Abstract
The effect of solidification history on the resultant microstructures in atomized Al–3Fe and Al–7Fe powders is studied, with particular emphasis on the relationships between droplet size, undercooling and phase stability. The atomized Al–Fe powders exhibit four microstructural features, i.e. Al3Fe phase, Al + Al6Fe eutectic, α-Al dendrite and a predendritic structure. The presence of these is noted to depend on a kinetic phase competitive growth mechanism, which was determined by the initial undercooling experienced by the powders. The results of scanning electron microscope analysis demonstrate that the content of Fe in the α-Al phase increases with decreasing powder particle size, i.e. for Al–3 wt % Fe powders, the content of Fe in the α-Al phase is 2.21 and 2.56 wt % corresponding to powder particle sizes of 90 and 33 μm, respectively; for Al–7 wt % Fe powders, the content of Fe in the α-Al phase is 5.51 and 5.98 wt % corresponding to powder sizes of 90 and 33 μm, respectively. In the present study, homogeneous nucleation undercooling, corresponding to the α-Al phases, is also estimated using an existing correlation.
Similar content being viewed by others
References
A. Lawley, in "Processing of Structural Metals by Rapid Solidification," edited by F. H. Froes and S. J. Savage (American Society for Metals International, Metals Park, OH, Baton Rouge, LA, 1987) p. 31.
H. Jones, in "Rapid Solidification Processing: Principles and Technology," edited by R. Mehrabian, B. H. Kear and M. Cohen (Claitor's Publishing Division, 1978) p. 28.
E. J. Lavernia, J. D. Ayers and T. S. Srivatsan, Int. Mater. Rev. 37 (1992) 1.
D. Turnbull, in "Undercooled Alloy Phases," edited by E. W. Collings and C. C. Koch (American Institute of Mining, Metallurgical and Petroleum Engineers-TMS, Warrendale, PA, 1987) p. 3.
J. H. Perepezko, Mater. Sci. Eng. A226-228 (1997) 374.
P. G. Hockel, H. Sieber and J. H. Perepezko, in "Solidification 1998," edited by S. P. Marsh, J. A. Dantzig, R. Trivedi, W. Hofmeister, M. G. Chu, E. J. Lavernia and J.-H. Chun (The Minerals, Metals & Materials Society, Warrendale, PA, 1998) p. 289.
D. J. Skinner, K. Okazaki and C. M. Adam, in "Rapidly Solidified Powder Aluminum Alloys," edited by M. E. Fine and E. A. Starke, Jr (ASTM-STP 890, Philadelphia, PA, 1986) p. 211.
M. J. Couper and R. F. Singer, in "High Strength Powder Metallurgy Aluminum Alloys II," edited by G. J. Hildeman and M. J. Koczak (American Institute of Mining, Metallurgical and Petroleum Engineers-TMS, Warrendale, PA, 1986) p. 199.
W. G. J. Bunk, Mater. Sci. Eng. A134 (1991) 1087.
C. Suryanarayana, F. H. Froes and W. E. Quist, in "Advances in Powder Metallurgy, 1991," Vol. 6 (American Powder Metallurgy Federation, Princeton, NJ, 1991) p. 15.
P. S. Gilman, R. G. Rateick and A. Testa, in ibid. p. 47.
W. J. Boettinger, L. Bendersky and J. G. Early, Metall. Trans. A, 17A (1986) 781.
R. F. Cochrane, P. V. Evans and A. L. Greer, Mater. Sci. Eng. A133 (1991) 803.
R. F. Cochrane, S. B. Newcomb, P. V. Evans and A. L. Greer, Key Eng. Mater. 38 & 39 (1989) 21.
J. D. Cotton and M. J. Kaufman, Metall. Trans. A 22A (1991) 927.
C. M. Adam, in "Rapidly Solidified Amorphous and Crystalline Alloys," edited by B. H. Kear, B. C. Giessen and M. Cohen (Elsevier, New York, 1982) p. 411.
J. H. Perepezko, J. A. Graves and B. A. Mueller, in "Processing of Structural Metals by Rapid Solidification," edited by F. H. Froes and S. J. Savage (American Society for Matals International, Metals Park, OH, 1987) p. 13.
E. J. Lavernia, T. S. Srivatsan and R. H. Rangel, Atomization and Sprays 2 (1992) 253.
S. Nukiyama and Y. Tanasawa, Trans. Jpn. Soc. Mech. Eng. 5 (1939) 68.
H. Lubanska, J. Metals 22 (1970) 45.
A. H. Lefebvre, J. Eng. Gas Turbines Power 114 (1992) 89.
V. H. Ahlborn and D. Merz, Aluminium 47 (1971) 671.
R. Mehrabian, Int. Met. Rev. 27 (1982) 185.
H. Jones, in "Rapid Solidification of Metals and Alloys" edited by H. Jones (Institution of Metallurgists, London, 1982).
J. P. Hirth, Metall. Trans. A 9 A (1978) 401.
J. H. Perepezko, in "Science and Technology of the Undercooled Melt," edited by P. R. Sahm, H. Jones and C. M. Adam (Martinus Nijhoff Publishers, Dordrecht, 1986) p. 29.
P. G. Bosewell and G. A. Chadwick, J. Mater. Sci. 12 (1977) 1879.
J. L. Murray, in "Alloy Phase Diagrams," edited by L. H. Bennett, T. B. Massalski and B. C. Giessen (Elsevier, New York, 1983) p. 249.
C. M. Adam and L. M. Hogan, J. Aust. Inst. Metals 17 (1972) 81.
P. G. Keong, J. A. Sames, C. M. Adam and R. M. Sharp, in "Solidification and Casting of Metals" (The Metals Society, London, 1979) p. 110.
P. Gilgien, A. Zryd and W. Kurz, Acta Metall. Mater. 43 (1995) 3477.
M. G. Chu and D. A. Granger, Metall. Trans. A 21A (1990) 205.
H. Jones, Phil. Mag. B 61 (1990) 487.
M. C. Flemings, in "Solidification Processing" edited by M. C. Flemings (McGraw-Hill, New York, 1974).
Rights and permissions
About this article
Cite this article
Juarez-Islas, J., Zhou, Y. & Lavernia, E.J. Spray atomization of two Al–Fe binary alloys: solidification and microstructure characterization. Journal of Materials Science 34, 1211–1218 (1999). https://doi.org/10.1023/A:1004509022619
Issue Date:
DOI: https://doi.org/10.1023/A:1004509022619