Dual Grain Refinement Effect for Pure Aluminum with the Addition of Micrometer-Sized TiB2 Particles

The inefficiency of grain refinement processes has traditionally been attributed to the limited utilization of heterogeneous nucleation particles within master alloy systems, resulting in the formation of abundant inactive particles. This study aims to investigate the alternative influences of particles by incorporating external micrometer-sized TiB2 particles into the grain refinement process. Through a series of experiments, the refinement efficiency, grain refinement mechanism, and resultant microstructure of TiB2 particle-induced grain refinement specimens are comprehensively examined using various microscopy and analytical techniques, including polarization microscopy (OM), scanning electron microscopy (SEM), differential scanning calorimetry (DSC), and transmission electron microscopy (TEM). Our findings demonstrate a direct correlation between increased levels of TiB2 particles and enhanced grain refinement efficiency. Moreover, the microstructure analysis reveals the distribution of TiB2 particles along grain boundaries, forming a coating due to self-assembly phenomena, while regions with a lower particle content may exhibit irregular grain structures. DSC analysis further confirms reduced undercooling, indicating the occurrence of heterogeneous nucleation events. However, TEM observations suggest that heterogeneous nucleation is not significantly influenced by the growth restriction factor attributed to TiAl3 2DC compounds. The grain refinement mechanism involving TiB2 particles is elucidated to entail both heterogeneous nucleation and physical growth restriction effects. Specifically, a reduction in average grain size is attributed not only to heterogeneous nucleation but also to the physical growth restriction effect facilitated by the TiB2 particle coating. This study offers insights into leveraging particles that do not participate in heterogeneous nucleation within master alloy-based grain refinement systems.