Composition templating for heterogeneous nucleation of intermetallic compounds.

Refinement of intermetallic compounds (IMCs) through enhancing heterogeneous nucleation during casting process is an important approach to improve the properties of aluminium alloys, which greatly increases the economy value of recycled Al-alloys. However, heterogeneous nucleation of IMCs is inherently more difficult than that of a pure metal or a solid solution. It requires not only creation of a crystal structure but also the positioning of 2 or more different types of atoms in the lattice with specific composition close to that of the nucleated IMCs. Previous understanding on heterogeneous nucleation is based on structural templating, usually considering the small lattice misfit at the interface between the nucleating solid and substrate. In this work, we proposed a hypothesis and demonstrated that composition templating plays a critical role in heterogeneous nucleation of IMCs. The experimental results revealed that segregation of Fe atoms on the AlB2 surface, i.e., the Fe modified AlB2 particle, provides the required composition templating and hence enhances heterogeneous nucleation of α-Al15(Fe, Mn)3Si2, resulting in a significant refinement of the α-Al15(Fe, Mn)3Si2 particles in an Al-5 Mg-2Si-1.0Mn-1.2Fe alloy.

Direct Chill Casting and Extrusion of AA6111 Aluminum Alloy Formulated from Taint Tabor Scrap.

AA6111 aluminum automotive body-sheet alloy has been formulated from 100% Taint Tabor scrap aluminum. Direct chill casting with and without high shear melt conditioning (HSMC) was used to produce the AA6111 alloy billets. Both homogenized and non-homogenized billets were extruded into sheets. The optical micrographs of the melt conditioned direct chill (MC-DC) samples showed refined equiaxed grains in comparison to direct chill (DC) cast and direct chill grain refined (DC-GR) samples. Optical metallography showed extensive peripheral coarse grain (PCG) for the DC, DC-GR and MC-DC planks extruded from the homogenized standard AA6111 billets while planks extruded from modified AA6111 billets (with recrystallization inhibitors) showed thin PCG band. The co-addition of recrystallization inhibitors Mn, Zr, and Cr with elimination of the billet homogenization step had a favorable impact on the microstructure of the AA6111 alloy following the extrusion process where a fibrous grain structure was retained across the whole section of the planks. The mechanical properties of as-cast planks extruded from non-homogenized billets were similar to those extruded from homogenized billets. Eliminating the homogenization heat treatment step prior to extrusion has important ramifications in terms of processing cost reduction.

Impeding Nucleation for More Significant Grain Refinement.

Grain refinement has been a topic of extensive research due to its scientific and technological importance as a common industrial practice for over seven decades. The traditional approach to grain refinement has been to reduce nucleation undercooling by the addition of potent nucleant particles. Here we show both theoretically and experimentally that more significant grain refinement can be achieved through increasing nucleation undercooling by using impotent nucleant particles. Based on the concept of explosive grain initiation, this new approach is illustrated by grain initiation maps and grain refinement maps and validated by experiments. It is anticipated that this new approach may lead to a profound change in both nucleation research and industrial practice well beyond metal casting.

Melt Conditioned Direct Chill (MC-DC) Casting and Extrusion of AA5754 Aluminium Alloy Formulated from Recycled Taint Tabor Scrap.

The melt conditioned direct chill (MC-DC) casting process has been used to produce billets and extruded planks of AA5754 alloy formulated from 100% recycled Taint Tabor scrap aluminum. The billets were homogenized and then extruded into flat planks. Optical metallography of the MC-DC cast billets showed equiaxed refined grains in comparison to conventional direct chill (DC) cast and direct chill grain refined (DC-GR) cast billets formulated from the same Taint Tabor scrap. Microstructural evaluation of the extruded planks showed extensive peripheral coarse grain (PCG) for the DC, DC-GR and MC-DC cast planks. The 2 mm and 1 mm MC-DC cast planks produced after cold rolling and heat treatment showed a fully recrystallized microstructure at 380 °C and 300 °C for 10 min respectively with an improvement in mechanical properties over DC-GR cast and similarly processed planks. The as-extruded MC-DC cast planks tensile tested in the transverse direction showed 34% elongation and 213 MPa ultimate tensile strength. These tensile results showed 5.8% higher elongation and 1.2% higher ultimate tensile strength compared with the DC-GR planks after applying high shear melt conditioning.

Melt Conditioning of Light Metals by Application of High Shear for Improved Microstructure and Defect Control.

Casting is the first step toward the production of majority of metal products whether the final processing step is casting or other thermomechanical processes such as extrusion or forging. The high shear melt conditioning provides an easily adopted pathway to producing castings with a more uniform fine-grained microstructure along with a more uniform distribution of the chemical composition leading to fewer defects as a result of reduced shrinkage porosities and the presence of large oxide films through the microstructure. The effectiveness of high shear melt conditioning in improving the microstructure of processes used in industry illustrates the versatility of the high shear melt conditioning technology. The application of high shear process to direct chill and twin roll casting process is demonstrated with examples from magnesium melts.

Enhanced production of polyhydroxybutyrate by multiple dividing E. coli.

BACKGROUND: Most bacteria are grown in a binary fission way meaning a bacterial cell is equally divided into two. Polyhydroxyalkanoates (PHA) can be accumulated as inclusion bodies by bacteria. The cell division way and morphology have been shown to play an important role in regulating the bacterial growth and PHA storages. RESULTS: The common growth pattern of Escherichia coli was changed to multiple fission patterns by deleting fission related genes minC and minD together, allowing the formation of multiple fission rings (Z-rings) in several positions of an elongated cell, thus a bacterial cell was observed to be divided into more than two daughter cells at same time. To further improve cell growth and PHA production, some genes related with division process including ftsQ, ftsL, ftsW, ftsN and ftsZ, together with the cell shape control gene mreB, were all overexpressed in E. coli JM109 ∆minCD. The changing pattern of E. coli cell growth and morphology resulted in more cell dry weights (CDW) and more than 80 % polyhydroxybutyrate (PHB) accumulation increases compared to its binary fission control grown under the same conditions. CONCLUSIONS: This study clearly demonstrated that combined over-expression genes ftsQ, ftsW, ftsN, ftsL and ftsZ together with shape control gene mreB in multiple division bacterial E. coli JM109 ∆minCD benefited PHA accumulation. Our study provides useful information on increasing the yield of PHA by changing the cell division pattern and cell morphology of E. coli.

DNA damage induces the accumulation of Tiam1 by blocking ß-TrCP-dependent degradation.

The Rac1/JNK cascade plays important roles in DNA damage-induced apoptosis. However, how this cascade is activated upon DNA damage remains to be fully understood. We show here that, in untreated cells, Tiam1, a Rac1-specific guanine nucleotide exchange factor, is phosphorylated by casein kinase 1 (CK1) at its C terminus, leading to Skp, Cullin, F-box-containing(ß-TrCP) recognition, ubiquitination, and proteasome-mediated degradation. Upon DNA-damaging anticancer drug treatment, CK1/ß-TrCP-mediated Tiam1 degradation is abolished, and the accumulated Tiam1 contributes to downstream activation of Rac1/JNK. Consistently, tumor cells overexpressing Tiam1 are hypersensitive to DNA-damaging drug treatment. In xenograft mice, Tiam1-high cells are more susceptible to doxorubicin treatment. Thus, our results uncover that inhibition of proteasome-mediated Tiam1 degradation is an upstream event leading to Rac1/JNK activation and cell apoptosis in response to DNA-damaging drug treatment.