectic niobium carbonitrides, while MnS non-metallic inclusions played an important role in the heterogeneous nucleation.

When extruding the casted rods from EN AW 2011 aluminium alloys, not only their homogenized structure, but also their extrudable properties were significantly influenced by the hardness of the alloy. In this study, the object of investigations was the EN AW 2011 aluminium alloy, and the effect of homogenisation time on hardness was investigated. First, homogenisation was carried out at 520 °C for different times, imitating industrial conditions. After homogenisation, the samples were analysed by hardness measurements and further characterised by microscopy and image analysis to verify the influence of homogenisation on the resulting microstructural constituents. In addition, non-equilibrium solidification was simulated using the program Thermo-Calc and phase formation during solidification was investigated. The homogenisation process enabled more rounded shape of the Al2Cu eutectic phase, equilibrium formation of the phases, and the precipitation in the matrix, leading to a significant increase in the hardness of the EN AW 2011 aluminium alloy. The experimental data revealed a suitable homogenisation time of 4–6 h at a temperature of 520 °C, enabling optimal extrusion properties.

The high-temperature oxidation of hot-work tool steel AISI H11 was studied. The high-temperature oxidation was investigated in two conditions, the soft annealed condition, and the hardened and tempered condition. First, calculations of the compositions of the oxide layers formed were carried out using the CALPHAD method. The samples were oxidised in a chamber furnace and in a simultaneous thermal analysis instrument, for 100 h in the temperature range between 400 °C and 700 °C. The first samples were used for metallographic (optical microscopy and scanning electron microscopy) and X-ray diffraction analysis of the formed oxide layers, and the second ones for the analysis of the oxidation kinetics by thermogravimetric analysis. Equations describing the high-temperature oxidation kinetics were derived. The kinetics can be described by three mathematical functions, namely: exponential, parabolic, and cubic. However, which function best describes the kinetics depends on the oxidation temperature and the thermal condition of the steel. Hardened and tempered samples have been shown to oxidise less, resulting in a slower oxidation rate. The oxide layers consist of three sublayers, the inner one being spinel-like oxide (Fe, Cr)3O4, the middle one a mixture of magnetite and hematite and the outer one of hematite. At 700 °C there is also some wüstite in the inner oxide sublayer of the soft annealed sample.

In the present work, free-cutting aluminum alloy AA6026 with 1.1 wt.% bismuth addition was fabricated by different melt preparation methods in order to investigate whether the melt preparation route affects the solidification sequence and thus has an influence on the machinability of the alloy. All experiments were designed to simulate variable industrial conditions: addition of bismuth in an induction melting furnace, addition of bismuth in an electric resistance holding furnace, addition of bismuth together with grain refiner, effect of holding time and melt temperature before casting. Detailed thermodynamic analyses (DSC, Thermo-Calc) and microstructural characterization (SEM-EDS, XRD) have been performed to explain the solidification sequence, microstructure development and especially formation of the intermetallic Mg3Bi2 phase.

Additive manufacturing is a form of powder metallurgy, which means the properties of the initial metal powders (chemical composition, powder morphology and size) impact the final properties of the resulting parts. A complete characterization, including thermodynamic effects and the behavior of the metal powders at elevated temperatures, is crucial when planning the manufacturing process. The analysis of the Fe-Mn and Fe-Mn-Ag powder mixtures, made from pure elemental powders, shows a high susceptibility to sintering in the temperature interval from 700 to 1000 °C. Here, numerous changes to the manganese oxides and the αMn to βMn transformation occurred. The problems of mechanically mixed powders, when using selective laser melting, were highlighted by the low flowability, which led to a less controllable process, an uncontrolled arrangement of the powder and a large percentage of burnt manganese. All this was determined from the altered chemical compositions of the produced parts. The impact of the increased manganese content on the decreased probability of the transformation from γ-austenite to ε-martensite was confirmed. The ε-martensite in the microstructure increased the hardness of the material, but at the same time, its magnetic properties reduce the usefulness for medical applications. However, the produced parts had comparable elongations to human bone.

The production of clean steel is associated with high-quality steel grades for demanding applications. The formation of oxide inclusions mainly depends on the deoxidation practice; it is usually carried out through Al additions, but alumina inclusions can have detrimental effects. An alternative zirconium inclusion modification was used in a creep-resistant steel to improve the cleanliness of laboratory-made steel. The thermodynamics behind the inclusion modification are presented, the reaction products are identified and the steel cleanliness improvement is quantified. The resulting influence of zirconium addition on non-metallic inclusions and mechanical properties is discussed. While the Zr additions drastically reduce the non-metallic inclusion size and area, additions above a certain amount result in the formation of zirconium nitrides that ultimately soften the martensitic steel due to the depletion of nitrogen in solid solution.

The industrial production of products, such as foil and aluminium alloy strips, begins with the production of semi-finished products in the form of slabs. These are produced by the continuous casting process, which is quick and does not allow the equilibrium conditions of solidification. Non-homogeneity—such as micro and macro segregation, non-equilibrium phases and microstructural constituents, as well as stresses arising during non-equilibrium solidification—are eliminated by means of homogenization annealing. In this way, a number of technological difficulties in the further processing of semi-finished products can be avoided. The aim of this research was the optimization of the homogenization annealing of the EN AW 8006 alloy. With the Thermo-Calc software, a thermodynamic simulation of equilibrium and non-equilibrium solidification was performed. Differential scanning calorimetry (DSC) was performed on selected samples in as-cast state and after various regimes of homogenization annealing and was used for the simulation of homogenization annealing. Using an optical microscope (OM), a scanning electron microscope (SEM) and an energy dispersion spectrometer (EDS), the microstructure of the samples was examined. Based on the results, it was concluded that homogenization annealing has already taken place after 8 h at 580 °C to the extent, that the material is then suitable for further processing.

For Inconel 625, where the γ” and δ phases precipitate, the influence of prior hot rolling on the process is not well covered. The influence of segregation bands and prior hot rolling on the precipitation of secondary phases during aging at 750 °C for different times was investigated. Prior hot-rolling was conducted on a hot rolling mill at 1050 °C and 1150 °C with three different deformation levels. The hot rolled samples were aged at 750 °C for 1, 5, 25 and 125 h. The γ″ precipitated in both the deformed and recrystallized grains in the segregation bands containing a high concentration of niobium and molybdenum and a lower concentration of nickel, chromium and iron. The opposite was observed between the segregation bands where no γ″ precipitate was found. There was a smooth transition in the density and the size of the γ″ particles in the deformed grains at the border of the segregation bands, while a more complex transition occurred in the recrystallized grains. This occurred in the area where the average niobium concentration decreased from 4.5 to 2.7 wt. %, which influenced the mechanical properties.