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Spray forming of bulk ultrafine-grained Al-Fe-Cr-Ti

Banjongprasert, C.; Hogg, S. C.; Liotti, E.; Kirk, C. A.; Thompson, S. P.; Mi, J.; Grant, P. S.


C. Banjongprasert

S. C. Hogg

E. Liotti

C. A. Kirk

S. P. Thompson

P. S. Grant


An Al-2.7Fe-1.9Cr-1.8Ti alloy has been spray formed in bulk and the microstructure and properties compared with those of similar alloys produced by casting, powder aomization (PA), and mechanical alloying (MA) routes. In PA and MA routes, a nanoscale metastable icosahedral phase is usually formed and is known to confer high tensile strength. Unlike previous studies of the spray forming of similar Al-based metastable phase containing alloys that were restricted to small billets with high porosity, standard spray forming conditions were used here to produce a ~98 pct dense 19-kg billet that was hot isostatically pressed (‘‘HIPed''), forged, and/or extruded. The microstructure has been investigated at all stages of processing using scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and synchrotron X-ray diffraction (XRD) at the Diamond Light Source. Consistent with the relatively low cooling rate in spray forming under standard conditions, the microstructure showed no compelling evidence for the formation of metastable icosahedral phases. Nonetheless, after downstream processing, the spray-formed mechanical properties as a function of temperature were very similar to both PA rapid solidification (RS) materials and those made by MA. These aspects have been rationalized in terms of the typical phases, defects, and residual strains produced in each process route.


Banjongprasert, C., Hogg, S. C., Liotti, E., Kirk, C. A., Thompson, S. P., Mi, J., & Grant, P. S. (2010). Spray forming of bulk ultrafine-grained Al-Fe-Cr-Ti. Metallurgical and materials transactions. A, Physical metallurgy and materials science, 41(12), 3208-3215.

Journal Article Type Article
Acceptance Date Aug 13, 2010
Online Publication Date Aug 13, 2010
Publication Date 2010-12
Journal Metallurgical and Materials Transactions A: Physical Metallurgy and Materials Science
Print ISSN 1073-5623
Electronic ISSN 1543-1940
Publisher Springer Verlag
Peer Reviewed Peer Reviewed
Volume 41
Issue 12
Pages 3208-3215
Keywords Mechanics of Materials; Condensed Matter Physics; Metals and Alloys
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