Filomena Viana

Retrogression and re-ageing of 7075 aluminium alloy: microstructural characterization

Abstract Industrial Summary: The 7075 aluminium alloy presents a low stress corrosion cracking strength when aged to achieve maximum mechanical strength, T6 temper; high stress corrosion cracking strength is attained with overageing, T7 temper; but with loss of mechanical strength. Retrogression and re-ageing treatments improves the stress corrosion behaviour of the alloy whilst maintaining the mechanical resistance of the T6 temper. The microstructures produced by the retrogression and re-ageing treatments were characterized in this study by transmission electron microscopy, electron diffraction and differential scanning calorimetry. The precipitation is extremely fine and distributed homogeneously inside the grains, being slightly denser and more stable than that resulting from the T6 temper; whilst the grain boundary precipitation is quite different from that resulting from T6 treatment, the particles being coarser, and much closer to the precipitation resulting from T7 temper. The retrogression temperature is the main property controlling factor; a higher retrogression temperature, increasing the dissolution degree, promotes the formation of more stable precipitates on re-ageing.

Joining of Superalloys to Intermetallics Using Nanolayers

Joining nickel based superalloys to gamma-TiAl intermetallic alloys will contribute to a more efficient application of these advanced materials, particularly in extreme environments. In this study, Inconel alloy and gamma-TiAl are joined using as filler alternated nanolayer thin films deposited onto each base material. The nanolayers consisted in Ni/Al exothermic reactive multilayer thin films with periods of 5 and 14 nm deposited by d.c. magnetron sputtering in order to improve the adhesion to the substrates and to avoid the reaction between Ni and Al. Diffusion bonding experiments with multilayer coated alloys were performed under vacuum at 800°C by applying 50 MPa during 1h. Bonding was achieved in large areas of the centre of the joints where regions without cracks or pores were produced, especially when using multilayer thin films with a 14 nm modulation period.

Joining Ti-47Al-2Cr-2Nb with a Ti/(Cu,Ni)/Ti clad-laminated braze alloy

The joining of Ti-47Al-2Cr-2Nb using Ti-15Cu-15Ni (wt%) as braze alloy was investigated. Experiments were conducted at 980 and 1000°C for 10 min. The microstructure and the chemical composition of the interfaces were studied by scanning electron microscopy (SEM) and by energy dispersive X-ray spectroscopy (EDS), respectively. For both processing conditions the reaction between the γ-TiAl alloy and the braze alloy produced layered interfaces, which are essentially composed of α2-Ti3Al and of Ti-Ni-Cu-Al and Ti-Ni-Cu intermetallic compounds. Microhardness tests showed that all reaction layers are harder than either the γ or the (α2 + γ) lamellar grains of the intermetallic alloy.

The effect of brazing temperature on the titanium/glass-ceramic bonding

Abstract The aim of this work is to study the effect of time and brazing temperature on the interfacial microstructure and mechanical properties of the joint obtained by active metal brazing between c.p. titanium and a fluorosilicate machinable ceramic–glass using a 64Ag–34.5Cu–1.5Ti (wt%) brazing alloy. The reaction between the brazing alloy and the two materials leads to the formation of several interfacial reaction layers with different compositions, morphologies and extensions. These layers are constituted by various reaction products that ensure chemical bonding between the two materials, their stability and capability to accommodate the discontinuity of properties across the interface determining the success of the joining. The interfacial microstructure was analysed by SEM and the composition of each reaction layer was investigated by EDS. Microhardness tests were performed across the interfacial zone and the global interfacial mechanical behaviour was evaluated by means of shear tests.

TEM and HRTEM characterization of TiAl diffusion bonds using Ni/Al nanolayers.

Diffusion bonding of TiAl alloys can be enhanced by the use of reactive nanolayer thin films as interlayers. Using these interlayers, it is possible to reduce the conventional bonding conditions (temperature, time, and pressure) and obtain sound and reliable joints. The microstructural characterization of the diffusion bond interfaces is a fundamental step toward understanding and identifying the bonding mechanisms and relating them to the strength of the joints. The interface of TiAl samples joined using Ni/Al nanolayers was characterized by transmission electron microscopy and scanning transmission electron microscopy. Microstructural characterization of the bond revealed that the interfaces consist of several thin layers of different composition and grain size (nanometric and micrometric). The bonding temperature (800, 900, or 1,000°C) determines the grain size and thickness of the layers present at the interface. Phase identification by high-resolution transmission electron microscopy combined with fast Fourier transform and electron energy-loss spectroscopy analyses reveals the presence of several intermetallic compounds: AlTiNi, NiAl, and Al2TiNi. For bonds produced at 800 and 900°C, nanometric grains of Ti were detected at the center of the interface.

Reaction-Assisted Diffusion Bonding of Advanced Materials

The aim of this work is to join -TiAl intermetallics to Ni based superalloys by solid state diffusion bonding. The surface of the -TiAl alloys and Ni superalloys to be joined was prepared by magnetron sputtering with a few microns thick Ni/Al reactive multilayer thin films with nanometric modulation periods. Sound joining without cracks or pores is achieved along the central region of the bond, especially at 800°C and when a 14 nm period Ni/Al film is used as filler material. During the diffusion bonding experiments interdiffusion and reaction inside the Ni/Al multilayer thin film and between the interlayer film and the base materials is promoted with the formation of intermetallic phases. The final reaction product in the multilayer films is the B2-NiAl intermetallic phase. The interfacial diffusion layers between the base materials and the multilayer films should correspond to: 3-NiTiAl and 4-Ni2TiAl phases from the -TiAl side; Ni-rich aluminide and -phase from the Inconel side. These intermetallic phases are responsible for the hardness increase observed on the diffusion layers.

Joining Ti-47Al-2Cr-2Nb with a Ti-Ni Braze Alloy

Ti-47Al-2Cr-2Nb was joined by diffusion brazing using a Ti-Ni clad-laminated filler alloy. Brazing was performed in the temperature range of 1000 to 1200oC for 10 min. The microstructure and the chemical composition of the interfaces were studied by scanning electron microscopy (SEM) and by energy dispersive X-ray spectroscopy (EDS), respectively. The reaction between the γ-TiAl alloy and the liquid produced interfaces essentially composed of α2-Ti 3Al and TiNiAl intermetallics. When joints are brazed at 1150 and 1200oC, the γ-TiAl phase is also detected at the interface.

TEM characterization of As-deposited and annealed Ni/Al multilayer thin film.

Reactive multilayer thin films that undergo highly exothermic reactions are attractive choices for applications in ignition, propulsion, and joining systems. Ni/Al reactive multilayer thin films were deposited by dc magnetron sputtering with a period of 14 nm. The microstructure of the as-deposited and heat-treated Ni/Al multilayers was studied by transmission electron microscopy (TEM) and scanning transmission electron microscopy (STEM) in plan view and in cross section. The cross-section samples for TEM and STEM were prepared by focused ion beam lift-out technique. TEM analysis indicates that the as-deposited samples were composed of Ni and Al. High-resolution TEM images reveal the presence of NiAl in small localized regions. Microstructural characterization shows that heat treating at 450 and 700°C transforms the Ni/Al multilayered structure into equiaxed NiAl fine grains.

Microstructural Characterization of Aluminum-Carbon Nanotube Nanocomposites Produced Using Different Dispersion Methods.

This research focuses on characterization of the impact of dispersion methods on aluminum-carbon nanotubes (Al-CNTs) nanocomposite structure. Nanocomposites were produced by a conventional powder metallurgy process after the dispersion of the CNTs on the Al powders, using two approaches: (1) the dispersion of CNTs and mixture with Al powders were performed in a single step by ultrasonication; and (2) the CNTs were previously untangled by ultrasonication and then mixed with Al powders by ball milling. Microstructural characterization of Al-CNT nanocomposites was performed by optical microscopy, scanning and transmission electron microscopy, electron backscatter diffraction, and high-resolution transmission electron microscopy (HRTEM). Microstructural characterization revealed that the use of ball milling for mixing CNTs with Al powders promoted the formation of CNT clusters of reduced size, more uniformly dispersed in the matrix, and a nanocomposite of smaller grain size. However, the results of HRTEM and Raman spectroscopy show that ball milling causes higher damage to the CNT structure. The strengthening effect of the CNT is attested by the increase in hardness and tensile strength of the nanocomposites.

Ni/Al Multilayers Produced by Accumulative Roll Bonding and Sputtering

Ni/Al multilayers are known to transform into NiAl in a highly exothermic and self-sustaining reaction. The fact that this reaction has a high heat release rate and can be triggered by an external impulse, are reasons why it has already attracted much research attention. There is a huge potential in the use of Ni/Al multilayers as a controllable and localized heat source for joining temperature-sensitive materials such as microelectronic components. The heat released and the phases resulting from the reaction of Ni and Al multilayers depend on the production methods, their composition, as well as the bilayer thickness and annealing conditions. The present research aims to explore the influence of these variables on the reaction of different multilayers, namely those produced by accumulative roll bonding (ARB) and sputtering. Structural evolution of Ni/Al multilayers with temperature was studied by differential scanning calorimetry, x-ray diffraction and scanning electron microscopy. Phase evolution, heat release rate and NiAl final grain size are controlled by the ignition method used to trigger the reaction of Ni and Al. The potential use of these multilayers in the diffusion bonding of TiAl was analyzed. The ARB multilayers allow the production of joints with higher strength than the joints produced with commercial multilayers (NanoFoil®) produced by sputtering. However, the formation of brittle intermetallic phases (Ni3Al, Ni2Al3 and NiAl3) compromises the mechanical properties of the joint.