Fabrication of aluminum alloy functionally graded material using directional solidification under an axial static magnetic field

Aluminum alloy in situ functionally graded materials (FGMs) have been successfully fabricated using directional solidification under an axial static magnetic field. Al-Zn, Al-Ni and Al-Cu alloys with a hypereutectic composition were selected to produce FGMs. Experimental results show that the graded composition of the primary phases (i.e., Zn, Al3Ni and Al2Cu) is obvious along the longitudinal section of the sample. The graded composition of the primary phases could be controlled by the value of the magnetic field, growth rate and temperature gradient. A proposed model and simulations are carried out to explain the origin of the graded composition of the primary phases in FGMs during directional solidification under an axial static magnetic field. It should be attributed to the combined actions of heavier species migration under gravity force and thermoelectric (TE) magnetic convection under magnetic field. Furthermore, it can be found that the magnetic field can induce the columnar FGMs to change into equiaxed FGMs. This work not only presents a new approach to fabricate FGMs using the directional solidification under an axial static magnetic field but also deeply understands the effect of the solute migration and temperature distribution on the crystal growth during directional solidification.