A series of binary to hexanary alloys (Ni, Co, Mo, Al, Fe, Cu) are produced by mechanical alloying. Formation of an FCC solid solution is observed in the binary system. For ternary to quinary systems the presence of an amorphous phase and a BCC solid solution is identified, and for the hexanary system a combination of BCC and FCC solid solutions is detected. There is a very small change in the lattice parameter of Mo, reflecting the limited solid solubility of other element in this structure. However, Mo induces the fast amorphization of other elements and the reduction of crystallite size.

Solidification of a simple casting made of ductile iron is mathematically modeled in this work. The model is able to numerically simulate the cooling rate and solidification of the whole casting system composed by a cubic piece, a blind riser connected through a rectangular neck, and immersed in a green sand mold. The center of the neck acts as a valve that allows the flow of liquid metal between the casting and the riser based on the feeding technique known as Pressure Control Risering (PCR). The developed model couples the energy conservation equation and the solidification kinetics of ductile iron, through the statement of proper nucleation and growth laws. This model is satisfactorily validated by comparing the thermal histories predictions with experimental cooling curves obtained in the foundry laboratory for the same casting. According to a process analysis developed in this work, the pouring temperature is the variable that affects the most the solidification and the feeding behavior, since it increases significantly the solidification times in all regions of the casting system.

Gas jets play a key role in several steelmaking processes as in the Basic Oxygen Furnace (BOF) or in the Electric Arc Furnace (EAF). They improve heat, mass and momentum transfer in the liquid bath, improve mixing of chemical species and govern the formation of foaming slag in EAF. In this work experimental measurements are performed to determine the dimensions of the cavity formed at the liquid free surface when a gas jet impinges on it as well as liquid velocity vector maps measured in the zone affected by the gas jet. Cavities are measured using a high speed camera while the vector maps are determined using a Particle Image Velocimetry (PIV) technique. Both velocities and cavities are determined as a function of the main process variables: gas flow rate, distance from the nozzle to the free surface and lance angle. Cavity dimensions (depth and diameter) are statistically treated as a function of the process variables and also as a function of the adequate dimensionless numbers that govern these phenomena. It is found that Froude number and Weber number control the depression geometry.

Haynes™ HR-120™ alloy is a solid-solution-strengthened heat resistant alloy. The main characteristics of this alloy are strength at elevated temperature combined with resistance to carburizing and sulfidizing environments. Typical solution heat treatment for this alloy is usually performed above 1100°C. Solution heat treatment promotes non-desired precipitates to dissolve and, if deformation parameters are adequate, re-crystallization after forging procedures. It is reported that the solution temperature can also promote non-controlled grain coarsening. This investigation summarizes results on the effect of solution heat treatment on the microstructure of forgings when it is performed at 1000°C, 1050°C and above 1100°C. The experimental conditions resemble industrial environments. The obtained results include the alloy microstructural evolution by optical microscopy and Scanning Electron Microscopy (SEM) and the effect of these heat treatments on mechanical properties such as tensile, hardness and stress-rupture properties.