Heat-treated aluminum-silicon (Al-Si)-based alloys have dominated the cast lightweight alloy industry for several decades. However, in the last decade, Al-Ce-based alloys have shown promise in replacing Al-Si alloys due to their ability to remove the need for costly heat treatments. Since the properties of Al-Ce alloys depend on the as-cast microstructure, it is important to characterize the solidification kinetics of these alloys. Therefore, this study focused on characterizing the solidification of a near eutectic Al-Ce alloy with additions of Ni and Mn. The alloy was cast in a wedge mold configuration, resulting in cooling rates between 0.18 and 14.27 °C/s. SEM coupled with EDS and DSC techniques characterized the evolution rate of solid phases. The SEM/EDS data revealed that an Al10CeMn2 phase is present at higher cooling rates. At lower cooling rates, near the center of the casting, a proeutectic Al23Ce4Ni6 phase was more present. It was observed that up to 2.6 at. % of Mn was dissolved in this proeutectic Al23Ce4Ni6 phase, thereby removing a large portion of the available Mn for forming the Al10CeMn2 phase. DSC analysis showed differences in the samples' liquidus temperatures which is indicative of compositional variations. Inductively coupled plasma atomic emission spectroscopy (ICP-OES) and Scheil solidification simulations correlated the compositional differences to phase formation, which agreed with the SEM and DSC results. This experimentation provides insight into novel Al-Ce-Ni-Mn alloys and where their potential lies in industrial applications.

Rapid solidification during metal additive manufacturing (AM) leads to non-equilibrium microsegregation, which can result in the formation of detrimental phases and cracking. Most of the microsegregation models, assume a Scheil-type solidification, where the solidification interface is planar and there exists local equilibrium at the interface along with either zero or infinite solute diffusion in the respective participating phases - solid and liquid. This assumption leads to errors in prediction. One has to account for finite solute diffusion and the curvature at the dendritic tip for more accurate predictions. In this work, we compare different microsegregation models that do and do not consider finite diffusion and dendrite tip kinetics against the experiments. We also propose a method to couple dendrite tip kinetics with the diffusion module (DICTRA®) implemented in Thermo-Calc®. The models which accounted for both finite diffusion and dendrite tip kinetics matched well with the experimental data.

Directional solidification experiments were carried out to investigate the effect of micro-alloying element Sn and magnetic field on the solidification of Al-Bi immiscible alloys. Experimental results show that the size distribution of the dispersed particles in the low-speed solidified Al-3.4wt%Bi alloy presents two peaks, while it only shows one peak when solidified at a relatively high speed. The addition of Sn not only can enhance the nucleation rate and the number density of the Bi-rich droplets in the sample, but also decrease the Marangoni migration velocity and the axial resultant velocity of minority phase droplets in front of the solidification interface. Thereby it promotes the formation of Al-Bi alloys with a well-dispersed microstructure. A static magnetic with the strength of 0.2T increase the number density of the dispersed particles and decrease the average size and the size distribution width of the dispersed particles. Under the effect of Sn addition and static magnetic field, the average radius of the dispersed particles <R> and the solidification velocity V_0 satisfy <R>∝〖V_0〗^(-1/3) when the alloy was solidified at a relatively low velocity, <R> and V_0 satisfy <R>∝〖V_0〗^(-1/2) when the alloy is solidified at a high velocity.

In this study, an alternative method to conventional production methods involving thin section copper permanent mould casting (rapid solidification), hot rolling and heat treatment processes to manufacture AISI DC 53 cold work tool steel, has been investigated. In this new method, solidification of the AISI DC 53 was done in the thin section copper mould instead of traditional ingot casting. After solidification, thin slabs obtained was homogenized to 1150 ^oC and hold at this temperature for one hour and then hot rolling was be applied. During hot rolling process, about % 30 reduction in thickness of slab was obtained. After hot rolling, heat treatment (austenitizing, quenching and tempering) have been applied to thin slab. The samples have been taken as cast, as rolled and as heat treated (austenitized and tempered) and the microstructural analysis, hardness tests, retained austenite quantity measurement by XRD method have been performed. The heat treatment and tests have been performed for a commercially available AISI DC 53 which is manufactured by thick section ingot casting and rolling. Hardness values of the AISI DC 53 steels produced by traditional route is in the range of 52-54 HRC after austenitization at 1025 ^oC for one hour and quenched in compressed air and tempered twice at 525 ^oC for 120 mins. On contrary the permanent mould cast AISI DC 53 after homogenization at 1150 ^oC and immediately hot rolling then air cooling and austenitized at 1025 ^oC for one hour then quenched by compressed air and tempered twice at 525 ^oC for 120 mins have hardness valeus in the range of 55-57 HRC. Experiments have revealed that the properties of new rapid solidified steel in permanent copper mould are better than the commercially available steel and have a more refined microstructure than commercially produces alternative. Therefore, the new proposed method can be used as an alternative manufacturing method for cold-work tool steels.

Understanding the infiltration and solidification processes of liquid 5083Al alloy into Al2O3 three-dimensional reticulated porous ceramic (Al2O3(3D) RPC) is essential for optimizing the microstructure and properties of Al2O3(3D)/5083Al interpenetrating phase composites (IPCs) prepared by low-pressure infiltration process (LPIP). This study employs ProCAST software to simulate the infiltration and solidification processes of liquid 5083Al with pouring velocities (PV) of 0.4 m/s infiltrating into Al2O3(3D) RPC preforms with varying porosities at different pouring temperatures (PT) to prepare Al2O3(3D)/5083Al IPCs using LPIP. The results demonstrate that pore diameter of Al2O3(3D) RPC preforms and PT of liquid 5083Al significantly influence the of the infiltration. Solidification process analysis reveals that the Al2O3(3D) RPC preform with smaller pore diameters allows the lower pouring velocity of 5083Al to solidify faster compared to the preform with larger pore diameters. Al2O3(3D)/5083Al IPCs were prepared successfully from Al2O3(3D) RPC porosity of 15 PPI with liquid 5083Al at PV 0.4 m/s and PT 800 °C using LPIP, resulting in nearly fully dense composites, where both Al2O3(3D) RPCs and 5083Al interpenetrate throughout the microstructure. The infiltration and solidification defects were reduced under air pressure of 0.3 MPa (corresponding to PV of 0.4 m/s) during LPIP. Finite volume method simulations are in good agreement with experimental data, validating the suitability of the simplified model for Al2O3(3D) RPCs in the infiltration simulation.

We summarise contributions made to the computational phase-field modelling of alloy solidification from the University of Leeds spoke of the LiME project. We begin with a general introduction to phase-field, and then reference the numerical issues that arise from solution of the model, before detailing each contribution to the modelling itself. These latter contributions range from controlling and developing interface-width independent modelling; controlling morphology in both single and multiphase settings; generalising from single to multi-phase models; and creating a thermodynamic consistent framework for modelling entropy flow and thereby postulate a temperature field consistent with the concepts of, and applicable in, multiphase and density-dependent settings.

This work explored and contrasted the effect of microstructure on the tensile properties of AlSi10Mg alloys generated by transient directional solidification depending on variations in cooling rate and Magnesium (Mg) content (i.e., 0.45 and 1wt.% Mg), with a focus on understanding the dendritic growth and phases constitution. Optical and Scanning electron (SEM) microscopies, CALPHAD and thermal analysis were used to describe the microstructure, forming phases and resulting tensile properties. The findings showed that the experimental evolution of the primary dendritic spacing is very similar when both directionally solidified (DS) Al-10wt.% Si-0.45wt.% Mg and Al-10wt.% Si-1wt.% Mg alloys samples are compared. The secondary dendritic spacing was lower for the alloy with more Mg, especially considering the range of high growth velocities. Moreover, a greater fraction of (Al+Si+Mg2Si) ternary eutectic islands surrounding the -Al dendritic matrix was noted for the alloy with 1wt.% Mg. As a result of primary dendritic spacings greater than 180 m related to lower cooling rates, slightly higher tensile properties were attained for the Al-10wt.% Si-0.45wt.% Mg alloy. In contrast, combining dendritic refining (< 150 m) and larger Mg2Si fraction, fast solidified DS Al-10wt.% Si-1wt.% Mg samples exhibited higher tensile strength and elongation. The control of cooling rate and fineness of the dendritic array provided a new insight related to the addition of Mg in slightly higher levels than conventional ones, capable of achieving a better balance of tensile properties in AlSi10Mg alloys.

Under pure diffusive growth conditions, layered peritectic solidification is possible. In reality, the competitive growth of the primary alfa-phase and the peritectic beta-phase revealed some complex peritectic solidification morphologies due to thermo-solutal convection. The binary organic components TRIS-NPG were used as model system for metal-like solidification. The transparency of the high-temperature non-faceted phases allows studying the dynamic of the solid/liquid interface which lead to peritectic solidification morphologies. Investigations were carried out by using the Bridgman technic for process conditions where one or both phases solidify in a non-planar manner. Different growth conditions were observed which led to competitive peritectic growth morphologies. Additionally, the competitive growth was solved numerically to interpret the observed transparent solidification patterns.

The microstructure and solidification behavior of nickel based GTD222 superalloy at different cooling rates are studied. The solidification of the GTD222 superalloy proceeds as follows: L→L+γ, L→L+γ+MC, L→L+(γ/γ ′)-Eutectic and L→η phase. The temperature of liquidus of GTD222 superalloy is 1360 °C while the solidus is slightly lower at 1310 °C, which due to the alloying elements redistribution. It was found that the dendrite arm spacing of the alloy decreased with the increase of cooling rate (From 200 μm at 2.5 K/min to 100 μm at 20 K/min).

Railway transportation is one of the main modes of long-distance coal transportation, and it is inevitable to cause environmental pollution during the transportation process. In order to improve the environment along the railway and increase the utilization rate of coal resources, this paper proposes a detection algorithm for scattered coal solidification layer during transportation based on the YOLO v8 model, and designs an intelligent recognition model suitable for coal solidification layer detection devices by combining fluorescence detection methods. Through experimental analysis, the model meets the requirements of practical detection and plays a crucial role in environmental protection, with strong practical application value.

The effects of chemical composition and solidification rate on the solidification behavior of high-Cr white irons were investigated through directional solidification. Increasing the solidi-fication rate in hypoeutectic alloys caused the finer dendrite arm spacing as expected. The eutec-tic structure which formed in the interdendritic region comprised of M7C3 and austenite, how-ever, secondary dendrite arms of hypoeutectic alloys contained a few M7C3 particles that solidi-fied prior to the eutectic structure. The transition from cellular to dendritic solidification oc-curred at a solidification rate between 50 µm/s and 100 µm/s in a near eutectic alloy. In the near eutectic alloy with cellular solidification, a directionally arrayed in-situ composite of M7C3/austenite formed within the cell. Speckle-like feature appeared in the intercellular region due to M23C6 carbide precipitation during subsequent cooling after freezing. Like dendrite arm spacing in hypoeutectic alloys, the inter-speckle spacing and the inter-fibre spacing became finer with increasing solidification rate in the cellular solidification range.

Direct Energy Deposition (DED) is a versatile and efficient method in metal additive manufacturing. However, humping, caused by abnormal dynamics in the melt pool (MP), poses a significant threat to the geometric integrity of manufactured products. Current state-of-the-art (SOTA) methods primarily detect humping by analyzing late-stage spatial abnormalities, such as MP detachment. This approach is fundamentally reactive, leading to a tendency to miss early humping spatiotemporal dynamics, like cyclic elongation of the MP. This study introduces a novel, proactive indicator named VIMPS (Variability of Instantaneous MP Solidification-Front Speed), a physics-based tool designed to quantify early abnormal fluctuations in MP solidification speed. The experiments demonstrate VIMPS correlation with humping-induced geometric inaccuracies. By capturing early spatiotemporal dynamics of the MP, VIMPS reduces detection latency by 30 seconds compared to existing SOTAs that focus solely on spatial abnormalities. This significant improvement transforms detection from reactive to proactive, providing the time needed for corrective actions to enhance the overall productivity and quality of the DED process.

In order to study the feasibility of copper-nickel smelting slag（CNSS） and palygorskite for large-scale consumption and utilization in the field of mine filling, gellable composite materials were prepared from copper-nickel smelting slag ,cement and palygorskite. The effects of palygorskite addition and curing time on the mechanical properties and microstructure of copper-nickel smelting slag-based cementitious materials were studied in detail. The results showed that the addition of palygorskite had a positive effect on the curing of the cemented filler of the non-ferrous smelting slag by promoting the early hydration reaction. palygorskite also affected the mechanical properties of the cementitious materials with different maintenance times and the ability to cure heavy metals. The strength of gellable composite materials reaches 23.05MPa when 1% palygorskite, 50% of copper-nickel smelting slag and 48% cement were used, which meet the standards requirements of filling materials for mine goaf. The addition of 1% palygorskite can improve the ability of cementitious materials to solidify heavy metals to realize the economic utilization of solid waste in mining areas.

The development of Al-Ni alloys with a controlled microstructure has had a great impact on the field of study of aluminum-based alloys. In the present research, the influence of thermal parameters on the grain structures resulting from the directional solidification process of Al-Ni alloys with different alloy content has been studied. It has also been evaluated how different structures and the distribution of second phases influence the corrosion behavior and microhardness of alloys. The columnar-to-equiaxed transition (CET) was observed to occur when the temperature gradient in the melt decreased to values between 1.3 to 2.9 ° C/cm. In addition, a small increase in the microhardness values was observed as a function of the Ni-content. When the Ni-content increase, the resistance to polarization decreases for samples with equiaxed grain structure, throughout the range of compositions studied. Furthermore, the equiaxed grain structure presents higher resistance to polarization values than the columnar grain zone, for alloys with a composition equal to or lower than the eutectic composition.

The corrosion behavior of Fe-containing directionally solidified (DS) and centrifugally cast (CC) Al-Si-Cu-Zn alloys with either Co or Ni additions has been investigated. Electrochemical and immersion corrosion methods were used to investigate the corrosion behavior in 0.6 M NaCl after short (1-hour) and long (30-day) exposure periods. The employed solidification methods allowed the production of samples with a wide range of secondary dendrite arm spacing (SDAS) while preserving Si and Fe-containing phases. The 0.5 wt.% Ni and Co additions led to the growth of the AlFeSi(Ni) and AlFeSi(Co) phases, but no binary AlNi nor AlCo intermetallic par-ticles have been generated. Potentiodynamic polarization studies at early exposure revealed an increase in the corrosion potential as the Ni was added for either fast or slow solidified samples. The electrochemical impedance spectroscopy at early exposure demonstrated that the Ni-modified alloy, on the other hand, was associated to smaller charge transfer resistances, in-dicating a reduction in corrosion resistance after short elapsed time into the electrolyte. Howev-er, 30-day immersion tests revealed much lower corrosion rate of the Ni-modified alloy than the other alloys, while the corrosion rates of the Co-modified and non-modified alloys were simi-lar. In the Ni-containing alloy, decreased corrosion rate under long-term corrosion process was attributed to the formation of a thick and dense alumina layer, effectively protecting the surface under such conditions. This work contributes to a better knowledge of the corrosion behavior of Ni- and Co-corrected Al industrial scrap compositions.

In this paper, the effect of multi-rotational speeds super-gravity field on the grain refinement and tensile properties of as-cast H13 steel were investigated systematically. The experimental results revealed that the as-cast grains of H13 steel can be significantly refined in multi-rotational speeds supergravity field. In conventional supergravity field, with the decrease of rotational radius, the secondary dendrite average spacing (SDAS) and the austenite grain average size (AGAS) increase, and the maximum values of SDAS and AGAS are 90 µm and 55 µm, respectively. while in multi-speeds supergravity fields, at the range of increasing rotational speeds, SDAS and AGAS decrease as the rotational radius decreases. In three-rotational speeds supergravity field, the maximum values of SDAS and AGAS are 80 µm and 50 µm. In five-rotational speeds supergravity field, the maximum values of SDAS and AGAS are reduced to 58 µm and 34 µm. Accordingly, both the tensile strength and the plasticity are enhanced with the increasing the number of rotational speeds in supergravity field, especially for the inner position of supergravity sample. The ultimate tensile strengths at outer, middle, and inner positions of H13 steel solidified in conventional supergravity field are 1445 MPa, 1378 MPa, and 1023 MPa, corresponding elongations of 2%, 1.5%, and 0.5%, while in the five-rotational speeds supergravity field, they are 1408 MPa, 1443 MPa, and 1453 MPa, corresponding elongations of 1.8%, 3.9%, and 2.2%. The mechanism for the grain refinement is that multi-speeds super-gravity can reduce the critical nucleation work of austenite, and the tangential force produced by changing the rotational speeds breaks dendrites at the solidification front, refining solidification structure.

Melting, solidification and viscosity properties of a multicomponent Fe-Cu-Nb-Mo-Si-B alloys with low aluminum addition up to 0.42 at.% Al were studied using an oscillating cup viscometer. It is shown that melting and solidification are divided into two stages with a knee point at 1461 K. The temperature dependences of the liquid fraction between the liquidus and solidus temperatures during melting and solidification are calculated. It has been proven that aluminum accelerates the processes of melting and solidification and leads to an increase in liquidus and solidus temperatures. In the liquid state at temperatures above 1700 K in an alloy with a low aluminum content, the activation energy of viscous flow increases. This growth was associated with the liquid – liquid structure transition caused by the formation of large clusters based on the metastable Fe23B6 phase. Aluminum atoms attract iron and boron atoms and contribute to the formation of clusters based on the Fe2AlB2 phase and metastable phases of a higher order.

The treatment, disposal, and resource utilization of waste mud are challenges for engineering construction. This study investigates the road performance of waste mud–solidified soil and reveals the mechanism of how solidifying materials influence the strength and deformation characteristics of waste mud. Waste mud, collected from a highway reconstruction project, was mixed with ordinary Portland cement as a solidifying material. Unconfined compressive strength tests, consolidated undrained triaxial shear tests, resonant column tests, and consolidation compression tests were conducted to evaluate the solidification effect. The test results show that with an increase in cement content from 5% to 9%, the unconfined compressive strength of the waste mud–solidified soil increased by over 100%, the curing time was extended from 3 days to 28 days, and the unconfined compressive strength increased by approximately 70%. However, an increase in initial water content from 40% to 60% reduced the unconfined compressive strength by 50%. With the increase of cement content from 5% to 9%, the cohesion and friction angles increased by approximately 78% and 24%, respectively. The initial shear modulus under dynamic shear increased by approximately 38% and the shear strain corresponding to a damping ratio decay to 70% of the initial shear modulus decreased by nearly 11%. The compression coefficient decreased by approximately 55%. Scanning electron microscopy and X-ray diffraction tests showed that a higher cement content led to the formation of more hydration reaction products, especially an increase in the content of AlPO4. The bonding material between soil particles significantly increased, exerting a bonding and filling effect on soil particles and firmly adhering them together. Consequently, the strength of the waste mud–solidified soil increased significantly while its compressibility decreased.

Municipal solid waste incineration fly ash (MSWI FA) predominantly consists of compounds comprising elements such as calcium, aluminum, silicon, sodium, and others. Additionally, it encompasses a complex mixture of heavy metals, chlorides, sulfates, organic pollutants, and other constituents. The effective and economically viable treatment of MSWI FA poses a formidable challenge for the current stage of resource cycling. In this research report, we will adopt a novel low-temperature sintering method called "Cold Sintering Process" (CSP) as a means to immobilize heavy metals within the fly ash. By utilizing a Taguchi orthogonal array, we will adjust five control factors in the CSP, including sintering temperature, uniaxial pressure, sintering time, initial water addition, and sodium carbonate dosage. The leaching of cadmium element from the fly ash, as measured by TCLP, will serve as the quality indicator. Through the application of CSP, the MSWI FA will be transformed into structurally stable ceramic blocks, effectively immobilizing the heavy metals within the blocks. The results of the experiments showed that MSWI FA under the conditions of a temperature of 300℃, uniaxial pressure of 312 MPa, sintering time in 60 minutes, 25 wt% water addition, and 9 wt% Na2CO3 addition could effectively reduce the leaching of cadmium by 77.71%, lead by 21.14%, zinc by 42.37%, and chromium by 99.99%, as compared to the original MSWI FA TCLP results.

Hyper duplex stainless steels, HDSS, are a new alloy group of duplex stainless steels with the highest corrosion resistance and mechanical properties among the existing modern stainless steel. Due to the addition of extra high content of alloying elements, e.g. Cr, Ni, Mo, etc., the crystallization behavior of the δ-ferrite from the liquid is of vital importance for controlling the steel properties. In this work, the effect of cooling rate (i.e. 4°C/min and 150 °C/min) on the growth process of δ-ferrite in S33207 during the solidification process was investigated using high-temperature confocal scanning laser microscopy (HT-CLSM) in combination with electron microscopes and thermodynamic calculation. The results showed that the solidification mode of S33207 steel was a ferrite-austenite type (FA mode). L→δ transformation occurred at a certain degree of supercooling, and merging occurred during the growth of δ phase dendrites. Similar microstructures were observed after solidification under these two different cooling rates. The variation of area fraction of δ ferrite at the free surface and temperature as well as time during solidification of S33207 steels were calculated at different cooling rates of 4 °C/min and 150 °C/min, respectively. The current HT-CLSM study provides in-situ experimental evidence to confirm that a low cooling rate favored the growth of primary δ-ferrite, whereas a high cooling rate favored the nucleation of primary δ-ferrite during the solidification process. The post-microstructure as well as composition evolution is also briefly investigated. This work shed light on the real time insights for the crystallization behavior of hyper duplex stainless steels during solidification, which aims to contribute to the process control of manufacturing of this steel grade.

The article continues the search for a general law that describes the physical properties of a solid body, represented as a complex compound, through the physical properties of its elements. For a set of mixtures of metal oxides (actinide oxides), their melting or solidification temperatures were described in terms of the atomic weighted sum of the melting/solidification temperatures of these metals and molecular oxygen, multiplied by a variable which depending on the crystal structure and properties of melt of the compound and on the atomic numbers of the elements that make up the compound.

Solidification cracking is a major obstacle when joining dissimilar alloys using additive manufacturing. In this work, location-specific solidification cracking susceptibility has been investigated using an integrated computational materials engineering (ICME) approach for a graded alloy formed by mixing P91 steel and Inconel 740H superalloy. An alloy derived from a mixture of 26 wt.% P91 steel and 74 wt.% Inconel 740H, with high configurational and total entropy, was fabricated using wire-arc additive manufacturing. Microstructure characterization revealed intergranular solidification cracks, which increased in length along with the build height. With inputs from experiments, such as secondary dendrite arm spacing, the DICTRA (diffusion-controlled transformations) module within the Thermo-Calc software was used to model location-specific solidification cracking susceptibility. The top region, with the highest cooling rate, has the highest solidification cracking susceptibility and is in good agreement with the experimentally observed crack length. From Scheil simulations, it was deduced that pronounced segregation of Nb and Cu within the cracks increased the solidification range by suppressing the solidus temperature. The overall solidification cracking susceptibility and freezing range was highest for the 26 wt.% P91 alloy amongst the mixed compositions between P91 steel and 740H superalloy, proving that solidification characteristics play a major role in alloy design for additive manufacturing.

Additive manufacturing enables the realization of complex component designs that can not be achieved with conventional processes, such as the integration of lattice structures for weight reduction. To include lattice structures in component designs, an automated algorithm compatible to conventional CAD is required that is able to handle various lattice topologies as well as variable local shape parameters such as strut radii. Furthermore, smooth node transitions are desired since previous studies indicate advantages regarding reduced stress concentrations and the structural response to loadings such as fatigue performance. The surface patch-based algorithm developed in this work is able to solidify given lattice frames to smooth lattice structures without manual construction steps. The algorithm requires only a few seconds of sketching time for each node and favours paralellization. Automated special case workarounds as well as fallback mechanisms are considered for non-standard inputs. It is demonstrated on irregular lattice topologies and applied for the construction of a lattice infill of an aircraft component that was additively manufactured.

Dissimilar welds between ferritic and austenitic steels represent a good solution for exploiting the best performance of stainless steels at high and low temperatures and in aggressive environments, while minimizing costs. Therefore, they are widely used in nuclear and petrochemical plants, however, due to the different properties of the steels involved, the welding process can be challenging. Fusion welding can be specifically addressed to connect low-carbon, or low-alloy steels, with high-alloy steels, which have similar melting point. Welding of thick plates can be performed with electric arc in multiple passes or in a single pass by means of a laser beam equipment. Since microstructure and consequently mechanical properties of the weld are closely related to composition, the choice of the filler metal and processing parameters, which in turn affects the dilution rate, plays a fundamental role. Numerous technical solutions were proposed for welding dissimilar steels and much research was developed on the weldment metallurgy; therefore, this article is aimed at a review of the most recent scientific literature on the issues relating to the fusion welding of ferritic / austenitic steels. Two specific sections are dedicated respectively to electric arc and laser beam welding; finally, metallurgical issues, related to dilution and thermal field are debated in the discussion section.

Non steady applied magnetic field impact on a liquid metals has good prospects for industry. For a better understanding of heat and mass transfer processes under these circumstances, numerical simulations are needed. A combination of finite elements and volumes methods was used to calculate the flow and solidification of liquid metal under electromagnetic influence. Validation of numerical results was carried out by means of measuring with ultrasound Doppler velocimetry technique, as well as with neutron radiography snapshots of the position and shape of the solid/liquid interface. As a result of the first part of the work, a numerical model of electromagnetic stirring and solidification was developed and validated. This model could be an effective tool for analyzing the electromagnetic stirring during the solidification process. In the second part, the dependences of the velocity pulsation amplitude and the melt velocity maximum value on the magnetic field pulsation frequency are obtained. It was found numerically the ability of the pulsating force action to develop higher values of the liquid metal velocity at a frequency close to the MHD resonance. Obtained characteristics give a more detailed description of the electrically conductive liquid behaviour under action of pulsating traveling magnetic field.

Solidification microstructure is formed under high cooling rates and temperature gradients in powder-based additive manufacturing. In this study, a non-equilibrium multi-phase field method (MPFM), which was based on a finite interface dissipation model proposed by Steinbach et. al., coupled with a CALPHAD database was developed for a multicomponent Ni alloy. A qua-si-equilibrium MPFM was also developed for comparison. Two-dimensional equiaxed micro-structural evolution for the Ni (Bal.)–Al–Co–Cr–Mo–Ta–Ti–W–C alloy was performed at various cooling rates. The temperature–γ fraction profiles obtained under 10^5 K/s using non- and qua-si-equilibrium MPFMs were in good agreement with each other. Over 10^6 K/s, the differences between non- and quasi-equilibrium methods grew as the cooling rate increased. The non-equilibrium solidification was strengthened over a cooling rate of 10^6 K/s. Colum-nar-solidification microstructural evolution was performed under cooling rates from 5×10^5 K/s to 1×10^7 K/s at various temperature gradient values under the constant interface velocity (0.1 m/s). The results showed that as the cooling rate increased, the cell space decreased in both methods, and the non-equilibrium MPFM agreed well with experimental measurements. Our results show that the non-equilibrium MPFM can simulate solidification microstructure in powder bed fusion additive manufacturing.

The theory of heterogeneous nucleation was initially developed as a part of condensed matter physics and later it was used as an important engineering tool to design metallurgical processes. The success leads to wide applications of the theory in metallurgical practice. For example, engineering heterogeneous nucleation in ductile iron has been used to reduce shrinkage defects, suppress cementite formation, and modify size and shape of micro-structural constituencies. This demonstrates how theoretical knowledge could benefit industry practice. This overview aims to summarize the authors’ published studies in co-authorship with colleagues and students, which covered different aspects of engineering heterogeneous nucleation in multiphase cast alloys. Several approaches for engineering heterogeneous nucleation using thermodynamic simulation and practical methods for improving efficiency of nucleation using co-precipitation technique and a local transient melt supersaturation were suggested. Automated Scanning Electron Microscopy Energy-Dispersive-X-ray (SEM/EDX) analysis and a high-resolution Transmission Electron Microscopy (TEM) were used to verify simulation predictions. Practical examples of controlling micro-porosity shrinkage in cast irons with spheroidal graphite are presented to illustrate the power of engineering heterogenous nucleation. The authors appreciate the great efforts that the co-authors have made on the original, overviewed articles here.