Rapid Solidification Techniques for Metal Processing: Microstructure and Properties

Abstract

In recent years, rapid solidification techniques have garnered considerable attention due to their capacity to yield metals with unique microstructures and properties unattainable through conventional processing methods. These techniques involve swiftly cooling the metal, resulting in a fine-grained microstructure, unlike the coarse-grained microstructures typically obtained through traditional methods. This paper offers an overview of several rapid solidification techniques, such as melt spinning, spray forming, and gas atomization. These methods entail rapidly cooling molten metal by either quenching it onto a swiftly rotating wheel or spraying it onto a substrate. The cooling rates achieved, typically ranging from 104 to 107 K/s, far exceed those of conventional casting methods. The distinctive microstructure resulting from rapid solidification techniques presents numerous advantages over conventional methods. These include enhanced homogeneity, increased strength, improved ductility, heightened thermal stability, and augmented corrosion resistance. Consequently, rapid solidification techniques hold significant promise for applications across aerospace, automotive, and medical industries. This review also underscores recent advancements in rapid solidification techniques and their potential applications. These encompass the production of high-strength, wear-resistant materials for cutting tools, the development of lightweight alloys for aerospace applications, and the manufacture of biocompatible alloys for medical implants. In summation, this review offers a comprehensive examination of the latest progress in rapid solidification techniques for metal processing and their diverse applications across various industries.