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Favorable Environment for a Nondendritic Morphology in Controlled Diffusion Solidification

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Abstract

The novelty of the controlled diffusion solidification (CDS) process is the mixing of two precursor alloys with different thermal masses to obtain the resultant desired alloy, which is subsequently cast into a near-net-shaped product. The critical event in the CDS process is the ability to generate a favorable environment during the mixing of the two precursor alloys to enable a well-distributed and copious nucleation event of the primary Al phase leading to a nondendritic morphology in the cast part. The turbulence dissipation energy coupled with the undercooling of the precursor alloy with the higher temperature enables the copious nucleation events, which are well distributed in the resultant mixture.

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Notes

  1. PANDAT 8.1 is a trademark of CompuThermLLC, Madison, WI.

  2. SCXI-1100 is a trademark of National Instruments, Vaudreuil-Dorion, PQ, Canada.

  3. NIKON AZ 100M is a trademark of Eberbach Corporation, Ann Arbor, MI.

  4. JEOL is a trademark of Japan Electron Optics Ltd., Tokyo.

Abbreviations

Alloy 1:

precursor alloy with higher thermal mass (higher temperature and higher mass)

Alloy 2:

precursor alloy with lower thermal mass

Alloy 3:

resultant desired alloy

C1 and C2:

average solute concentration of Alloys 1 and 2, respectively

C Cu :

transient solute concentration (Cu)

f :

final

L :

characteristic length

m1, m2, and m T :

mass of Alloy 1, Alloy 2, and total mass, respectively

NWe :

Weber number

S/L:

solid-liquid interface

T1 and T2:

temperatures of Alloys 1 and 2, respectively

T actual :

actual temperature

T B :

temperature of point B

TL1, TL2, TL3:

liquidus temperatures of Alloys 1, 2, and 3, respectively

T m :

melting temperature

T quench :

quenching temperature

u :

velocity

ξ :

transient instantaneous position

ρ :

density

μ :

dynamic viscosity

σ :

surface tension

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Acknowledgments

The authors acknowledge the financial support provided by the Natural Science and Engineering Research Council (NSERC) of Canada through their Discovery Grant Program.

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Authors and Affiliations

  1. The Light Metal Casting Research Centre (LMCRC), Department of Mechanical Engineering, McMaster University, Hamilton, ON, L8S 4L7, Canada

    Abbas A. Khalaf (Post Doctoral Fellow) & Sumanth Shankar (Associate Professor and Director)

Authors
  1. Abbas A. Khalaf
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  2. Sumanth Shankar
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Correspondence to Sumanth Shankar.

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Manuscript submitted October 30, 2010.

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Khalaf, A.A., Shankar, S. Favorable Environment for a Nondendritic Morphology in Controlled Diffusion Solidification. Metall Mater Trans A 42, 2456–2465 (2011). https://doi.org/10.1007/s11661-011-0641-z

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