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Dr E Galindo-Nava and T E J Edwards

The high performance of modern alloys stems from the sophisticated microstructures tailored during component manufacturing. Understanding the process-property relationships via the microstructure is critically important to develop materials with improved properties. New alloys require the use of tailored manufacturing routes involving as much effort as the material design process itself. In addition, with the advent of Additive Layer Manufacturing (ALM) techniques, the prospects of producing near net-shape components can potentially offer dramatic improvements in alloys’ performance. However, there are many technical challenges that need to be addressed before reaching successful implementation.

This course will cover the Materials aspects of Advanced Metals Processing with emphasis in the microstructure. We will use case studies to highlight how existing and emerging manufacturing technologies affect the microstructure in different metallic systems.

The first part of the course will present relevant aspects of existing and emerging manufacturing technologies in engineering alloys (4 lectures, Dr. Enrique Galindo-Nava).

Existing manufacturing technologies

  • Review of the process-microstructure-property paradigms in modern systems
  • Overview of the general process route for metals manufacturing: Casting/Powder Processing, Forming, Thermal treatments, and Finishing
  • Introduction of relevant equations for microstructure evolution
  • Case studies

Additive Layer Manufacturing

  • Background of ALM techniques in metals processing
  • Introduction of physical processes involved in ALM of metals. Discuss similarities and differences with existing manufacturing methods
  • Definition of relevant equations to understand process-microstructure links
  • Overview of existing Materials-related challenges in ALM
  • Case studies

The second part of this course covers novel processing methods for emerging high temperature alloy classes, otherwise unsuited to conventional processing (3 Lectures, Tom Edwards). The focus is on lightweight aluminides and extreme high temperature-capable refractory metal intermetallics.

  • Work-free processing of intermetallics. Background to structural intermetallics. Case study: γ-TiAl alloys. Solidification and heat treatment strategies to optimise microstructure & mechanical properties without working. Aside: successes in ALD of γ-TiAl alloys.
  • Wrought processing of intermetallics. Reasons for wrought processing intermetallics. γ-TiAl: strategies to increase ductility to enable wrought processing. Isothermal wrought processing. Secondary forming. Downsides to wrought processed intermetallic alloys. Alternative solid state processing techniques for intermetallics: mechanical alloying and self-propagating high-temperature synthesis.
  • Processing of refractory metal intermetallics. Definition and uses of refractory metal alloys, limitations. Case study: Nb silicides. Solidification strategies, e.g. spark plasma sintering (SPS). Deformation processing of refractory metal alloys.