BURA Collection: BCAST is striving for international excellence on both fundamental and applied research on solidification of metallic materials. BCAST sees itself as a reliable source of both new knowledge and new solidification technologies for the metallurgical industry.

Mathematical modeling of grain fragmentation induced by flow shearing in high-pressure die casting of light alloys

Thu, 14 May 2026 00:00:00 GMT

Title: Mathematical modeling of grain fragmentation induced by flow shearing in high-pressure die casting of light alloys Authors: Lu, J-Z; Dou, K; Zhang, Y-J; Lordan, E; Jacot, A; Fan, Z; Wang, W-L Abstract: In the cold-chamber high-pressure die casting (CC-HPDC) process for light alloys, strong shear stress generated by the fast-flowing melt through narrow runners breaks externally solidified crystals (ESCs). Two runner configurations were applied in the CC-HPDC process of aluminum alloy to address this problem. A comprehensive finite element model was established to calculate shear stress in the runner regions during die filling, and a novel mathematical model of grain breakup was proposed to quantitatively analyze ESCs fragmentation through different runners. Particles ranging in size from 12.2 to 16.1 μm constitute a significant proportion of the ESCs and serve as the primary focus of subsequent shear fragmentation. Finally, HPDC test trials validate the mathematical model by characterizing grain morphology and size distribution in as-cast samples and the error of the model is less than 20%. The results demonstrate that the novel model is highly effective for the design of runner systems and the optimization of process parameters in the CC-HPDC process for light alloys.

Solid/liquid interface energy and its anisotropy of pure metals

Sun, 28 Jun 2026 00:00:00 GMT

Title: Solid/liquid interface energy and its anisotropy of pure metals Authors: Fan, Z; Men, H Abstract: Solid/liquid (S/L) interface energy (𝛾_sl) and its anisotropy (φ) play a critical role in the understanding of nearly every single phenomenon that occurs during solidification of metals, such as nucleation, morphological instability and dendrite growth. However, due to difficulties associated with both experimental measurement and computer simulations, our current understanding of this topic is rather limited. In this work, a simple analytical model is developed to predict 𝛾_sl and φ for pure metals. This model suggests that S/L interface energy originates from atomic ordering in the S/L interface templated by the solid. 𝛾_sl can be expressed as the sum of contributions from both atomic layering (𝛾_z) and the in-plane atomic ordering ((𝛾_xy). Further analysis shows that 𝛾_sl for pure metals is determined by both heat of fusion per atom (∆𝐻_f) and their crystal structures, while anisotropy depends only on crystal structure. The analytical model reveals that the physical origin of 𝛾_sl is atomic ordering in the S/L interface templated by the solid, while the physical origin of anisotropy is the difference in structural templating power between different crystal planes. It is demonstrated that the current analytical model is capable of predicting solid/liquid interface energy (𝛾_sl) and its anisotropy (φ) for any metallic element using parameters readily available in the literature. Description: Data availability: All relevant experimental and theoretical data within the article will be provided by the corresponding author on reasonable request. This is a PDF of an article that has undergone enhancements after acceptance, such as the addition of a cover page and metadata, and formatting for readability. This version will undergo additional copyediting, typesetting and review before it is published in its final form. As such, this version is no longer the Accepted Manuscript, but it is not yet the definitive Version of Record; we are providing this early version to give early visibility of the article. Please note that Elsevier’s sharing policy for the Published Journal Article applies to this version, see: https://www.elsevier.com/about/ policies-and-standards/sharing#4-published-journal-article. Please also note that, during the production process, errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain.

Recovery of fatigue and manufacturing damages by electropulsing treatment

Thu, 23 Nov 2023 00:00:00 GMT

Title: Recovery of fatigue and manufacturing damages by electropulsing treatment Authors: Chang, ITH; Cai, Q; Zhou, M; Assadi, H Abstract: Metals are vital to human society and have widespread uses across a broad spectrum of industries including but not limited to packaging, transport and construction applications. They are mainly used in load-bearing structural components. Nonetheless, they possess finite operational lifetime attributable to the dynamic interplay of environmental and mechanical stimuli, culminating in the generation of structural imperfections, deterioration, and the ultimate mechanical failure. It is estimated that metal fatigue is responsible for more than 80% of mechanical failure due to the existence of flaws such as cracks. Consequently, there is an imperative to pioneer advanced materials technology with the express aim of extending the operational lifetime of metallic components. This endeavour not only serves to increase material resource efficiency but also serves as a bulwark against environmental damage. ... Description: Meeting abstract presented at The 14th Thailand Metallurgy Conference (TMEC14), at the Amari Pattaya Hotel in Chonburi, Thailand, 23 November 2023.

Corrosion behaviour of SiC particulate reinforced AZ31 magnesium matrix composite in 3.5 % NaCl with and without heat treatment

Mon, 13 May 2024 00:00:00 GMT

Title: Corrosion behaviour of SiC particulate reinforced AZ31 magnesium matrix composite in 3.5 % NaCl with and without heat treatment Authors: Ignacio Ahuir-Torres, J; Yang, X; West, G; Kotadia, HR Abstract: Magnesium is a lightweight structural material widely utilised in automotive applications. To enhance its mechanical properties, ceramic particulate reinforcement can be incorporated, particularly for wear resistance and high-temperature applications. However, the addition of ceramic particles to magnesium can compromise its corrosion resistance due to microgalvanic cell formation at the interfaces between the Mg matrix and the second phase. This reduces the chemical protection provided by the passive film. In this study, the corrosion properties of AZ31 and AZ31-5SiC samples were investigated, with a focus on the effect of heat treatment. Detailed microstructural and electrochemical analyses revealed that the AZ31 cast sample forms an effective passive film, resulting in improved corrosion resistance. However, the addition of SiC particles to AZ31 increased the corrosion rate, with corrosion mechanisms evolving over time. To mitigate these effects, a heat treatment process was employed to dissolve β-Mg17Al12 eutectic and Al8Mn5 intermetallic phases. The heat-treated AZ31 with SiC exhibited an improvement in corrosion resistance. These findings highlight the potential for heat treatment to enhance their corrosion resistance, thereby broadening their application prospects. Description: Data availability: Data will be made available on request.