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    Microstructure Evolution of an Al–Fe–Ni Alloy with Zr and Sc Additions Upon Different Cooling Rates During Solidification for Improving the Mechanical and Electrical Conductivity Properties
    (2021-01-01) ;
    Eskin, Dmitry G.
    ;
    Limmaneevichitr, Chaowalit
    Al–Fe–Ni eutectic alloys have high potential for being alternative aluminum alloys for various electronic and electrical applications instead of conventional low-conductivity Al casting alloys. Furthermore, the addition of Zr and Sc up to 0.3–0.6 wt% improves the hardness for high temperature applications, which is a result of the finer Al–Fe–Ni eutectic structure, and precipitation hardening of Al<inf>3</inf>Zr and/or Al<inf>3</inf>Sc nanoprecipitates. Thus, the aim of the present contribution is to analyze the microstructure features changes in an Al-1.75Fe–1.25Ni eutectic alloy upon different cooling rates during solidification. The features of Al–Fe–Ni eutectics and intermetallics were studied quantitatively, and the mechanical properties and electrical conductivity were measured.
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    Improvement in the Uniformity of Bismuth Distribution in an Al-Bi Alloy by Ultrasonic Processing and Hydrogen Melt Enrichment
    (2026-01-01) ;
    Eskin, Dmitry G.
    ;
    Diewwanit, Onnjira
    Manufacturing of immiscible metallic alloysMetallic alloys, such as aluminumAluminum-bismuth, faces challenges in achieving uniform distribution of secondary phase droplets/particles due to their higher density and tendency to agglomerate/coalesce, which negatively affects mechanical propertiesMechanical properties. Recent studies on emulsification of immiscible liquids showed that ultrasonic treatment (UST) of gas-saturated systems improved the droplet distribution. In this work we tested this approach on Al-Bi alloys with melts saturated with hydrogenHydrogen. It was demonstrated that this combination resulted in the uniform distribution of fineFines Bi droplets in the aluminumAluminum matrix. UST had a dual role in the process: (a) increased cavitation facilitated by dissolved hydrogenHydrogen improved the efficiency of droplet formation and distribution and (b) ultrasonic degassing eliminated the adverse effects of gas porosity. Finer and evenly distributed Bi particles enhanced the wear resistance of the alloy.
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    Effect of Homogenization on Anodic Film and Electrochemical Behavior of an A535 Alloy After Sealing with Stearic Sealant
    (2022-01-01) ;
    Eskin, Dmitry G.
    ;
    Limmaneevichitr, Chaowalit
    ;
    Pandee, Phromphong
    ;
    Kengkla, Nattarat
    Almag 35 (A535) is a commercial aluminum alloy intended for a number of marine components, which is mainly justified by its excellent castability and corrosion resistance. However, the most important factor for corrosion resistance is the formation of intermetallics that can lead the defects in the oxide film and substrate, as well as activate the corrosion reaction. The characteristics of a sealant on the anodic film were investigated in this work. The alloy was subjected to homogenization at 400 °C for 5 h to improve the uniformity of the anodic oxide film due to the decreased number of intermetallics as a result of dissolving in the matrix. It also improved the hardness of this alloy. Electrochemical measurements were conducted to investigate the corrosion behavior. The effects of intermetallics and stearic sealing on the characteristics of the oxide layer are discussed. The decrease in the number of intermetallics can lead to reduced corrosion current density (I<inf>corr</inf>) and increased potential corrosion (E<inf>corr</inf>), which results in a lower corrosion rate of this alloy.
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    Effect of Zr and Sc on Intermetallic Morphology and Hardening of an Al–Fe Alloy
    (2023-01-01) ;
    Eskin, Dmitry G.
    ;
    Limmaneevichitr, Chaowalit
    ;
    Pandee, Phromphong
    ;
    Diewwanit, Onnjira
    We studied the effect of zirconium and scandium on an Al-7 wt% Fe cast alloy with potential heat- and wear-resistant applications. An addition of 0.2% Zr resulted in thinning of primary Al<inf>3</inf>Fe particles, while an addition of 0.15% Zr and 0.15% Sc changed the morphology of primary intermetallics from needles to flower-like shape. While the addition of Zr did not affect the properties, the Zr + Sc joint additions increased the hardness of the as-cast Al–Fe alloy. The hardness of the base alloy increased upon annealing from 40 to 80 HV (450 °C, 2 h) and to 110 HV (350 °C, 20 h). The wear resistance of the Al–Fe alloy was also improved by Zr and Sc addition, especially after annealing. The observed effects are likely to be linked to the supersaturation of Zr and Sc in the aluminum solid solution during solidification and precipitation of dispersoids during annealing.
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    Effects of Ultrasonic Melt Processing on Microstructure, Mechanical Properties, and Electrical Conductivity of Hypereutectic Al–Si, Al–Fe, and Al–Ni Alloys with Zr Additions
    (2021-01-01) ;
    Eskin, Dmitry G.
    ;
    Limmaneevichitr, Chaowalit
    Ultrasonic melt processing (USP) technique was used to study the effect of Zr addition on the structure refinement and mechanical properties of hypereutectic binary alloy in three different alloys (Al–Si, Al–Fe, and Al–Ni) as potential alternatives to the Al–Si eutectic system especially for high-temperature applications. Mechanical properties of these alloys were controlled through both structure refinement by USP and also Al<inf>3</inf>Zr nano-precipitation hardening. Significant refinement of primary intermetallics was achieved under USP during the Al<inf>3</inf>Zr formation in solidification process. The residual Zr in the aluminium solid solution enabled precipitation hardening at 450 °C. As a result, the tensile properties, especially ductility, were considerably improved at room and elevated temperatures. The mechanical properties were analyzed with respect to the volume fraction of intermetallic phases. Electrical conductivity was measured to better explore their potential applications. The effects of alloying elements and structural changes on the mechanical behaviour and electrical conductivity were discussed.
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    Towards the Design of Highly Heterogeneous Aluminum Alloys
    (2025-01-01)
    Eskin, Dmitry G.
    ;
    ;
    Zhu, Chengbo
    Modern engineering applications require new types of alloys with a unique combination of properties. Alloys with the large volume fraction of intermetallic phases started to attract the attention of researchers, for example, eutectic alloys of the Al–Fe–Ni and Al–Ce–Ni systems. Such alloys have high elasticity modulus, thermal stability, hardness and high-temperature properties, however their applications is limited to casting and mostly hypoeutectic or eutectic alloys. Formation of primary intermetallics poses a challenge unless they can be efficiently refined. Here we present a number of approaches to refine the structure of hypereutectic Al Fe, Al–Ni, Al–Ce–Ni–Mn alloys through additions, ultrasonic processing (USP) and increased cooling rates. As a result, the structure of alloys makes them suitable for deformation and additive manufacturing with extra strength gained through dispersion hardening. These approaches may pave way to the new type of alloys for demanding applications.