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Materials Science, Metallurgy; resistance projection welding; nugget size; maximum failure load; welding parameter
Online: 22 October 2018 (13:32:18 CEST)
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The aim of this paper is to at first evaluate the influence of three key parameters including weld current, weld time and electrode force on nugget diameter and tensile strength in resistance projection welding. Then, a 2-D axis-symmetric finite element model is developed to simulate the projection welding and predict the nugget diameter. Finally, the FEM results are compared to experimental data to verify the simulation model and simulated results. In the finite element model, the temperature-dependent material properties were taken into account.
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Materials Science, Metallurgy; TRIP steel sheet; cross-die test; forming limit diagram; finite element analysis; failure mechanisms
Online: 16 October 2018 (13:12:42 CEST)
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The formability and failure behavior of TRIP steel blanks were investigated through various stress states. The forming limit diagram (FLD) at fracture is constructed both experimentally and numerically. Numerical studies are performed to evaluate the applicability of different damage criteria in predicting the FLD as well as complex cross-die deep drawing process. The fracture surface and numerical results revealed that the material failed in a different mode for different strain path. Therefore, Tresca model which is based on shear stress accurately predicted the conditions where shear had the profound effect on the damage initiation, whereas Situ localized necking criterion was able to calculate the conditions which localization was dominant.
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Materials Science, Metallurgy; ironmaking; direct reduction; iron ore; DRI; shaft furnace; mathematical model; heterogeneous kinetics; heat and mass transfer
Online: 9 October 2018 (13:46:23 CEST)
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This paper addresses the modeling of the iron ore direct reduction process, a process likely to reduce CO2 emissions from the steel industry. The shaft furnace is divided into three sections (reduction, transition, and cooling), and the model is two-dimensional (cylindrical geometry for the upper sections and conical geometry for the lower one), to correctly describe the lateral gas feed and cooling gas outlet. This model relies on a detailed description of the main physical–chemical and thermal phenomena, using a multi-scale approach. The moving bed is assumed to be comprised of pellets of grains and crystallites. We also take into account eight heterogeneous and two homogeneous chemical reactions. The local mass, energy, and momentum balances are numerically solved, using the finite volume method. This model was successfully validated by simulating the shaft furnaces of two direct reduction plants of different capacities. The calculated results reveal the detailed interior behavior of the shaft furnace operation. Eight different zones can be distinguished, according to their predominant thermal and reaction characteristics. An important finding is the presence of a central zone of lesser temperature and conversion.
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Materials Science, Metallurgy; Additive manufacturing; Microstructure; Hardness; Mechanical properties; Aluminum alloys; Steels; Nickel alloys; Titanium alloys
Online: 5 October 2018 (12:00:36 CEST)
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The rapidly evolving field of additive manufacturing requires a periodic assessment of the progress made in understanding the properties of metallic components. Although extensive research has been undertaken by many investigators, the data on properties such as hardness from individual publications are often fragmented. When these published data are critically reviewed, several important insights that cannot be obtained from individual papers become apparent. We examine the role of cooling rate, microstructure, alloy composition, and post process heat treatment on the hardness of additively manufactured components. Hardness data for steels and aluminum alloys processed by additive manufacturing and welding are compared to understand the relative roles of manufacturing processes. Furthermore, the findings are useful to determine if a target hardness is easily attainable either by adjusting AM process variables or through appropriate alloy selection.
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Materials Science, Metallurgy; Powder compaction; Discrete element method (DEM); Cohesive contact models; LIGGGHTS; EDEM
Online: 4 October 2018 (17:02:44 CEST)
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The purpose of this work was analysing the compaction of a cohesive material using different DEM simulators to determine the equivalent contact models and identify how some parameters of the simulations affect the compaction results (maximum force and compacts appearance) and computational costs. For that purpose, three cohesion contact models were tested (‘linear cohesion’ in EDEM; ‘SJKR’ and ‘SJKR2’ in LIGGGHTS). The influence of the particle size distribution (PSD) on the results was also investigated. Further assessments were performed on the effect of selecting different timesteps, using distinct conversion tolerances for exporting the 3D models to STL files and moving the punch with different speeds. Consequently, it was possible to determine that a timestep equal to a 10% Rayleigh timestep, a conversion tolerance of 0.01 mm and a punch speed of 0.2 m/s are adequate for simulating the compaction process using the contact models in this work. In addition, the results determined that the maximum force was influenced by the PSD because of the rearrangement of the particles. The PSD was also related to the computational cost because of the number of simulated particles and their sizes. Finally, an equivalence was found between the linear cohesion and SJKR2 contact models
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Materials Science, Metallurgy; bauxite residue; scandium; leaching; sulfuric acid
Online: 3 October 2018 (19:10:03 CEST)
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Bauxite residue (BR) is a well promising resource for critical metals and especially scandium (Sc), a rare and expensive metal with increasing applications in advanced technology. Particularly, Greek BR’s composition indicates a sound possibility for a commercially viable recovery of Sc under the conditions of an optimized leaching process and the subsequent use of advanced separation techniques. Leaching with mineral acids emerges as the dominant selection with comparison to other techniques. This study investigates an optimized leaching condition set on Sc recovery, using sulfuric acid as the most suitable among different acids tested, in the context of process economics and environmental constraints. Several variables were studied individually or combined in order to achieve high Sc concentration in the leachate as well as to ensure selectivity, especially in respect to iron. The most significant parameters proved to be the solid to liquid ratio (S/L), the final pH value as well as the use of recycling of leachate on fresh BR batches. The proposed process, using sulfuric acid at low acid molarities under ambient conditions was integrated rapidly leading to high and selective Sc recovery. A flow diagram of the developed leaching process in industrial scale was proposed based on continuous operation.
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Materials Science, Metallurgy; Polycrystal plasticity; X-ray diffraction imaging; Topotomography; in situ experiment; Finite element simulation, lattice curvature, rocking curve
Online: 10 September 2018 (18:12:39 CEST)
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In this paper, we present a comprehensive 4D study of the early stage of plastic deformation in a polycrystalline binary AlLi alloy. The entire microstructure is mapped with X-ray diffraction contrast tomography and a set of bulk grains is further studied via X-ray topotomography during mechanical loading. The observed contrast is analyzed with respect to the slip system activation and the evolution of the orientation spread is measured as a function of applied strain. The experimental observations are augmented by the mechanical response predicted by crystal plasticity finite element simulations to analyze the onset of plasticity in details. Simulation results show a general agreement of the individual slip system activation during loading and that comparison with experiments at the length scale of the grains may be used to fine tune the constitutive model parameters.
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Materials Science, Metallurgy; Leaching of silver; Thiosemicarbazide-oxygen system; No toxic leaching process
Online: 31 August 2018 (10:59:37 CEST)
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The mining wastes generated during the last decades in the mining region of Pachuca-Real del Monte in Mexico, still contains silver values of interest. For this reason, the present work is a preliminary study of the leaching kinetics of silver contained in these residues, using as a leaching reagent the thiosemicarbazide-oxygen system, with the aim of proposing this leaching system as a less toxic alternative than cyaniding process. Previous the leaching process, representative samples were wholly characterized, finding 56 g of Ag and 0.6 g of Au per ton. For the kinetic study in the mentioned system, were evaluated the reagent concentration, temperature, partial pressure of oxygen, pH and stirring rate. According the experimental results found, it was observed that [CH5N3S] concentration showed a significant effect on the leaching rate, obtaining a reaction order of n = 0.93, in the range of 20 - 40 mol CH5N3S ⋅ m-3, getting so a silver recovery up to 76.9%. The effect of temperature gave an activation energy of Ea = 45.55 KJ mol-1, which was indicative of a chemical reaction control. Finally, partial pressure of oxygen has a notable effect on leaching rate, but pH and stirring rate have not apparent effect.
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Materials Science, Metallurgy; ferrite formation; mushy zone temperature, liquidus and solidus temperature, ingot forming, 0Cr17Ni4Cu4Nb stainless steel
Online: 24 August 2018 (07:10:49 CEST)
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Ferrite body is the origin of crack and corrosion initiation of steels. Distribution and density of ferrite in seven steel ingots were examined by light optical microscopy and computational modeling in the study to explore the correlation of ferrite formation to chemical composition and mushy zone temperature in ingot forming. The central segregation phenomenon in ferrite distribution was observed in all the examined steel specimens except 0Cr17Ni4Cu4Nb stainless steel. No significant difference was found in distribution and density of ferrite amongst zones of the surface, ½ radius and core in neither risers nor tails of 0Cr17Ni4Cu4Nb ingots. Additionally, fewer ferrite was found in 0Cr17Ni4Cu4Nb compared to other examined steels. The difference of ferrite formation in 0Cr17Ni4Cu4Nb elicited a debate on the traditional models explicating ferrite formation. Considering the compelling advantages in mechanical strength, plasticity and corrosion resistance, further investigation on the unusual ferrite formation in 0Cr17Ni4Cu4Nb would help understand the mechanism to improve steel quality. In summary, we observed that ferrite formation in steel was correlated with mushy zone temperature. The advantages of 0Crl7Ni4Cu4Nb in corrosion resistance and mechanical stability could be resulted from that fewer ferrites formed and distributed in a scattered manner in microstructure of the steel.
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Materials Science, Metallurgy; Reprocessing of mining wastes; Leaching of silver; Thiosemicarbazide-oxygen system; No toxic leaching process
Online: 16 August 2018 (17:20:17 CEST)
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The mining wastes generated during the last decades in the mining region of Pachuca-Real del Monte in Mexico, still contains silver values of interest. For this reason, the present work is a preliminary study of the leaching kinetics of silver contained in these residues, using as a leaching reagent the thiosemicarbazide-oxygen system, with the aim of proposing this leaching system as a less toxic alternative than cyaniding process. Previous the leaching process, representative samples were wholly characterized, finding 56 g of Ag and 0.6 g of Au per ton. For the kinetic study in the mentioned system, were evaluated the reagent concentration, temperature, partial pressure of oxygen, pH and stirring rate. According the experimental results found, it was observed that [CH5N3S] concentration showed a significant effect on the leaching rate, obtaining a reaction order of n = 0.93, in the range of 20 - 40 mol CH5N3S × m-3, getting so a silver recovery up to 76.9%. The effect of temperature gave an activation energy of Ea = 45.55 KJ mol-1, which was indicative of a chemical reaction control. Finally, partial pressure of oxygen has a notable effect on leaching rate, but pH and stirring rate have not apparent effect.
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Materials Science, Metallurgy; Thread fracture; tool wear; Taylor Equation; Scanning Electron Microscopy
Online: 16 August 2018 (15:59:10 CEST)
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The diameter of a H13 steel tool with M6 threads and a pin diameter of 5.9 mm and a pin length of 5 mm was measured after each 25.4 mm length of friction stir processing (FSP) of 6061-T6 extrusions. The change in pin diameter with FSP time or distance did not exhibit any steady state and was found to have two distinct regions. Metallographic analysis of two tools subjected to FSP for 60 and 120 seconds showed that (i) threads fractured in early stages of FSP, (ii) a built-up layer formed between the threads, and (iii) threads progressively wore with processing time. The metallographic analysis of an embedded tool showed the presence of a fractured piece of the tool in the stir zone. These points are discussed in detail in the paper.
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Materials Science, Metallurgy; weld toe grinding; WIG remelting weld toe; fatigue
Online: 3 August 2018 (22:36:50 CEST)
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There are many welded structures in the world such as bridges and viaducts that are subject to fatigue. These structures, generally made of non-alloy or low-alloy steels, have been put into operation some of them with many years ago and have accumulated a large number of variable load cycles over the time. For this reason the occurrence of fatigue phenomenon is inevitable and consists in the occurrence of failures at stresses applied to the structure, below the yield limit of the material. These stresses under the static loads would not cause the failures to appear..This paper will investigate whether two reconditioning techniques “weld toe grinding” and “WIG remelting weld toe”, influences favorably the behavior of welded structures made from HSLA steel, in static and variable loads and therefore if the application of these techniques is justified in both cases. In the paper will be presented the chemical composition and mechanical properties of the base and filler materials, micro and macrostructures, graphics with the variation of microhardness, static and fatigue tensile tests will be performed, and it will be rised durability curve in case of fatigue tests.
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Materials Science, Metallurgy; oxide metallurgy; impact toughness; metallographic structure; inclusion; ductile-brittle transition temperature
Online: 5 July 2018 (09:47:04 CEST)
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The welding performance of shipbuilding steel under large heat input could be improved greatly by the Mg addition to the steel, but the impact toughness of the HAZ is not stable. According to the three different thickness steel plates obtained in the industrial experiment, the large heat input welding was carried out by different heat input, and the impact toughness analysis, impact fracture analysis, metallographic microstructure analysis and inclusions analysis were carried out. The results showed that, the HAZ of three kinds of thickness plates induced a lot of IAF, with Mg addition, the inclusion dimension had been reduced effectively, and the IAF induced ability of the inclusions had also been improved. The difference of HAZ impact toughness with different welding heat input and different impact temperature is significant, in consideration of the influence of welding heat input and metallographic microstructure on impact toughness of HAZ, the welding heat load had far greater effect than metallographic microstructure on ductile-brittle transition temperature. At the same time, if the original metallographic microstructure of steel was coarse, the pinning effect of the inclusions would be reduced significantly, and the microstructure of HAZ would be coarsened and the impact toughness of HAZ would be decreased, so there is a certain matching relationship between the metallographic microstructure and the inclusion dimension.
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Materials Science, Metallurgy; corrosion resistance index; anodic dissolution; crystallographic texture; pipeline steels; material selection
Online: 29 June 2018 (14:30:28 CEST)
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The present work shows a novel physical-mathematical model to estimate the average corrosion resistance index from the crystallographic texture in API 5L steels. The crystallographic texture of the studied steels was measured by means of the X-ray diffraction technique. The model, based on the symmetric spherical surface harmonics for a BCC structure, is capable of describing the anisotropy surface of anodic dissolution resistance of the crystal and establishing a straightforward relationship between crystallographic texture, surface roughness, and metal corrosion behavior. The predictions of the average corrosion resistance index made from the crystallographic texture were in good agreement with those obtained from potentiodynamic polarization curves for the investigated steels. This agreement validates the capacity of this model and opens the possibility of applying it as a novel criterion for the material selection and design stages in order to combat metal corrosion problems.
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Materials Science, Metallurgy; operational aircraft; skin corrosion; fatigue crack growth; stress corrosion cracking; buckling
Online: 12 June 2018 (10:36:13 CEST)
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This paper studies the combined effect of corrosion and fatigue on the growth of cracks in aircraft and on the effect of skin corrosion and stress corrosion cracking on the load bearing capacity of rib stiffened aircraft wings. In this context it is shown that the growth of cracks from surface pitting, and also from intergranular cracking at a fastener hole, can be accurately computed using the Hartman-Schijve variant of the NASGRO crack growth equation. The examples studied support the lead crack approach, that has been independently developed by the USAF and the Australian Defence Science Technology Group, in which the growth of lead cracks is often exponential. In the case of skin corrosion it is shown that to be consistent with the US Joint Service Structural Guidelines (JSSG2006) assessment of its effect on the load bearing capacity of the wing should involve an assessment of whether at 115% DLL the remaining material exceeds the yield stress of the material.
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Materials Science, Metallurgy; titanium matrix composites; microstructure; mechanical properties; forging
Online: 6 June 2018 (07:54:56 CEST)
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In this study, a 5vol. % (TiBw+TiCp)/Ti composite pancake with a diameter of 260mm was prepared by casting followed by open die forging in (α+β) phase region. The microstructures of the composite pancake are inhomogeneous, in terms of both matrix microstructure and distribution of reinforcements. The matrix microstructures were gradually refined from the periphery to centre of the pancake. The TiBw and TiCp reinforcements tend to be uniformly distributed in the centre region and. It is suggested that the microstructure difference can be mainly ascribed to the temperature variation from the periphery to the centre. Additionally, tensile testing results showed that the centre region of the composite pancake exhibits higher strength than the peripheral region. The strengthening mechanism and the softening behavior of the composite pancake with temperature is discussed.
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Materials Science, Metallurgy; SA213-T23; cr-mo steel; CGHAZ; PWHT cracking; intergranular ferrite; Tint etching
Online: 28 May 2018 (17:44:20 CEST)
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The post-weld heat treatment (PWHT) cracking susceptibility of a coarse grain heat-affected zone (CGHAZ) in SA213-T23 (2.25Cr-1.6W steel), used for boiler tubes employed in thermal power plants, was investigated using a Gleeble thermal cycle simulator. The PWHT cracking susceptibility test was performed at 650℃, 700℃ and 750℃, and it can be judged that the lower the reduce of area, the more susceptible it is to PWHT cracking. The results of the test also showed higher cracking susceptibility at 650℃ and 700℃, mostly involving intergranular fracture, while at 750℃, transgranular fracture was exhibited. Therefore, the PWHT cracking susceptibility is considered to be closely related to grain boundary. The microstructure of the simulated CGHAZ and PWHT at 650℃, 700℃and 750℃ was observed after etching with nital and alkaline sodium picrate etchants. Alkaline sodium picrate etched microstructures showed a white band at the grain boundary at 650℃, 700℃ and 750, that did not appear in nital etching. Analysis of the white band using EPMA, TEM and nanoindentation revealed that it was intergranular ferrite depleted with C, W and Cr as compared to that in the matrix. Based on these results, we investigated the mechanism of intergranular ferrite formation during PWHT and its effect on PWHT cracking susceptibility at 650℃, 700℃ and 750℃.
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Materials Science, Metallurgy; titanium; strain hardening; anisotropy; strain heterogeneity; acoustic emission; statistical analysis; collective dislocation dynamics
Online: 25 May 2018 (17:41:14 CEST)
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Current progress in the prediction of mechanical behavior of solids requires understanding of spatiotemporal complexity of plastic flow caused by self-organization of crystal defects. It may be particularly important in hexagonal materials because of their strong anisotropy and combination of different mechanisms of plasticity, such as dislocation glide and twinning. These materials often display complex behavior even on the macroscopic scale of deformation curves, e.g., a peculiar three-stage elastoplastic transition, the origin of which is a matter of debates. The present work is devoted to a multiscale study of plastic flow in α-Ti, based on simultaneous recording of deformation curves, 1D local strain field, and acoustic emission (AE). It is found that the average AE activity also reveals three-stage behavior, but in a qualitatively different way depending on the crystallographic orientation of the sample axis. On the finer scale, the statistical analysis of AE events and local strain rates testifies to an avalanche-like character of dislocation processes, reflected in power-law probability distribution functions. The results are discussed from the viewpoint of collective dislocation dynamics and are confronted to predictions of a recent micromechanical model of Ti strain hardening.
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Materials Science, Metallurgy; Additive manufacturing; Maraging steel; Microstructure; Martensite structure; Orientation relationship; electron backscattering diffraction (EBSD)
Online: 25 May 2018 (17:26:43 CEST)
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This study characterizes the microstructure and its associated crystallographic features of bulk maraging steels fabricated by selective laser melting (SLM) combined with a powder bed technique. The fabricated sample exhibited characteristic melt pools in which the regions had locally melted and rapidly solidified. A major part of these melt pools corresponded with the ferrite (alpha) matrix, which exhibited a lath martensite structure with a high density of dislocations. A number of fine retained austenite (gamma) with a <001> orientation along the build direction was often localized around the melt pool boundaries. The orientation relationship of these fine gamma grains with respect to the adjacent alpha grains in the martensite structure was (111) gamma // (011) alpha and [-101] gamma // [-1-11] apha (Kurdjumov–Sachs orientation relationship). Using the obtained results, we inferred the microstructure development of maraging steels during the SLM process. The results depict that new and diverse high-strength materials can be used to develop industrial molds and dies.
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Materials Science, Metallurgy; laser beam, T-joints, weldability, TMCP steel
Online: 22 May 2018 (07:47:25 CEST)
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The article presents tests aimed to verify the possibility of making T-joints in TMCP steel using laser. The tests involved the use of 10 mm thick high yield point steel S700MC obtained in an industrial manufacturing process. The joints made in the tests were single and double-sided. Subsequent non-destructive tests revealed that the joints obtained in the tests represented quality level B in accordance with PN-EN ISO 13919-1. Single-sided welding performed using the laser beam having a power of 11 kW enabled the obtainment of 8 mm deep penetration without visibly deforming the web of the joint. The double-sided welded joints were characterised by proper geometry and the presence of gas pores in the welds not compromising the requirements of quality level B (strict requirements). The weld structure was bainitic-ferritic. The weld hardness was by approximately 60 HV1 higher than that of the base material (280 HV1). The HAZ area was slightly softer than the base material. The tests of thin foils performed using a high-resolution scanning transmission electron microscope revealed that, during welding, an increase in the content of the base material in the weld was accompanied by an increase in contents of alloying microagents Ti and Nb, particularly near the fusion line. The above-named alloying microagents, in the form of fine-dispersive (Ti,Nb)(C,N) type precipitates, could reduce plastic properties of joints.
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Materials Science, Metallurgy; ferrite; carbide; bainite; continuous cooling transformation (CCT) curve; charpy impact test
Online: 14 May 2018 (12:29:18 CEST)
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2.25Cr-1Mo steel with high strength at high temperatures and good hydrogen resistance is widely used for power generation boiler material in high temperature and pressure use environments. Following the test evaluation of the ASME Boiler and Pressure Vessel Code, specimens from the base metal of a boiler pipe were found to have impact toughness values of 285 and 21 ft-lb, which are drastically different values. The analysis of the fracture surface of the 21 ft-lb test specimen revealed MnS inclusions, and it was found that cracks initiated at the inclusions. Observation of the cross-section of the crack propagation front revealed that cracks propagated along the ferrite regions and precipitate voids. Inclusions were also found in the 285 ft-lb impact specimen; however, the volume fraction of the inclusions was significantly less than that of the 21 ft-lb specimen. It was also found that the ferrite and carbide content of the 285 ft-lb specimen was less than 21 ft-lb specimen. The reason that the inclusions, ferrite, and carbide content differed in the two adjacent impact test specimens was analyzed. The effects of micro-segregation, such as MnS inclusions on ferrite and carbide, were compared and analyzed.
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Materials Science, Metallurgy; pitting; sigma phase; 2205; duplex stainless steel
Online: 16 April 2018 (11:32:02 CEST)
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The precipitate phases often play an important influence on the corrosion resistance of 2205 Duplex stainless steel (DSS). In the presented paper, the microstructure and corrosion resistance in the hot-rolled and cold-rolled 2205 DSS aging for different time at 850 °C was investigated by XRD, SEM and potentiodynamic polarization. It has been found that the Chi(χ) phase and Sigm(σ) phase were precipitated in turn after aging treatment of hot-rolled and cold-rolled materials, but the precipitate amount in cold-rolled material is much more than that of hot-rolled samples. The corrosion resistance of the solution-annealed cold-rolled material is similar to the hot-rolled material, but the corrosion resistance of cold-rolled material with precipitate is weaker than that of hot-rolled material after aging treatment. Pitting initiates preferentially in the Cr-depleted region from σ phase in aged hot-rolled 2205, and severe selective corrosion occurs on sigma/ferrite interfaces aged for a long aged lime. However, the initiation of pitting corrosion may take place at the phase boundary, defect and martensite in the aged cold-rolled 2205. The σ phase is further selectively dissolved by electrochemical method to investigate the difference of microstructure and corrosion behavior in hot-rolled and cold-rolled 2205 duplex stainless steel.
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Materials Science, Metallurgy; superalloy; double vacuum smelting; cogging; inclusion.
Online: 28 March 2018 (11:38:29 CEST)
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Cogging is a key part in the production process of superalloy, but inclusions affect the performance of superalloy. It is therefore particularly important to study the effects of cogging on the inclusions in superalloy. In our study, the superalloy GH4738 was made by double vacuum smelting. Cogging was performed by unidirectional drawing, upsetting and drawing, and upsetting/drawing with radial forging. The types and distributions of the inclusions after the three cogging processes were analyzed using scanning electron microscopy, energy dispersive spectroscopy, and software such as Image Pro Plus. The results showed that double vacuum smelting essentially determined the types of the inclusions in the GH4738 superalloy. Four types of inclusions were found in the experiments: TiC-TiN-Mo-S composite, TiC-TiN composite, Ce-Mo-S composite, and SiC inclusions. In the case of cogging by unidirectional drawing, the average size of the inclusions first decreased and then increased, from the center to the edge. In the case of upsetting and drawing, and upsetting/drawing with radial forging, the average size of inclusions decreased from the center to the edge.
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Materials Science, Metallurgy; aluminum alloy; electromagnetic forming; friction stir welding; heat treatment; secondary phase
Online: 27 March 2018 (13:11:35 CEST)
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Among all the processing technologies of heat-treatable aluminum alloys like 2219 aluminum alloy, using friction stir welding (FSW) as the joining technology and using electromagnetic forming (EMF) for plastic forming technology both have obvious advantages and successful applications. Therefore, there is a broad prospect for the compound technologies which can be used on the 2219 aluminum alloy to manufacture the large-scale thin-wall parts in the astronautic industry. The microstructure and mechanical properties of 2219 aluminum alloy under the process compounded of FSW, heat treatment, and EMF were investigated by means of tensile test, optical microscope (OM), and scanning electron microscope (SEM). The results show that the reduction of strength, which was caused during the FSW process, can be recovered effectively by the post-welding heat treatment composed of solid solution and aging, while the ductility was still reduced after heat treatment. Under the compound technology of FSW, heat treatment, and EMF, the forming limit of 2219 aluminum alloy decreased distinctly due to the poor ductility of the welding joint. A ribbon-pattern, which was formed due to the banded structure caused by FSW process, was found on the fracture surface of welded 2219 aluminum alloy after EMF treatment. During the EMF process, because of the effects of induced eddy current, a unique structure, which was manifested as a molted-surface appearance under the SEM observation, was formed as the material fractured.
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Materials Science, Metallurgy; sustainable development, recycling, spent catalysts, zinc, copper
Online: 22 February 2018 (16:46:53 CET)
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CuO-ZnO-Al2O3 catalysts are designed for the low-temperature shift conversion in the process of hydrogen and ammonia synthesis gas production. The paper presents the results of research on recovery of copper and zinc from spent catalysts using pyrometallurgical and hydrometallurgical methods. Under reducing conditions, at high temperature, having appropriately selected the composition of the slag, more than 66% of copper in metallic form and about 70% of zinc in the form of ZnO can be extracted from this material. Hydrometallurgical processing of the catalysts was carried out using two leaching solutions: alkaline and acidic. Almost 62% of the zinc contained in the catalysts has been leached to the alkaline solution and about 98% of copper has been leached to the acidic solution. After the hydrometallurgical treatment of the catalysts, insoluble residue was also obtained in the form of pure ZnAl2O4. This compound can be reused to produce catalysts, or it can be processed under reducing conditions at high temperature to recover zinc. The recovery of zinc and copper from such a material is consistent with the policy of sustainable development and helps to reduce the environmental load of stored wastes.
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Materials Science, Metallurgy; metastable Ti alloy; high temperature deformation; stress-induced ω; stress-induced α˝ martensite; transmission electron microscopy; slip; X-ray diffraction.
Online: 22 January 2018 (18:17:03 CET)
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A metastable β-Ti alloy, Ti–10V–3Fe–3Al (wt.%), was subjected to thermos-mechanical processing including the compression test at 725°C, which is below the β transus temperature (780°C), and at strain rate of 10-3s-1. The presence of phases was determined using transmission electron microscopy and X-ray diffraction. Although the dynamic recovery took place together with slip, both deformation-induced α˝ martensite and ω were detected as other operating mechanisms for the first time in metastable-β Ti alloys deformed in α+β region. The volume fraction of stress-induced α˝ was higher than that of the same alloy deformed at room temperature due to higher strain applied. Stress-induced twinning was not operational, which could be related to the priority of slip mechanism at high temperature resulted from thermally-assisted nucleation and lateral migration of kink-pairs.
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Materials Science, Metallurgy; Cu-Cr-Zr alloy; grain refinement; severe plastic deformation; triple junctions; grain refinement kinetics
Online: 1 December 2017 (17:05:29 CET)
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The microstructure evolution and grain refinement kinetics of a solution treated Cu – 0.1Cr – 0.06Zr alloy during equal channel angular pressing (ECAP) at a temperature of 673 K via route BC were investigated. The microstructure change during plastic deformation was accompanied by the microband formation and an increase in the misorienations of strain-induced subboundaries. The refinement of initial coarse grains was considered as a result of continuous dynamic recrystallization. The dynamic recrystallization kinetics was discussed in terms of grain/subgrain boundary triple junction evolution. The strain dependence of the triple junctions of high-angle boundaries can be expressed by a modified Johnson-Mehl-Avrami-Kolmogorov relationship with a strain exponent of about 1.49. Severe plastic deformation by ECAP led to substantial strengthening of the Cu-0.1Cr-0.06Zr alloy. The yield strength increased from 60 MPa in the initial state to 445 MPa after the total strain of 12.
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Materials Science, Metallurgy; palladium; hydrochloric acid; Cyanex 301; LIX 63; synergism
Online: 9 November 2017 (04:50:44 CET)
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Cyanex 301 and LIX 63 can seletively extract Pd(II) over Pt(IV) from strong hydrochloric acid solutions. Therefore, solvent extraction experiments have been performed by extractant mixtures containing either Cyanex 301 or LIX 63 and the extraction behavior of Pd(II) was compared. Among the mixture of Cyanex 301, the highest synergistic enhancement coefficient was achieved by mixing Cyanex 301 and TOPO. However, it was very diffiuclt to strip the Pd(II) from the loaded mixture. Among the mixture of LIX 63, the mixture of LIX 63 and Alamine 336/TOPO enhanced the extraction of Pt(II). Although the synergistic coefficient by Cyanex 301 + TOPO was higher than that by LIX 63 + Alamine 336, the Pd(II) in the loaded mixture of LIX 63 and Alamine 336 was easily stripped by thiourea.
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Materials Science, Metallurgy; corrosion behavior; FG20; electrochemical measurements; EPMA; corrosion mechanism
Online: 1 November 2017 (05:15:39 CET)
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In some sour reservoirs and tertiary oil recovery blocks, SO42- in solution can cause the corrosion and corrosion fatigue of the sucker rods. In this paper, the corrosion behaviors of super-strength sucker rod FG20 (16Mn2SiCrMoVTiA) steel in the well fluid are investigated by electrochemical measurements, and electron probe micro-analyzer (EPMA) analysis. The results show that FG20 steel has a favorable corrosion resistance in neural solutions. When the hydrogen ion content increases, the hydrolysis of SO42- greatly accelerates the corrosion of FG20 steel. The energy dispersive X-ray(EDX)results demonstrate that the corrosion process of FG20 steel in neural well liquid is an oxygen concentration process, and the protective FeCO3 and Fe2O3 on the surface of the samples can prevent further corrosion. With the increase of the acidity in the well liquid, the corrosion process converts into a sulphide concentration process, and the sloppy FeS and mackinawite film cannot provide effective protection for the specimens, resulting in the increase of corrosion rate.
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Materials Science, Metallurgy; Alloy 625; aging sensitization treatment; intergranular corrosion; ASTM G28A methods
Online: 29 September 2017 (06:13:44 CEST)
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This paper investigates the evolution of microstructures and precipitations of an ultra-low iron alloy 625 subjected to long term aging treatment by scanning electron microscope (SEM) and X-ray diffraction(XRD). Use ASTM G28A acid Fe3(SO4)2 erosion to represent intergranular corrosion weightlessness and corrosive morphology. The result shows that alloy at 750C by aging treatment for 40h, precipitated γ'' phase in the grain boundary. In high density area of γ'' phase, occurs γ'' phase to δ phase degeneration transformation by aging treatment for 200h and the needle-like δ phase becomes more with time prolonged. And γ'' phase degenerated to δ phase completely until treated for 1000h. The sample which has aging treatment tends to have intergranular corrosion and mainly because alloy element spreading leads to dilution area and grain boundary precipitated phase, plus interlaced δ phase’s dissolving, which makes sample grain particle fall off and this results in apparent weightlessness. The weightlessness rate(WLR) is related with precipitated volume score. With aging sensitization time change, can be described by Johnson-Mehl-Avrami equation, i.e.:
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Materials Science, Metallurgy; in situ Titanium composites, microstructure analysis, TiB precipitates
Online: 27 September 2017 (18:49:28 CEST)
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This work focuses on the study of the microstructure, hardening and stiffening effect caused by the secondary phases formed in titanium matrices. These secondary phases were originated from reactions between the matrix and boron particles added in the starting mixtures of the composites. Not only was the composite composition studied as an influencing factor in the behaviour of the composites, but also different operational temperatures. Three volume percentages of boron content were tested (0.9, 2.5 and 5 vol % of amorphous boron). The manufacturing process used to produce the composites was inductive hot pressing, which operational temperatures were between 1000 °C to 1300 °C. Specimens showed optimal densification. Moreover, microstructural study revealed the formation of TiB in various shapes and proportions. Mechanical testing confirmed that the secondary phases had a positive influence on the properties of the composites. In general, adding boron particles increased the hardness and stiffness of the composites; however rising temperatures resulted in greater increases in stiffness than in hardness.
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Materials Science, Metallurgy; Mg-Al-Zn-Y magnesium alloy; SIMA; extrusion; semi-solid; microstructure evolution
Online: 15 September 2017 (14:07:30 CEST)
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Semi-solid feedstock of AZ80 magnesium alloy modified by minor rare-earth Y element (0, 0.2, 0.4, 0.8 wt.%) were fabricated by strain induces melting activated (SIMA) in the form of extrusion and partial remelting. The effect of Y addition on the microstructure evolution of extruded and isothermal treated alloy was observed by optical microscope (OM), scanning electron microscope (SEM), X-ray diffraction (XRD) and quantitative analysis. The results show that the Y addition can refine the microstructure and make the β-Mg17Al12 phases agglomerating. During the subsequent isothermal treatment at 570℃, the average solid grain size, shape factor and liquid fractions increased with prolonged soaking time. Smaller spheroidal solid grains and the larger shape factor were obtained due to Y addition. The coalescence and Ostwald ripening of solid grains operated the coarsening process simultaneously. The coarsening rate constants of AZ80M1 (0.2 wt.% Y addition) of 164.22 μm3s-1 was approximately four times less than the un-modified AZ80 alloy of 689.44 μm3s-1. In contrast, the desirable semi-solid structure featured by fine, well globular solid grains and appropriate liquid fractions and shape factor was achieved in AZ80M1 alloy treated at 570℃ for 20-30 min.
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Materials Science, Metallurgy; Tensile Strength; Hardness; Microstructure; Grain Morphology; Epitaxial Grain Growth; Scan Strategy; Directional Dependencies
Online: 18 August 2017 (18:05:46 CEST)
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The thorough description of the peculiarities of additively manufactured structures represents a current challenge for aspiring freeform fabrication methods, such as the selective laser melting (SLM). All of which have an immense advantage in the fast fabrication (no special tooling or moulds required), the geometrical flexibility in the design of components, and their efficiency when only low quantities are required. However, designs demand the precise knowledge of the material properties, which in case of additively manufactured structures are anisotropic and, under certain circumstances, in addition of an inhomogeneous nature. Furthermore, these characteristics are highly dependent on the fabrication settings. Within this study, the anisotropic tensile properties of selective laser melted stainless steel (1.4404, 316L) are investigated: The Young’s modulus ranged from 148 GPa to 227 GPa, the ultimate tensile strength from 512 MPa to 699 MPa and the breaking elongation ranged, respectively, from 12% to 43%. The results were compared to related studies, in order to classify the influence of the fabrication settings. Furthermore, the influence of the chosen raw material was addressed by comparing deviations on the directional dependencies reasoned by differing microstructural developments during manufacture. Stainless steel was found to possess its maximum strength at a 45° layer versus loading offset, which is precisely where AlSi10Mg was previously reported to be at its weakest.
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Materials Science, Metallurgy; grain boundary sliding; incompatibility stresses; anisotropic elasticity; heterogeneous elasticity; lattice rotations
Online: 1 May 2017 (11:06:32 CEST)
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Non-uniform grain boundary sliding can induce strain and rotation incompatibilities at perfectly planar interfaces. Explicit analytic expressions of stress and lattice rotation jumps are thus derived at a planar interface in the general framework of heterogeneous anisotropic thermo-elasticity with plasticity and grain boundary sliding. Both elastic fields are directly dependent on in-plane gradients of grain boundary sliding. It is also shown that grain boundary sliding is a mechanism that may relax incompatibility stresses of elastic, plastic and thermal origin although the latter are not resolved on the grain boundary plane. This relaxation may be a driving force for grain boundary sliding in addition to the traditionally considered local shears on the grain boundary plane. Moreover, the obtained analytic expressions are checked by different kinds of bicrystal shearing finite element simulations allowing grain boundary sliding and where a pinned line in the interface plane aims at representing the effect of a triple junction. A very good agreement is found between the analytic solutions and the finite element results. The performed simulations particularly emphasize the role of grain boundary sliding as a possible strong stress generator around the grain boundary close to the triple line because of the presence of pronounced gradients of sliding.
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Materials Science, Metallurgy; 7075 Aluminum alloy; eutectic mixture; formability; hardness.
Online: 26 April 2017 (20:12:46 CEST)
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Strain induced melt activation process (SIMA) creates a globular microstructure which improves the hardness and ultimate tensile stress (UTS) of 7075 aluminum alloys. But, at the grain boundaries of SIMA processed 7075 aluminum alloy, presence of continuous and brittle intermetallic compounds and the eutectic structure result in decreasing mechanical properties, such as elongation, formability and etc. Hence, in order to improve microstructure and formability of 7075 aluminum alloy respect to SIMA process, a new process was done that is called two-step strain induced melt activation (TSSIMA). This process, which has been mentioned in the experimental procedure section, both organized globular structure and significantly modified the microstructure of the alloy compared to that of the SIMA method. It promoted discontinuity and more homogeneity in distribution of the precipitates and, approximately removed the eutectic mixture. Performing the rolling process on the alloy also revealed that it is more effective in formability enhancement in comparison with SIMA process. Also, it increased the hardness of 7075 aluminum alloy respect to that of SIMA process.
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Materials Science, Metallurgy; Iron Aluminum Alloys; Cold/ Hot PM; Compressibility Factor; Wear Resistance.
Online: 3 April 2017 (18:23:00 CEST)
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Iron powders having average particle sizes of ~40µm are mechanically mixed thoroughly with aluminum powders ranging from 1 to 10 in wt.% with an average particle size of ~10µm. Two different powder metallurgical techniques cold and hot pressing are used to study the effect of the additive element powder on the mechanical properties, wear properties and the microstructure of the iron based alloys. The hot pressing technique was performed at a temperature up to 500°C at 445.6 MPa. The cold pressing technique was performed at 909 MPa in room temperature. By increasing the Al content to 10 wt. % in the base Fe-based matrix, the hardness was decreased from 780 to 690 MPa and the radial strength was decreased from 380 to 202 MPa with reductions of 11.5% and 40%, respectively. Improvement of the wear resistance with the increase addition of the Al powder to the Fe matrix up to 5 times was achieved compared to the alloy without Al addition for different wear parameters namely; wear time and sliding speed.
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Materials Science, Metallurgy; medium-carbon steel; fatigue life estimation; surface roughness
Online: 24 March 2017 (11:50:11 CET)
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Medium-carbon steel is commonly used for the rail, wire ropes, tire cord, cold heading, forging steels, cold finished steel bars, machinable steel and so on. Its fatigue behavior analysis and fatigue life estimation play an important role in the machinery industry. In this paper, the estimation of fatigue life of medium-carbon steel with different surface roughness using established S-N and P-S-N curves is presented. To estimate the fatigue life, the effect of the average surface roughness on the fatigue life of medium-carbon steel has been investigated using 75 fatigue tests in three groups with average surface roughness (Ra): 0.4μm, 0.8μm, and 1.6μm respectively. S-N curves and P-S-N curves have been established based on the fatigue tests. The fatigue life of medium-carbon steel is then estimated based on Tanaka-Mura crack initiation life model, the crack propagation life model using Paris law, and material constants of the S-N curves. 6 more fatigue tests have been conducted to validate the presented fatigue life estimation formulation. The experimental results have shown that the presented model could estimate well the mean fatigue life of medium-carbon steel with different surface roughness
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Materials Science, Metallurgy; Al-Zn-Cr Alloys; powder metallurgy; strengthening; extrusion; dry sliding wear
Online: 21 March 2017 (05:26:13 CET)
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Aluminum base alloys containing chromium (Cr) and zinc (Zn) were produced using extrusion and heat treated powder metallurgy. Cr addition ranged between 5 to 10 wt. % while Zn was added in an amount between 0 to 20 wt. %. Heat treatment processes were performed during powder metallurgy process at different temperatures followed by water quenching. Similar alloys were extruded, with an extrusion ratio of 4.6 to get proper densification. Optical microscopy was used for microstructure investigations of the produced alloys. The element distribution microstructure study was carried out using the Energy Dispersive X-ray analysis method. Hardness and tensile properties of the investigated alloys have been examined. Wear resistance tests were carried out and the results were compared with these of the Al-based bulk alloys. Results showed that the aluminum base alloys containing 10wt. % Chromium and heat treated at 500°C for one hour followed by water quenching exhibited the highest wear resistance and better mechanical properties.
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Materials Science, Metallurgy; 5754 Aluminum alloy; Two-pass hot compression; Dynamic softening; Metadynamic recrystallization
Online: 16 March 2017 (19:28:52 CET)
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Isothermal interrupted hot compression tests of 5754 aluminum were conducted on Gleeble-3500 thermo-mechanical simulator at temperature 350 °C and 450 °C, strain rate 0.1 s-1 and 1s−1. These tests simulated flat rolling to investigate how softening behaviors respond to controlled parameters, such as deformation temperature, strain rate and delay times. This data allowed the parameters for the hot rolling process to be optimized. The delay times during interrupted compression vary between 5s and 60s. The dynamic softening at each pass and metadynamic recrystallization at the intervals of deformation passes were analyzed in detail. 0.2% offset yield strength is applied to calculate the softening fraction undergoing metadynamic recrystallization. A kinetic model was developed to describe metadynamic recrystallization behaviors of the hot deformed 5754 aluminum alloy. Furthermore, the time constant for 50% recrystallization was expressed as functions related to the temperature and the strain rate. The experimental and calculated results were found to be in close agreement, which verified the developed model.
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Materials Science, Metallurgy; fracture toughness, scratch test, residual stress, tool steel, cryogenic treatment
Online: 24 February 2017 (15:46:47 CET)
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The scratch test consists in pushing a tool across the surface of a material at a given penetration depth or applied load. It has several applications in Science and Engineering including strength testing, damage and quality control of thin films and coatings. Despite numerous attempts in scientific literature, the application of scratch test to characterizations of fracture properties remains a heavily controversial topic. Therefore, this investigation arises as an experimental study in order to assess the fracture toughness using scratch test. A study on the effect of cryogenic treatment, performed after tempering, on fracture toughness, via scratch test experiments, of different tool steels has been made. A laboratory investigation on AISI D2, AISI M2 and X105CrCoMo18 steel confirms the possibility of increasing the fracture toughness by carrying out the cryogenic treatment after the usual heat treatment
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Materials Science, Metallurgy; Fe-Mn-Si alloy; isothermal holding time; powder sintering; density; weight loss; tensile properties
Online: 9 February 2017 (08:06:14 CET)
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This work investigated the isothermal holding time dependence of the densification, microstructure, weight loss and tensile properties of Fe-Mn-Si powder compacts. Elemental Fe, Mn and Si powder mixtures with a nominal composition of Fe-28Mn-3Si (in weight percent) were ball milled for 5h and subsequently pressed under a uniaxial pressure of 400 MPa. The compacted Fe-Mn-Si powder mixtures were sintered at 1200 ℃ for 0, 1, 2 and 3 h, respectively. In general, the density, weight loss and tensile properties increased with the increase of isothermal holding time. A significant increase in density, weight loss and tensile properties occurred in the compacts isothermally holding for 1 h, as compared to those with no isothermal holding. However, further extension of isothermal holding time (2 and 3 h) only played a limited role in promoting the density and tensile properties. The weight loss of the sintered compacts was mianly caused by the sublimation of Mn in Mn depletion region on the surface layer of the sintered Fe-Mn-Si compacts. The length of the Mn depletion region increased as isothermal holding time increased. A single α-Fe phase was detected on the surface of all the sintered compacts, and the locations beyond the Mn depletion region were comprised of a dual dominant γ-austenite and minor ε-martensite.
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Materials Science, Metallurgy; wüstite; magnetite; eutectoid transformation; oxide scale; hot strip mill
Online: 29 January 2017 (11:47:49 CET)
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It is important to realize the transformation behavior of wüstite because it greatly affects the final structure of the oxide layer and the surface quality of the steel products. In the present study, the transformation behaviors of the wüstite layer are examined under nearly-oxygen-free conditions, to simulate the cooling processes after the hot rolled strip is coiled. As the single phase wüstite was prepared at 950˚C, the 460˚C transformed oxide layer was composed of a mixture of iron and magnetite formed through eutectoid reactions. For the 750˚C-fabricated wüstite, only magnetite was observed after transformation, without iron precipitates and residual wüstite. It is speculated that the unusual transformation behavior of the low-temperature-made wüstite results from the pseudo-structural intermediate phase transformation between wüstite and magnetite. This pseudo-structure is a pre-transformed wüstite and of various concentration of ferrous ion, which is determined by the fabrication conditions. During the hot strip mill process, the so-called wet scale, wüstite, is produced continuously from finish mill to laminar flow sections and ended at 570˚C. Consequently, the final eutectoid transformation below 570˚C is dominantly controlled by the surface temperature ranged from 750˚C to 950˚C for low carbon steel.
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Materials Science, Metallurgy; Pin geometry; friction stir spot welding; mechanical properties; aluminum alloy
Online: 20 December 2016 (12:15:04 CET)
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Aluminum alloy Al 2024-T3 were successfully joined using friction stir spot jwelding joining (FSSW). Satisfactory joint strengths were obtained at different welding parameters (tool rotational speed, tool plunge depth, dwell time) and tool pin profile (straight cylindrical, triangular and tapered cylindrical). Resulting joints were welded with welded zone. The different tools significantly influenced the evolution on the stir zone in the welds. Lap-shear tests were carried out to find the weld strength. Weld cross section appearance observations were also done. The macrostructure shows that the welding parameters have a determinant effect on the weld strength (x: the nugget thickness, y: the thickness of the upper sheet and SZ: stir zone). The main fracture mode was pull out fracture modes in the tensile shear test of joints. The results of tensile shear tests showed that the tensile-shear load increased with increasing rotational speed in the shoulder penetration depth of 0.2 mm. Failure joints were obrerved in the weld high shoulder penetration depth and insufficient tool rotation.
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Materials Science, Metallurgy; Al wire, free air ball (FAB),electronic flame-off (EFO), coating, bias test
Online: 18 November 2016 (16:03:34 CET)
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Aluminum wire is a common material for wire bonding due to its resistance to oxidation and low price. It does not melt when becoming a free air ball (FAB) during the electronic flame-off (EFO) process with wettability, and is applied by wedge bonding. This study used 20μm Zn-Coated Al-0.5wt.%Si (ZAS) wires to improve the FAB shape after the EFO process, while maintaining stability of the mechanical properties, including the interface bonding strength and hardness. In order to test circuit stability after ball bonding, the current-tensile test was performed. During the experiment, it was found that 80nm ZAS with wire bonding has lower resistance and higher fusing current. For the bias tensile test, the thicker Zn film diffused into the Al-Si matrix easily, after which the strength was reduced. The ball-bond interfaces had no change in their condition before and after the bias. Accordingly, ZAS could be a promising candidate for ball bonding in the future.
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Materials Science, Metallurgy; Fe-Cr alloy; oxidation; sulfidation; H2S corrosion
Online: 18 October 2016 (10:04:51 CEST)
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Fe-(9, 19, 28, 37)wt.% Cr alloys were corroded at 700 and 800 oC for 70 h under 1 atm of N2,
1 atm of N2/3.2%H2O-mixed gas, and 1 atm of N2/3.1%H2O/2.42%H2S-mixed gas. The corrosion rate of
Fe-9Cr alloy increased with the addition of H2O, and furthermore with the addition of H2S in N2 gas.
Fe-9Cr alloy was always nonprotective. In contrast, Fe-(19, 28, 37) wt.%Cr alloys were protective in N2 and N2/H2O-mixed gas because of formation of the Cr2O3 layer. They were, however, nonprotective in N2/H2O/H2S-mixed gas because sulfidation dominated to form the outer FeS layer and the inner Cr2S3 layer containing some FeCr2S4.