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J O U R N A L O F M A T E R I A L S S C I E N C E 13 ( 1 9 7 8 ) 1 6 4 7 - 1 6 5 7

Microstructural characterization of cast


nickel aluminium bronze
E. A. C U L P A N , G. ROSE
Admiralty Underwater Weapons Establishment, Portland, Dorset, UK

The morphology and chemical analysis of the complex phases present in cast nickel
aluminium bronze, of nominal composition 10% aluminium, 5% nickel and 5% iron,
have been investigated using optical and electron microscopy techniques and energy
dispersive analysis. It has been shown that ~,/~ and four forms of ~ can exist in the as-
cast microstructure of this alloy. Heat treatment can lead to the precipitation of a further
phase which differs in morphology and chemical composition to those present in as-
cast structu res.

1. Introduction
Nickel aluminium bronze cast alloy to BS 1400 nickel and iron combine with aluminium to form a
AB2 is being used increasingly where high strength, complex phase, designated K, which effectively
high impact properties and good corrosion resist- increases the amount of aluminium which may be
ance are required. This alloy, of nominal compo- present in an alloy before the 3`2 phase is encoun-
sition 9.5% aluminium, 5% nickel, 5% iron and tered. Approximately 1% manganese is usually
copper remainder has replaced the binary alu- present in these alloys to aid castability, and to
minium bronze in many applications. Under retard the /3 transformation, and is considered
equilibrium conditions binary alloys, containing to be equivalent to 0.15% aluminium on the
up to 9.4% aluminium, form a single phase ~ solid phase diagram.
solution at room temperature, with the strength Because of the complex nature and small
being directly proportional to the aluminium con- volume fraction of many phases present in nickel
tent. Further addition of aluminium normally aluminium bronze, and the non-equilibrium cool-
results in an c~+/3 structure in metal cooled at ing conditions usually encountered, identification
moderate rates, but decomposition of the/3 phase and analysis of the phases and the mechanisms by
will occur during slow cooling or annealing below which they are produced have proved difficult to
565 ~ C to form an e + 72 eutectoid. The presence determine. This paper describes an investigation
of this eutectoid decreases both mechanical using optical microscopy, scanning electron
properties and corrosion performance, therefore microscopy (SEM) and scanning transmission
steps have to be taken to eliminate the 7z phase. electron microscopy (STEM) coupled to an
One possibility is to heat treat the alloy between energy dispersive analysis system to characterize
600 and 800~ followed by a rapid air cool or the phases present in this alloy system, and to
quench which suppresses the /3 transformation, follow the modifications to the structure produced
but unless the cooling rate is sufficiently rapid, by heat treatment. The amount and distribution of
the 72 phase may still be formed. A further the phases in nickel aluminium bronze and their
method is to add alloying elements which retard chemical composition has a significant effect on
the formation of 3'2 while maintaining the high the properties of this material. The influence of
strength properties that characterize aluminium microstructure on fracture behaviour [1] and on
bronze. The principal alloying elements used for corrosion properties [2] are the subject of further
this purpose are iron, nickel and manganese. Both publications.

9 1978 Chapman and Hall Ltd. Printed in Great Britain. 1647


IOOO
5 N I 5Fr
o:oook,: ON OFr ther deposition of a on existing a areas. This
continues until all the /3 has transformed to a
and K, although small areas of retained /3 can be
~ 800 found in most as-cast structures. Finally there is
a precipitation of a fine K-phase within the a
boundaries. This is summarized schematically in
~. 600
Fig. 2.
§ Work by Weill-Couly and Arnaud [7] has ident-
401: 400
II 12
ified various forms of the ~-phase that are evident
9 IO II 12 8 9 IO
WEIGHT PERCENTAGE WEIGHT PERCENTAGE
in cast nickel aluminium bronze, as shown
ALUMINIUM ALUMINIUM in Fig. 3. Using probe microanalysis they obtained
(a) (bl an indication of the chemical composition of some
of the phases. These were identified as follows:
Figure 1 (a) Vertical section of the Cu-A1-Ni Fe system
at 5% Ni, 5% Fe. (b) Binary Cu-AI system. KI a rosette form of composition 6% A1, 8%
Ni, 69% Fe, 13%Cu.
2. Cast alloy mierostructures Kit and ~iii a globular or lamellar form of
The constitution of the copper-aluminium alloys composition 18 to 20%A1, 23 to 34%Ni, 26 to
containing 5% nickel, 5% iron from the work of 43%Fe, 13 to 20%Cu.
Cook, et al. [3], is shown in Fig. 1, together with Kxv a fine precipitate within the a grains,
the binary copper-aluminium diagram for com- thought to be iron-rich.
parison. According to earlier workers [ 4 - 6 ] the More recently Duma [8] investigated the struc-
alloys complete solidification as a single phase ture and analysis of the K phases, and identified
structure. On further cooling the a phase grows at the • phases according to their morphologies. The
the /3 grain boundaries and along crystallographic analyses of the respective phases are shown in
planes to form a Widmanst~itten structure. The Table I, together with the identification adopted
nickel-iron-aluminium K is then precipitated by Weill-Couly and Arnaud. Duma [8] did not
from the /3 as rounded or dendritic "rosettes" isolate the KIII and KIv during analysis and the
rich in iron, whereas at lower temperatures a results quoted include the surrounding c~ matrix.
lamellar form of K is produced together with fur- In fact the analyses for K m + c~ and Kiv + ~ are
not very different from that of the a matrix,
P indicating a low volume fraction of precipitate
within the electron beam.

3. Development of microstructure
Specimens used in this investigation were held at
1000~ for l h and subsequently cooled to
successively lower temperatures at 25 ~ C intervals,
at a rate of 8 ~ -1, to simulate cooling of
25 mm castings, before quenching in cold water.
+ GLOBULAR Under these conditions the phase transformations

1
TABLE I
Phase Compositon (wt %)
Cu A1 Ni Fe
G + LAIdELLAR K Large globular phase (KI) 9 14 6.5 64
Lamellar two-phase 82 9 3 3
eutectoid (~:III 4- ~)
Fine two-phase 83 9 3 4
intermixture (~IV + c0
G + PtNt K
a matrix 87 6.5 7.5 3
Figure 2 Schematic representation of 13phase breakdown.

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Figure 3 Microstrueture of sand
cast nickel aluminium bronze
showing constituent phases (X
750).

occurred as shown in Table II. Although non- phase is seen to take place at the c~//3boundaries -
equilibrium cooling depresses the phase transform- the lamellar phase grows at right angles to this a//3
ation temperatures it is interesting to note that the boundary. It is possible that the lamellar KIII and
room temperature volume fractions of the various globular •II are essentially similar in chemical
phases approach those predicted from the equilib- composition as they are being rejected at the same
rium diagram (Fig. 1). temperature from the same phase. The similarity
Figs. 4 to 6 indicate the phase changes of nickel o f the tQI and tqH phases can be seen from Fig. 5
aluminium bronze at various temperatures. After which illustrates KII and Km growing together. It
quenching from 1000~ the alloy is wholly /3 is probable that the rosette K1 phase can nucleate
phase, however on cooling to 900 ~ C (Fig. 4) areas the KIII around its perimeter, which may explain
of light etching c~ are formed. The grey etching the dark etching band surrounding K1 particles
rosette K phase precipitates randomly in the c~ and shown in as-cast microstructures. This is shown
/3 phases, although traditionally thought to be more clearly in Fig. 6 where the continuity be-
formed only from the/3. The breakdown of the/3 tween the lamellar form of gIiI and the surround-
ing band is evident. At temperatures slightly below
TABLE II the/3 -+ a + Kii + Kni transformation, precipitates
Phase Equilibrium "25 mm casting" of ~iv are noted within the grains (Fig. 7).
transformation transformation transtbrmation An electrolytically etched surface of an as-cast
temperature temperature microstructure (gig. 8) shows clearly the lamellar
(~ C) (~ C) structure of the Kni phase.
#~c~ +r 1010 925 The crystal structures of the phases described
~-~ c~ + KI 900-920 820-830 above are not well characterized, Recent electron
-~ c~ + KII ~ KIII 840-870 775-750 diffraction studies of the c~ phase by the authors
c~-+c~ + KIV - 700-675
have confirmed a fc c structure with a = 3.57 A.
1649
Figure 4 Alloy slowly
cooled from 1000 to
900 ~ C and quenched,
showing nucleation of c~
phase (X 100).

Figure 5 Alloy slowly cooled from 1000 to 800 ~ C and


quenched, showing formation of KII and KIII at the a/fl Figure 7 Alloy slowly cooled from 1000 to 725 ~ C and
interface ( X 480). quenched, showing fine ~IV precipitation within the c~
grains ( • 480).

Figure 6 Rosette KI surrounded by lamellar t~iiI phase


( • 6500). Figure 8 LameUar •III phase ( • 6500).
1650
Figure 9 Alloy heat
treated at 675 ~ C for 6h
(X 600).

This compares favourably with a in Cu-10%A1 usually spheroidal (approximately 1 ~rn in diam-
with a = 3.62 A. The crystal structure o f the high eter) but on occasions closely resembling tiny ~t
temperature 13 phase cannot be confirmed by rosettes, was iron-rich, and was probably connec-
normal electron diffraction techniques, as a com- ted with the Kiv precipitation within the a grains
plex martensitic structure is obtained on quench- found in as-cast materials. The second form
ing from the 13 phase field. The normal high tem- (approximately 1/,tin x 0.1 gin) designated by the
perature/3 phase cannot exist at room temperature authors as Kv was cylindrical or lath-shaped and
and the, so-called, "retained /3" should be de- was rich in nickel and aluminium. The exact
scribed as /3'. The structure of the martensite has analyses of these phases are discussed in a later
been described as distorted h c p [9] and recently section.
as a mixture o f f c c and h c p [10]. Increasing the heat treatment temperature
Recent neutron diffraction [11] studies have resulted in an increase in the size of the lath Kv
confirmed that the rosette KI has a body centred precipitates and the apparent disappearance of the
cubic (b2) type of structure with a lattice para- globular Kiv phase. This trend continued until at
meter of 2.973,. No crystal structure determi- 840~ (Fig. 10), the Kv phase having increased
nations of the lamellar and globular phases in
nickel aluminium bronze have been reported.

4. Heat treatment of nickel aluminium


bronze
Heat treatment of the as-cast nickel aluminium
bronze at temperatures under 840~ did not
produce any changes in the major phases present
except that retained 13' was transformed to ~ + K.
There was however a significant increase in the
amount of fine precipitate present within the
grains, shown in Fig. 9. Closer examination o f
these precipitates has shown that the precipitates
were a mixture of two distinct forms. One type, Figure 10 Alloy heat treated at 840 ~ C for 3 h ( X 3250).

1651
Figure 11 Alloy heat treated
at 675~ for 16h (X 10000).

in size to a large rod-like form (approximately 5. Chemical analysis of constituent phases


10/~m x 2/Jm). A similar trend was noticed when 5.1. Experimental
the alloys were held for longer times at lower 5. 1.1. Bulk specimens
temperatures, although the precipitate sizes were As-cast specimens for phase analysis were held at
significantly smaller ( ~ 1/.tin x 0.5/~m) (Fig. 11). 1000 ~ C (i.e. in the/3 phase field) for 1 h and then
At treatment temperatures above 820 to 850 ~ C cooled at 8 ~ C min-1 to intermediate temperatures
the alloy can enter the ~ + a + K region depending before quenching in cold (20 ~ C) water. The inter-
on its exact composition. Heat treatment in this mediate temperatures were 9 7 5 ~ reducing by
region for sufficient time resulted in spheroid- 25 ~ C intervals to 675 ~ C.
ization of the K phase and the resulting structure Phase analysis was also carried out on heat
is shown in Fig. 12. treated specimens. The heat treatments employed
There are various additional heat treatments were :
that could be carried out on nickel aluminium (a) 675 ~ C - 2 h , 6 h and 16h air-cooled;
bronze, in particular by quenching from elevated (b) 740 ~ C 3 h air-cooled;
temperatures and tempering in an analogous (c) 790 ~ C 3 h air-cooled;
manner to steel heat treatment. However these (d) 840 ~ C 3 h air-cooled;
treatments are rarely applicable to large castings (e) 860 ~ C 72 h air-cooled.
and have not been included in this paper. Both as-cast and heat treated specimens were pre-
pared for analysis by normal metallographic tech-
niques. The specimens were examined on a
Cambridge Scientific Instruments $600 SEM with
a Link Systems Energy Dispersive Analysis attach-
ment. Analyses were carried out with a spot size
of 200 3, and the data computed using the Nazir
technique [ 12].
Two stage carbon replicas were also taken from
etched specimens and the extracted phases ana-
lysed in the STEM mode on a JEOL 100B electron
microscope with an Energy Dispersive attachment.

5. 1.2. Thin foil specimens


3 m m diameter electron transmission thin foil
Figure 12 Alloy heat reated at 860~ C for 72 h ( X 480). specimens in the as-cast condition were prepared
1652
by ion beam machining and examined using a 5.2~2~ Thin foils
JEOL 100B/ASID electron microscope with a The technique employed was essentially that of
Link Systems Energy Dispersive Analysis attach- Cliff and Lorimer [14] whereby quantitative ana-
ment in the STEM mode. A spot size of about lysis was obtained from a thin foil specimen with
200 A in diameter was used for analysis. the X-ray intensities of the two elements measured
The chemical composition of both bulk and simultaneously (at a constant kV and independent
thin foil specimens was as follows: A19.42%; Ni of specimen thickness). Thus
4.70%; Fe 4.24%; Mn 1.09%; copper remainder. C1 kilt
C: k112
5.2. Analysis t e c h n i q u e s
5.2. 1. Bulk specimens where C1 and C~ are the concentrations of two
The quantitative analysis of bulk specimens by elements in alloy (wt %), kt and k2 are intensity
solid state Si(Li) X-ray detectors on scanning correction factors for the two elements, and
electron microscopes has developed rapidly over Ix and /2 are characteristic X-ray intensities for
the last few years. The technique requires com- each element.
parison of the characteristic X-ray peak intensity The correction factors for the elements were
(Ix) in the unknown sample with that of a well- evaluated by analysing standards of known chemi-
defined standard (e.g. pure X). Numerous com- cal composition and the resulting factors are
puter programs are available to evaluate the shown in Table IIl for analysis at 100 kV.
required atomic number (Z), absorption (A) and
secondary fluorescence (F) corrections to the 6. R e s u l t s
data obtained (ZAF). The accumulation of data The average chemical analysis of the six phases
from a multi-component alloy takes a considerable usually found in as-cast nickel aluminium bronze,
time and difficulty has been experienced in using SEM and STEM (both thin foil and replicas)
maintaining instrumental parameters constant are shown in Table IV.
during analysis. This has been found to be a signifi- In most cases between 20 and 30 analyses were
cant source of error. taken of each phase present and the standard
To reduce the analysis time Nazir [12] has deviations of these results are also shown in
deduced analytical expressions and computed Table IV. No standard deviations are quoted when
normalization factors which compensate for the number of analyses taken were less than 10.
atomic number corrections and X-ray transmission It is apparent from the analysis results that the
through the solid state detector. These factors chemical composition of constituent phases in
allow concentrations to be calculated directly nickel aluminium bronze can vary quite appreci-
from the peak intensities of the alloy examined, ably from specimen to specimen and within the
without reference to standards. same specimen. This is particularly pronounced
In the analysis of nickel aluminium bronze the with the various K phases, indicating that they can
predominant correction is the absorption correc- exist over a wide range of chemical composition.
tion with respect to aluminium. To eliminate the The globular KI and Kiv phases have similar com-
necessity for computer correction, empirical ab- positions rich in iron, and are thought to be Fe~ A1
sorption correction factors for aluminium in cop- TABLE Ill Calibration factors (k) for JEOL 100B/
per have been evaluated by analysing a series of STEM at 100 kV
A1-Cu alloys using a ZAF correction program and
Element Factor (k)
comparing the results with the data from the
standardless technique of Nazir. The difference in Mg 2.858
the two sets of results represents, to a first ap- AI t,71i
Si 1,0O0
proximation, the degree of absorption correction
Ca 1.106
for aluminium in copper. The fluorescence correc- Mn 1.118
tion is minimal. This technique has shown itself to Fe 1.196
have an accuracy comparable with the ZAF correc- Ni 1,410
tion computer program with a significant decrease Cu 1.548
Zn 1.655
in analysis time [ 13 ].

1653
o]

T A B L E I V C h e m i c a l a n a l y s i s o f p h a s e s p r e s e n t in cast n i c k e l a l u m i n i u m b r o n z e

Phase SEM/bulk STEM/thin foil STEM/replica

II
A1 Mn Fe Ni Cu AI Mn Fe Ni Cu AI Mn Fe Ni Cu

c~ 8.3+- 1.7 1.4+-0.1 2.7+-2 2.5+- 1.4 85.4-+4 8+- 2 0.8+-0.3 2.4+- 1 3+- 2 86• . . . . .

8.7 1.0 1.6 3.5 85.2 . . . . . . . . . .

KI 13+-5 2+-0.4 55+-7 15+-3 15+-5 . . . . . . . . . .

KII 19 +- 3 2.2 +- 0.6 32 • 3 27 +- 4 21 +- 5 18 +- 4 1.6 +- 0.3 34 _+ 5 2 4 +- 5 23 +- 4 19 +- 5 t . 3 • 0.1 34 +- 5 3 0 +- 3 15 • 5

KIII 18 -+ 6 2 +- 0.3 22 +- 0.7 32 +- 2 26 -+ 4 2 2 +- 4 1.6 +- 0.4 22 • 5 28 +- 5 26 ~ 4 . . . . .

KIV 20+-3 1.5+-0.3 62-+4 4+- 1 13-+ 1 9+-4 1.6+-0.4 60• 6+-4 23-+6 '14+-2 1.1+-0.4 63+-6 14-+4 8+-3
where Fe* is iron plus minor additions of copper, Analyses were also carried out on the boundary
nickel and manganese. The ~:tl and KIII also have layer surrounding the ~:t phase, typically shown
a wide range of compositions, and there appears to in Fig. 7, and the mean analysis of this layer was:
be a significant difference in the nickel:iron ratio A116%; Mn 1.2%; Fe22%; Ni34%; Cu26%. This
of these phases which is consistent for each ana- is consistent with a ~nz analysis indicating a
lysis technique. In the case of KII the percentage deposition of lamellar n on the rosette Kz phase.
of iron generally exceeds that of nickel by ap- The composition of the retained /3 phase in
proximately 5 to 10%, whereas in Km nickel specimens that had been quenched from de-
exceeds iron by a similar amount. It is apparent. creasing temperatures from 975 to 675~ is
therefore fhat there are statistically significant shown in Fig. 13. Only the major elements iron,
differences in the composition of KH and ~HI nickel and atuminium are displayed, as it is clear
despite the fact that these phases are precipitated from the previous work that manganese is distri-
from the matrix at the same temperature. buted evenly throughout the material. It can be

% 4
Fr
3

t I
950 a~o 6S 0

7
% 6
NI
5-

3 I I I ,,, I, I I
950 9oo aso 800 7S0 7OO 6S

9' X

-
At 78 -
f
6

S i i i 1.. | !
950 900 8S0 800 750 700 65(

TEMPERATURE (~ }

,e 0--..- o " ,8
(+ ISOLATED K I )

Figure 13 Variation of/3 composition with respect to temperature.


] ~ '---'~" O + K.IT § I ~

I
~

1655
seen in Fig. 13 that the composition of the /3 are more likely to develop in this area than else-
accurately reflects the changes caused by the where due to very large surface area to volume
transformation to c~ and K phases. Below 9 0 0 ~ of these particles and their extremely close prox-
the large iron rich tq rosettes are formed with a imity to each other as shown in Fig. 11. Under
corresponding decrease in the iron content of the these conditions diffusion should be enhanced
/3. This results in a slight increase in the aluminium even at moderate heat treatment temperatures.
and nickel content of the/3 until 825 ~ C, where the
KII and KIII (NiA1-FeA1) phases start to form, 7. Conclusions
with a consequent decrease in aluminium, nickel (1) Optical and electron microscopy techniques
and iron in the/3. have been successful in identifying and analysing
A similar survey of the changes in composition the microstructural phases in cast nickel alu-
of c~ from its formation around 9 0 0 ~ down to minium bronze, namely c~,/3 and four tc phases.
room temperature was carried out. Little change in (2) The microstructural changes that occur
c~ composition was noted through the temperature during heat treatment lead to the precipitation of
range with the exception of iron content which a further K phase which differs in morphology and
was approximately 5% at 900 ~ C and was reduced chemical composition to those present in as-cast
to 2.7% at room temperature. This is consistent structures.
with formation of an iron-rich precipitate within
the c~ phase on cooling. Acknowledgements
The analyses carried out on the fine precipitates The authors wish to thank Mrs A. E. Morris,
within the c~ grains following various heat treat- Mr K. Stokes and Mr D. Moth for their assistance
ments are shown in Table V. These results confirm during this investigation. Any views expressed
the microscopical evidence that the high iron ~r are those of the authors and do not necessarily
phase is not apparent following heat treatments at represent those of the Procurement Executive,
temperatures greater than 740 ~ C or at 675 ~ C for Ministry of Defence. This paper is printed with
16h. The lath-like toy precipitate, found in in- the kind permission of the Controller, HMSO,
creasing volume as the heat treatment temperature holder of Crown Copyright.
is raised, contains a substantial amount of alu-
minium, nickel and iron. It is interesting that the References
proportion of iron found in the phase increases as 1. E. A. CULPAN and J. T. BARNBY, J. Mater. Sci.
the temperature of heat treatment is raised, indi- 13 (1978) 323.
cating that the iron-rich t q v phase is taken up by 2. E.A. CULPAN and G. ROSE (to be published).
the Kv phase. This high temperature tCv has a 3. M. COOK, W. P. FENTIMAN and E. DAVIES, J.
Inst. Met. 80 (1951) 419.
composition similar to that of the annealed K
4. W. L. J. CROFTS, D. W. TOWNSEND and A. P.
produced after heat treatment at 860 ~ C for 72 h. BATES, British Foundryman 57 (1964) 89.
Thus it is possible that an equilibrium tc phase is 5. P. J. MACKEN and A. A. SMITH, "The Aluminium
produced locally in the c~ grains under the in- Bronzes", Copper Development Association Publi-
fluence of heat treatment. Equilibrium conditions cation No. 31 (1966).

TAB L E V Chemical analysis of the fine precipitates within the K phase of heat treated nickel aluminium bronze
Phase SEM/bulk STEM/replica
AI Mn Fe Ni Cu A1 Mn Fe Ni Cu
KIV globular phase (675~ C for 2 h) 13+3 1-+0.2 62-+6 16-+3 8-+3
Kv lath phase (675~ C for 2h) 23-+ 2 1-+0.3 25-+ 3 39-+ 2 11-+ 1
KIv globular phase (675~ C for 6 h) 14-+2 1-+0.5 63-+6 14+5 8+_5
KV lath phase (675~ C for 6 h) 27-+4 1.5-+0.3 27-+4 35-+ 3 10+_2
KV lath phase (675~ C for 16 h) 20-+3 1.3-+0.3 34-+3 35+-2 10-+1
•V lath phase 740~ C 26 1.1 26 21 26 21-+2 1.8-+0.5 33-+3 35-+2 9-+2
Kv lath phase 790~ C 23 1.2 33 21 22 18 -+2 1.6 -+ 0.3 40 -+ 2 30 -+ 1 10 +- 1
KV large lath phase 840~ 25 1.1 34 21 19 17 -+ 3 1.7 -+ 0.1 39 +-5 32 -+ 3 10 +- 1
Spheroidized Kphase (840~ for 3 days) 19 1.6 35 24 21 17-+2 1.6-+0.2 40-+3 31+_3 l.G-+l

1656
6. J.N. BRADLEY, unpublished work (1967). 12. M. NAZIR, J. Microscopy 108 (1976) 79.
7. P. WEILL-COULY and D. ARNAUD, Fonderie 28 13. G. ROSE and D. A. MOTH, private communication
(1973) 123. (1977).
8. J.A. DUMA, NavaIEng. J. 87 (1975) 45. 14. G. CLIFF and G. W. LORIMER, Proceedings of the
9. W. B. PEARSON, "Handbook of Lattice Spacings Fifth European Congress on Electron Microscopy,
and Structures of Metals and Alloys" (Pergamon, Manchester (Institute of Physics, London, 1972).
Oxford, 1964) p. 331.
10. J. J. REGIDOR, M. A. CRISTINA and J. M.
SISTIAGA, Rev. Metal. Cenirn 10 (1974) 165.
11. J.G. BOOTH, private communication (1977). Received 30 August and accepted 14 November 1977.

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