1. ISCAME 10-11. october 2013. Hungary Manufacturing of Metallic Emulsions István BUDAI Ph.D. University of Derbecen Hungary

2. 2 Motivation and theoretical basic Research goal: opening a principally new route to produce thick wall monotectic alloys EMULSION: is a mixture of two or more liquids which are normally immiscible (un-blendable). Emulsions are part of a more general class of two-phase systems of matter called colloids. Although the terms colloid and emulsion are sometimes used interchangeably, emulsion is used when both the dispersed and the continuous phase are liquid. In an emulsion, one liquid (the dispersed phase) is dispersed in the other (the continuous phase) immisciblemattercolloidsliquidphasedispersed MONOTECTIC alloy: An isothermal reversible reaction in a binary system, in which a liquid, on cooling, decomposes into a second liquid of a different composition and a solid. István BUDAI:Manufacturing of Metallic Emulsions István BUDAI: Manufacturing of Metallic Emulsions

3. powder metallurgy (high pressure, grinding cost) strip casting (high cooling and crystallization rate) plannar flow casting (high cooling rate) microgravity (high cost) laser technology (high cost) emulsificaton technology Production of monotectic alloys István BUDAI:Manufacturing of Metallic Emulsions István BUDAI: Manufacturing of Metallic Emulsions

4. polymer Instabil droplet tensid Solid particle Stabilized droplet Stabilized droplet Emulsification 4 Pickering emulsions István BUDAI:Manufacturing of Metallic Emulsions István BUDAI: Manufacturing of Metallic Emulsions

5. 5 Pickering emulsion water particle water oil István BUDAI:Manufacturing of Metallic Emulsions István BUDAI: Manufacturing of Metallic Emulsions

6. 6 Method István BUDAI:Manufacturing of Metallic Emulsions István BUDAI: Manufacturing of Metallic Emulsions

7. 7 Experimental setup baffles István BUDAI:Manufacturing of Metallic Emulsions István BUDAI: Manufacturing of Metallic Emulsions

8. 8 Experimental method The weighed specimens of one of the Al-matrix composites and the second phase (Bi, or Cd or Pb) were placed into the crucible. The crucible was kept open, but the constant flow of argon gas with the flow rate of 1 l/min was blown on the surface of the metal to prevent severe oxidation. The crucible was heated with the heating rate of 350 °C/h until the final temperature of 700 °C. The system was kept at this temperature during 1 hour. Then, the mixer was introduced and the system was first mixed with the rotational speed of 50 rotation/min during 20 minutes. After that, the emulsification took place with the rotational speed of 1000 rotation/min during 5 minutes. After this, the mixer was switched off and taken out of the crucible. The crucible was taken out of the furnace and was spontaneously cooled in air.

9. 9 A356 + 25,2 v/v % Bi (without particles) MMC1 (Al-Si(7) + 20 v/v % SiC p ) + 24,7 v/v % Bi MMC1 (Al-Si(7) + 30 v/v % SiC p ) + 47 v/v % Bi MMC1 (Al-Si(7)+ 20 v/v % SiC p ) + 24, 60, 70 v/v % Cd MMC1 (Al-Si(7) + 20 v/v % SiC p ) + 25 and 67 v/v % Pb MMC2 (Al + 5,2 v/v % Al 2 O 3p ) + 6,8 v/v % Bi MMC2 (Al + 5,2 v/v % Al 2 O 3p ) + 7,4 v/v % Cd MMC3 (Al + Sr(10) + Ti(1) + B(0,2)) +6,5 v/v %Bi MMC3 (Al + Sr(10) + Ti(1)+ B(0,2)) + 7,2 v/v % Cd MMC3 (Al + Sr(10) + Ti(1)+ B(0,2)) + 7,2 and 14,6 v/v % Pb Materials

10. 10 Microstructure 1. MMC1 (Al-Si(7) + 20 v/v % SiC) + 24,7 v/v % Bi

11. 11 Microstructure 2. - phase inversion- MMC1 (Al-Si(7) + 30 v/v % SiC) + 47 v/v % Bi

12. 12 Microstructure 3. MMC3 (Al + Sr(10) + Ti(1)+ B(0,2)) + 7,2 v/v % Cd

13. 13 Limit of this technology to long mixing time: 25 min. limited experimental rotate max: 1600 1/min coalesce, sedimentation Bottom of experimental product

14. 14 New mixer - disperser mixing time: 30 sec. experimental rotate: 10000 1/min István BUDAI:Manufacturing of Metallic Emulsions István BUDAI: Manufacturing of Metallic Emulsions

15. 15 Microstructure MMC3 (Al + Sr(10) + Ti(1)+ B(0,2)) + 7,2 v/v % Cd Bottom of experimental product István BUDAI:Manufacturing of Metallic Emulsions István BUDAI: Manufacturing of Metallic Emulsions

16. 16 Summary / conclusion / future Particle-stabilized liquid metallic emulsions can be produced under the same conditions (contact angle and liquid-phase ratio), as commonly known for particle-stabilized oil/water emulsions. Upon solidification, these emulsions become particle-stabilized monotectic alloys with homogeneously distributed second phase at least in a part of the ingot. Thus, stabilizing particles can open a principally new production route of monotectic alloys In colloid chemistry, it is known that when reducing the size of the stabilizing particles, the size of the emulsion droplets can be reduced. To produce Al-matrix composite with submicron particles To investigate the mechnical properties István BUDAI:Manufacturing of Metallic Emulsions István BUDAI: Manufacturing of Metallic Emulsions

17. 17 Relevant papers United States Patent US 2011/0185855 A1, Aug. 4. 2011: Method to produce monotectic disperesed metallic alloys (György Kaptay, István Budai) I. Budai, O. Z. Nagy, G. Kaptay: Inversion of a liquid Bi/Al metallic emulsion stabilized by solid SiC particles, Coll Surf A, 2011, vol.377, pp. 325–329 (2010 IF = 1.988) I. Budai, G. Kaptay: Monotectic Al/Cd alloys with homogeneously dispersed Cd-droplets stabilized by strontium aluminide precipitates, INTERMETALLICS, 2011, vol.19, pp. 423-425 (2010 IF = 2.231) I. Budai, G. Kaptay: Wettability of SiC and alumina particles by liquid Bi under liquid Al, J Mater Sci, 2010 vol. 45, pp. 2090–2098 (2009 IF = 1.471) I. Budai, G. Kaptay: A new class of engineering materials: particles stabilized metallic emulsions and monotectic alloys, Metall. Mater Trans A, 2009 vol.40A, pp.1524-1528. (IF = 1.564)

18. 18 Thank You for your attention! "This research was realized in the frames of TÁMOP 4.2.4. A/2-11-1-2012-0001 "National Excellence Program - Elaborating and operating an inland student and researcher personal support system convergence program" The project was subsidized by the European Union and co-financed by the European Social Fund „