Determination of Saturation Conditions of the Aluminum Metal Matrix Composites Reinforced with Al2O3 Sinter.

Aluminum metal matrix composites (Al MMCs) are a class of materials characterized by being light in weight and high hardness. Due to these properties, Al MMCs have various applications in the automobile, aeronautical and marine industries. Ceramic-reinforced Al MMCs in the form of sinters are known for having excellent abrasive properties, which makes them an attractive material in certain fields of technology. The biggest problem in their production process is their low ability to infiltrate ceramics with alloys and consequently the difficulty of filling a ceramic preform. The castability of such composites has not yet been researched in detail. The aim of this study was to create aluminum metal matrix composite castings based on aluminum alloys (AlSi11) reinforced with an Al2O3 sinter preform using a Castability Trials spiral mold, and then to determine the degree of saturation with the liquid metal of the produced ceramic shaped body (Castability Trials spiral). For the selected AlSi11 alloy, the liquidus (Tl) and solidus (Ts) temperatures were determined by performing thermal-derivation analysis during cooling, which is Tl-579.3 °C and Ts-573.9 °C. The resultant pressure necessary for the infiltration process was estimated for the reinforcement capillaries with the following dimensions: 10, 15, 20, 25, 30 and 35 microns. The following values were used to determine the capillary pressure (Pk): surface tension of the alloy-σ = 840 mN/m; the extreme wetting angle of the reinforcement by the metal-θ = 136°. It has been experimentally confirmed that for the vacuum saturation process, the estimated resultant pressure enables saturation of reinforcement with capillaries larger than 25 microns, provided that the alloy temperature does not drop lower than the infiltration temperature. After the experiment, the time and route of the liquid metal flow in the spiral were determined. On the basis of the obtained values, a simulation was developed and initial assumptions such as saturation time, alloy temperature, reinforcement and mold temperature were verified. The energy balance showed that the saturation limit temperature was Tk = 580.7 °C for the reinforcement temperature of 575 °C. In contrast to the above, the assumption that the temperature of the metal after equalizing the temperature of the composite components must be higher than the liquidus temperature (Tliq = 579.3 °C) for the aluminum alloy used must be fulfilled. After the experiment, the time and path of the liquid metal flow in the spiral were determined. Then, on the basis of the obtained values, a simulation was developed, and the initial assumptions (saturation time and temperature) were verified.

Single Crystalline Films of Ce3+-Doped Y3MgxSiyAl5-x-yO12 Garnets: Crystallization, Optical, and Photocurrent Properties.

This research focuses on LPE growth, and the examination of the optical and photovoltaic properties of single crystalline film (SCF) phosphors based on Ce3+-doped Y3MgxSiyAl5-x-yO12 garnets with Mg and Si contents in x = 0-0.345 and y = 0-0.31 ranges. The absorbance, luminescence, scintillation, and photocurrent properties of Y3MgxSiyAl5-x-yO12:Ce SCFs were examined in comparison with Y3Al5O12:Ce (YAG:Ce) counterpart. Especially prepared YAG:Ce SCFs with a low (x, y < 0.1) concentration of Mg2+ and Mg2+-Si4+ codopants also showed a photocurrent that increased with rising Mg2+ and Si4+ concentrations. Mg2+ excess was systematically present in as-grown Y3MgxSiyAl5-x-yO12:Ce SCFs. The as-grown SCFs of these garnets under the excitation of α-particles had a low light yield (LY) and a fast scintillation response with a decay time in the ns range due to producing the Ce4+ ions as compensators for the Mg2+ excess. The Ce4+ dopant recharged to the Ce3+ state after SCF annealing at T > 1000 °C in a reducing atmosphere (95%N2 + 5%H2). Annealed SCF samples exhibited an LY of around 42% and similar scintillation decay kinetics to those of the YAG:Ce SCF counterpart. The photoluminescence studies of Y3MgxSiyAl5-x-yO12:Ce SCFs provide evidence for Ce3+ multicenter formation and the presence of an energy transfer between various Ce3+ multicenters. The Ce3+ multicenters possessed variable crystal field strengths in the nonequivalent dodecahedral sites of the garnet host due to the substitution of the octahedral positions by Mg2+ and the tetrahedral positions by Si4+. In comparison with YAG:Ce SCF, the Ce3+ luminescence spectra of Y3MgxSiyAl5-x-yO12:Ce SCFs greatly expanded in the red region. Using these beneficial trends of changes in the optical and photocurrent properties of Y3MgxSiyAl5-x-yO12:Ce garnets as a result of Mg2+ and Si4+ alloying, a new generation of SCF converters for white LEDs, photovoltaics, and scintillators could be developed.

New Dinuclear Macrocyclic Copper(II) Complexes as Potentially Fluorescent and Magnetic Materials.

Two dinuclear copper(II) complexes with macrocyclic Schiff bases K1 and K2 were prepared by the template reaction of (R)-(+)-1,1'-binaphthalene-2,2'-diamine and 2-hydroxy-5-methyl-1,3-benzenedicarboxaldehyde K1, or 4-tert-butyl-2,6-diformylphenol K2 with copper(II) chloride dihydrate. The compounds were characterized by spectroscopic methods. X-ray crystal structure determination and DFT calculations confirmed their geometry in solution and in the solid phase. Moreover, intermolecular interactions in the crystal structure of K2 were analyzed using 3D Hirshfeld surfaces and the related 2D fingerprint plots. The magnetic study revealed very strong antiferromagnetic CuII-CuII exchange interactions, which were supported by magneto-structural correlation and DFT calculations conducted within a broken symmetry (BS) framework. Complexes K1 and K2 exhibited luminescent properties that may be of great importance in the search for new OLEDs. Both K1 and K2 complexes showed emissions in the range of 392-424 nm in solutions at various polarities. Thin materials of the studied compounds were deposited on Si(111) by the spin-coating method or by thermal vapor deposition and studied by scanning electron microscopy (SEM/EDS), atomic force microscopy (AFM), and fluorescence spectroscopy. The thermally deposited K1 and K2 materials showed high fluorescence intensity in the range of 318-531 nm for K1/Si and 326-472 nm for the K2/Si material, indicating that they could be used in optical devices.

Experimental and Theoretical Studies of the Optical Properties of the Schiff Bases and Their Materials Obtained from o-Phenylenediamine.

Two macrocyclic Schiff bases derived from o-phenylenediamine and 2-hydroxy-5-methylisophthalaldehyde L1 or 2-hydroxy-5-tert-butyl-1,3-benzenedicarboxaldehyde L2, respectively, were obtained and characterized by X-ray crystallography and spectroscopy (UV-vis, fluorescence and IR). X-ray crystal structure determination and DFT calculations for compounds confirmed their geometry in solution and in the solid phase. Moreover, intermolecular interactions in the crystal structure of L1 and L2 were analyzed using 3D Hirshfeld surfaces and the related 2D fingerprint plots. The 3D Hirschfeld analyses show that the most numerous interactions were found between hydrogen atoms. A considerable number of such interactions are justified by the presence of bulk tert-butyl groups in L2. The luminescence of L1 and L2 in various solvents and in the solid state was studied. In general, the quantum efficiency between 0.14 and 0.70 was noted. The increase in the quantum efficiency with the solvent polarity in the case of L1 was observed (λex = 350 nm). For L2, this trend is similar, except for the chloroform. In the solid state, emission was registered at 552 nm and 561 nm (λex = 350 nm) for L1 and L2, respectively. Thin layers of the studied compounds were deposited on Si(111) by the spin coating method or by thermal vapor deposition and studied by scanning electron microscopy (SEM/EDS), atomic force microscopy (AFM), spectroscopic ellipsometry and fluorescence spectroscopy. The ellipsometric analysis of thin materials obtained by thermal vapor deposition showed that the band-gap energy was 3.45 ± 0.02 eV (359 ± 2 nm) and 3.29 ± 0.02 eV (377 ± 2 nm) for L1/Si and L2/Si samples, respectively. Furthermore, the materials of the L1/Si and L2/Si exhibited broad emission. This feature can allow for using these compounds in LED diodes.

Influence of Heat Treatment on Surface, Structural and Optical Properties of Nickel and Copper Phthalocyanines Thin Films.

The work presents the effect of annealing on the change of polycrystalline α and ß phases of copper and nickel phthalocyanines. We have found that this process has a great influence on the optical properties of the vapor-deposited layers. The performed measurements showed that for various forms of MPc, the values of the refractive index and the extinction coefficient increased, and consequently, so did the absorption coefficient. The AFM images taken showed that the values before and after heating are morphologically different. Raman measurements showed that the band at about 1526 cm-1 (B1g symmetry) has higher intensity for the α form than for the ß form. The intensity of this band is related to changing the form of phthalocyanine from α to ß. Our measurements have shown that by changing the annealing temperature of the layers, we change their optical properties. As a consequence, we change their optoelectronic parameters, adjusting them to the requirements of new optoelectronic devices, such as solar cells, sensors, displays and OLEDs.

Heat Transfer Analysis of 3D Printed Wax Injection Mold Used in Investment Casting.

Investment casting is one of the precise casting methods where disposable wax patterns made in wax injection molds are used to make a casting mold. The production capacity of precision foundry is determined by the time taken for producing wax patterns, which depends on the time taken for wax solidification. Wax injection molds are usually made of aluminum or copper alloys with the use of expensive and time-consuming computer numerical control (CNC) processing, which makes low-volume production unprofitable. To reduce these costs, the authors present a heat transfer analysis of a 3D printed wax injection mold. Due to the low thermal conductivity of the photopolymer resin, the influence of different cooling channels' shapes was investigated to improve the time of the manufacturing process. Transient thermal analysis was performed using COMSOL software based on the finite element method (FEM) and included a simulation of wax injection mold cooling with cold air (-23 °C), water, and without cooling. The analysis showed that use of cooling channels in the case of photopolymer material significantly reduces the solidification time of the sample (about 10 s shorter), and that under certain conditions, it is possible to obtain better cooling than obtained with the aluminum reference wax injection mold (after approximately 25-30 s). This approach allows to reduce the production costs of low-volume castings.

Non-Contact Multiscale Analysis of a DPP 3D-Printed Injection Die for Investment Casting.

The investment casting method supported with 3D-printing technology, allows the production of unit castings or prototypes with properties most similar to those of final products. Due to the complexity of the process, it is very important to control the dimensions in the initial stages of the process. This paper presents a comparison of non-contact measurement systems applied for testing of photopolymer 3D-printed injection die used in investment casting. Due to the required high quality of the surface parameters, the authors decided to use the DPP (Daylight Polymer Printing) 3D-printing technology to produce an analyzed injection die. The X-ray CT, Structured blue-light scanner and focus variation microscope measurement techniques were used to avoid any additional damages to the injection die that may arise during the measurement. The main objective of the research was to analyze the possibility of using non-contact measurement systems as a tool for analyzing the quality of the surface of a 3D-printed injection die. Dimensional accuracy analysis, form and position deviations, defect detection, and comparison with a CAD model were carried out.

Material Databases and Validation in Modelling the Structure of Castings Using the Cellular Automaton Method.

The paper presents the scope of applicability and the usefulness of the method of predicting crystalline structure of castings using a commercially available system called Calcosoft CAFE. The influence of individual values of the parameters of the thermal model and the model predicting the structure (phenomenon of nucleation and crystal growth), and the method of interpretation of the results were identified. In simulation studies, it is important to use reliable and validated material database, under appropriate conditions. It is necessary to predict the properties of castings with a comprehensive, new and practical approach to modelling the formation of phase components of structure in terms of both macroscale and microscale phenomena (Multiscale and Multiphysics). Therefore, in this paper, the experimental-simulation validation of the CAFE code was undertaken. The tests were carried out on castings solidifying under various heat transfer conditions controlled by mould materials such as: a homogenous mould made of moulding sand, moulding sand with chill, and mould made of insulating mass with chill. These conditions directly influence the structure formation. The method of validation of the structure was determined in terms of its three parameters, i.e., the degree of refinement of the crystals, the location of the columnar-to-equiaxed transition zone-CET and the angle of the crystals. The above tests enabled to extend the content of databases, which often lack the necessary values of parameters used in modelling, e.g., crystallization of a specific alloy under given conditions (sand casting, chills or laser surface treatment). On this basis, the basics of correlating the simulation results on a micro- and macroscale were generalized, the limits of the application of individual parameters (mould, alloy materials) and their impact on the structure formation were determined. It resulted in the extension of the database for simulation calculations.

Characterization of W-Cr Metal Matrix Composite Coatings Reinforced with WC Particles Produced on Low-Carbon Steel Using Laser Processing of Precoat.

The paper presents the study results of laser processing of precoat applied on C30 steel. The precoat consisted of powder mixtures with a binder in the form of water glass. Tungsten powder, chromium, and tungsten carbide (WC) were used to produce the precoat. The laser processing was carried out using a Yb:YAG disc laser with a rated power of 1 kW. Constant producing parameters (power of laser beam, 600 W; laser beam scanning rate, 400 mm/min) were applied. Chemical composition of the precoat was a variable parameter in coating production. A mixture consisting of 50% W and 50% Cr as a metal matrix was prepared. Subsequently, WC particles in weight ratios of 25%, 50%, and 75% were added to matrix. As a result, W-Cr metal matrix composite coatings reinforced with WC particles were formed. This study focused on investigation of microstructure, microhardness, phase, and chemical composition as well as corrosion and wear resistance, of the newly formed W-Cr/WC coatings. An instrumented nanoindentation test was also used in this study. As a result of laser beam action, the newly formed coatings had an interesting microstructure and good properties which were improved in comparison to substrate material. It is anticipated that the resulting coatings, depending on the treatment parameters (e.g., W-Cr/WC powder mixture) used, can be successfully applied to metal forming or foundry tools.

Decision Support System in the Field of Defects Assessment in the Metal Matrix Composites Castings.

This paper presented a new approach to decision making support of defects assessment in metal matrix composites (MMC). It is a continuation of the authors' papers in terms of a uniform method of casting defects assessment. The idea of this paper was to design an open-access application (follow-up system called Open Atlas of Casting Defects (OACD)) in the area of industry and science. This a new solution makes it possible to quickly identify defect types considering the new classification of casting defects. This classification complements a classical approach by adding a casting defect group called structure defects, which is especially important for metal matrix composites. In the paper, an application structure, and the possibility of its use in casting defects assessment were introduced.

Polyethylene Wax Modified by Organoclay Bentonite Used in the Lost-Wax Casting Process: Processing-Structure-Property Relationships.

In this paper, the influence of bentonite (BNT) on rheological properties, linear shrinkage, hardness, and structure of polyethylene wax (PE-wax) used in the lost-wax casting process are studied. Experiments were conducted with PE-wax with different contents of bentonite (from 0.1 to 5 wt.%). The structural changes of modified polyethylene wax were evaluated using differential scanning calorimetry (DSC) and scanning electron microscopy (SEM). The addition of bentonite in a concentration range between 0 and 0.8 wt.% into PE-wax caused a decrease of the linear shrinkage and the hardness of PE-wax/BNT blends. Modified polyethylene wax containing greater than 1 wt.% of the filler showed an increase in viscosity. The DSC-based investigations confirmed good miscibility and a uniform structure of PE-wax with BNT. Moreover, an increase in melting temperature onset and its enthalpy observed for filler PE-wax material showed an influence of bentonite on the crystalline structure of the polymeric matrix. SEM observations of the fractured surfaces confirmed the homogeneous structure of blends with contents up to 0.8 wt.% BNT. In the case of higher filler concentrations, the presence of more numerous and large clusters of filler in the polymer matrix was observed due to the increase in the viscosity of the PE-wax/BNT melt composition during mixing. The PE-wax blend with 0.4 wt.% BNT gives better results of reduced linear shrinkage and lower hardness than unmodified material. Lastly, a new developed material (PE-wax/0.4 BNT) was subjected to technological tests, consisting of the preparation of the mold and manufacture of a high-quality aluminum cast, using the lost-wax method.