Showing papers in "Journal of Materials Engineering and Performance in 2008"

Correlation of Yield Strength and Tensile Strength with Hardness for Steels

Abstract: Hardness values as well as yield and tensile strength values were compiled for over 150 nonaustenitic, hypoeutectoid steels having a wide range of compositions and a variety of microstructures. The microstructures include ferrite, pearlite, martensite, bainite, and complex multiphase structures. The yield strength of the steels ranged from approximately 300 MPa to over 1700 MPa. Tensile strength varied over the range of 450-2350 MPa. Regression analysis was used to determine the correlation of the yield strength and the tensile strength to the diamond pyramid hardness values for these steels. Both the yield strength and tensile strength of the steels exhibited a linear correlation with the hardness over the entire range of strength values. Empirical relationships are provided that enable the estimation of strength from a bulk hardness measurement. A weak effect of strain-hardening potential on the hardness-yield strength relationship was also observed.

Study of the Performance of Stainless Steel A-TIG Welds

Abstract: The purpose of the present work was to investigate the effect of oxide fluxes on weld morphology, arc voltage, mechanical properties, angular distortion and hot cracking susceptibility obtained with TIG welding, which applied to the welding of 5 mm thick austenitic stainless steel plates. A novel variant of the autogenous TIG welding process, oxide powders (Al2O3, Cr2O3, TiO2, SiO2 and CaO) was applied on a type 304 stainless steel through a thin layer of the flux to produce a bead on plate welds. The experimental results indicated that the increase in the penetration is significant with the use of Cr2O3, TiO2, and SiO2. A-TIG welding can increase the weld depth to bead-width ratio, and tends to reduce the angular distortion of the weldment. It was also found that A-TIG welding can increase the retained delta-ferrite content of stainless steel 304 welds and, in consequence, the hot-cracking susceptibility of as-welded is reduced. Physically constricting the plasma column and reducing the anode spot are the possible mechanism for the effect of certain flux on A-TIG penetration.

The Effect of Boronizing on Metallic Alloys for Automotive Applications

Abstract: In this study the wear resistance, corrosion resistance, and oxidation resistance of boronized metallic alloys were investigated. Thermochemical treatment was performed by powder pack boronizing process at temperature 850-950 °C for 4 h. Saw-tooth morphology and smooth interface microstructures were observed with an optical microscope; microhardness was measured across the coating depth. The phases present in the boron coatings depend on the substrate material. High-temperature oxidation resistance was investigated and it was found that boron coating on ferrous alloys can resist temperatures up to 800 °C. The corrosion resistance of the boronized samples was improved and the corrosion rate was calculated for boronized and plain specimens. Wear testing was conducted by following the procedures of ASTM G99, ASTM D2526, and ASTM D4060. The obtained experimental results revealed that boronizing significantly improves the wear-resistance, corrosion-resistance, and oxidation resistance of metallic alloys.

A Study on Process Parameters of Ultrasonic Assisted Micro EDM Based on Taguchi Method

Abstract: Experimental investigation of ultrasonic assisted micro electro discharge machining was performed by introducing ultrasonic vibration to workpiece. The Taguchi experimental design has been applied to investigate the optimal combinations of process parameters to maximize the material removal rate and minimize the tool wear. Analysis of variance (ANOVA) was performed and signal-to-noise (S/N) ratio was determined to know the level of importance of the machining parameters. Based on ANOVA, ultrasonic vibration at 60% of the peak power with capacitance of 3300 PF was found to be significant for best MRR. The machining time plays a significant role in the tool wear. The results were confirmed experimentally at 95% confidence interval.

Strain Hardening and Strain-Rate Sensitivity of an Extruded Magnesium Alloy

Abstract: The strain-hardening behavior and strain-rate sensitivity of an extruded AZ31B magnesium alloy were determined at different strain rates between 10−2 and 10−5 s−1 in relation to the thickness of specimens (2.5 and 4.5 mm). Both the common approach and Lindholm’s approach were used to evaluate the strain-rate sensitivity. The yield strength (YS) and the ultimate tensile strength (UTS) increased, the ductility decreased, and the brittle fracture characteristics increased with increasing strain rate. The thinner specimens exhibited a slightly higher UTS, lower ductility, higher strain-hardening exponent, and strain-hardening rate due to smaller grain sizes. The stage III strain-hardening rate linearly decreased with increasing true stress, but increased with increasing strain rate. In comparison to the common approach, the Lindholm’s approach was observed to be more sensitive in characterizing the strain-rate sensitivity due to larger values obtained. The thinner specimens also exhibited higher strain-rate sensitivity. As the true strain increased, the strain-rate sensitivity decreased.

Comparison of GRCop-84 to Other Cu Alloys with High Thermal Conductivities

Abstract: The mechanical properties of six highly conductive copper alloys, GRCop-84, AMZIRC, GlidCop Al-15, Cu-1Cr-0.1Zr, Cu-0.9Cr, and NARloy-Z were compared. Tests were done on as-received hard drawn material, and after a heat treatment designed to simulate a brazing operation at 935 °C. In the as-received condition AMZIRC, GlidCop Al-15, Cu-1Cr-0.1Zr, and Cu-0.9Cr had excellent strengths at temperatures below 500 °C. However, the brazing heat treatment substantially decreased the mechanical properties of AMZIRC, Cu-1Cr-0.1Zr, Cu-0.9Cr, and NARloy-Z. The properties of GlidCop Al-15 and GRCop-84 were not significantly affected by the heat treatment. Thus there appear to be advantages to GRCop-84 over AMZIRC, Cu-1Cr-0.1Zr, Cu-0.9Cr, and NARloy-Z if use or processing temperatures greater than 500 °C are expected. Ductility was the lowest in GlidCop Al-15 and Cu-0.9Cr; reduction in area was particularly low in GlidCop Al-15 above 500 °C, and as-received Cu-0.9Cr was brittle between 500 and 650 °C. Tensile creep tests were done at 500 and 650 °C; the creep properties of GRCop-84 were superior to those of brazed AMZIRC, Cu-1Cr-0.1Zr, Cu-0.9Cr, and NARloy-Z. In the brazed condition, GRCop-84 was superior to the other alloys due to its greater strength and creep resistance (compared to AMZIRC, Cu-1Cr-0.1Zr, Cu-0.9Cr, and NARloy-Z) and ductility (compared to GlidCop Al-15).

Developing an Empirical Relationship to Predict Tensile Strength of Friction Stir Welded AA2219 Aluminum Alloy

Abstract: AA2219 aluminum alloy (Al-Cu-Mn alloy) has gathered wide acceptance in the fabrication of lightweight structures requiring a high strength-to-weight ratio and good corrosion resistance. Friction stir welding (FSW) process is an emerging solid state joining process in which the material that is being welded does not melt and recast. This process uses a nonconsumable tool to generate frictional heat in the abutting surfaces. The welding parameters such as tool rotational speed, welding speed, axial force, etc., and tool pin profile play a major role in deciding the joint strength. An attempt has been made to develop an empirical relationship between FSW variables to predict tensile strength of the friction stir welded AA2219 aluminum alloy. To obtain the desired strength, it is essential to have a complete control over the relevant process parameters to maximize the tensile strength on which the quality of a weldment is based. Therefore, it is very important to select and control the welding process parameter for obtaining maximum strength. To achieve this various prediction methods such as response surface method (RSM), analysis of variance (ANOVA), Student’s t-test, coefficient of determination, etc., can be applied to define the desired output variables through developing mathematical models to specify the relationship between the output parameters and input variables. Four factors, five levels central composite design have been used to minimize number of experimental conditions. The developed mathematical relationship can be effectively used to predict the tensile strength of FSW joints of AA2219 aluminum alloy at 95% confidence level.

Development of Forming Limit Diagrams of Aluminum and Magnesium Sheet Alloys at Elevated Temperatures

Abstract: Magnesium components are increasingly being considered for use in vehicle structures due to the potential for weight reduction, fuel economy improvement, and emission reduction. Apart from castings, magnesium sheet components can open an entirely new opportunity for mass reduction. Magnesium’s poor ductility at room temperature, however, requires sheet forming to be carried out at elevated temperatures. The forming limits of magnesium alloy AZ31B-O were measured with both in-plane (Marciniak) and out-of-plane (limiting dome height) test methods at 300 °C. Forming limits of aluminum alloys 5182-O and 5754-O were also measured at room temperature and compared with published forming limit diagram data to validate the test procedures. Differences between the in-plane and out-of-plane test methods are discussed along with a description of failure modes and experimental challenges in obtaining strain localization and fracture in the appropriate locations. The plane strain forming limit (FLDo) of AZ31B at 300 °C was on the order of 67% strain, which agrees well with published data.

Wear Evolution in a Stranded Rope Subjected to Cyclic Bending

Abstract: Wire ropes, due to their construction, combine two very interesting properties: high axial strength and flexibility in bending. However, the assemblage of wires to form flexible ropes results in the sliding of contacting wires and the creation of wear scars, which can act as stress risers and reduce the fatigue life of ropes. Therefore, in order to understand the fatigue behavior of wire ropes, the degradation that occurs between the wires and the strands has to be studied first. In this study, after identifying the main wear patterns for a polymer-covered stranded rope, the wear evolution along the number of cycles and the effect of the sheave diameter in the preferential wear sites were analyzed. The tests were carried out in a custom-made Bending over Sheave (BoS) fatigue test bench and short segments of the rope were analyzed by Scanning Electron Microscope (SEM) and confocal imaging profilometry in order to characterize the wear scars. The worn volume and the wear scar depth were selected as the most suitable parameters to characterize the wear behavior of wires. In addition, the importance of the polymeric cover and sheave diameter was proved: a reduction of the sheave diameter results in a bigger wear rate (μm3/cycle).

Characterization of Superplastically Formed Friction Stir Weld in Titanium 6AL-4V: Preliminary Results

Abstract: A collaborative University and Industry research project was undertaken to evaluate the performance of as friction stir welded (FSW) and friction stir welded and superplastically formed (FSW-SPF) titanium 6Al-4V alloy sheets. The purpose of this initial phase of research is to test and evaluate the mechanical properties of FSW and post SPF-FSW 2-3 mm thick sheets of titanium. As-FSW and FSW with SPF Ti alloy (standard and fine grain size) butt joints were characterized in terms of microstructures, micro-hardness, metallurgy and tensile properties. The preliminary results of the FSW and post FSW-SPF joint were found to be close to that of as-received titanium with respect to strength, but elongations were decreased.

Pressureless Sintering of TiB2-B4C Ceramic Matrix Composite

Abstract: The effect of TiB2 addition on sinterability and mechanical properties of B4C material was investigated. It was found that addition of TiB2 aids the sintering process and permits pressureless sintering at temperatures between 2050 and 2150 °C. This also alleviates grain growth during sintering. The relative density reaches 98.5% of the theoretical density by increasing the percentage of TiB2 in the composition. The mechanical properties such as hardness, fracture toughness, and bending strength were improved remarkably by addition of TiB2.

Failure During Sheared Edge Stretching

Abstract: Failure during sheared edge stretching of sheet steels is a serious concern, especially in advanced high-strength steel (AHSS) grades. The shearing process produces a shear face and a zone of deformation behind the shear face, which is the shear-affected zone (SAZ). A failure during sheared edge stretching depends on prior deformation in the sheet, the shearing process, and the subsequent strain path in the SAZ during stretching. Data from laboratory hole expansion tests and hole extrusion tests for multiple lots of fourteen grades of steel were analyzed. The forming limit curve (FLC), regression equations, measurement uncertainty calculations, and difference calculations were used in the analyses. From these analyses, an assessment of the primary factors that contribute to the fracture during sheared edge stretching was made. It was found that the forming limit strain with consideration of strain path in the SAZ is a major factor that contributes to the failure of a sheared edge during stretching. Although metallurgical factors are important, they appear to play a somewhat lesser role.

Pitting and Stress Corrosion Cracking Susceptibility of Nanostructured Al-Mg Alloys in Natural and Artificial Environments

Abstract: The stress corrosion cracking (SCC) behavior of two developmental nanocrystalline 5083 alloys with varied composition and processing conditions was studied. The results were compared to a commercial aluminum AA 5083 (H111) alloy. The pitting densities, size and depths, and residual tensile strengths were measured after alternate immersion in artificial seawater and atmospheric exposure under different loading conditions. Optical and scanning electron microscopy (SEM) with EDX was used to analyze the fracture surfaces of failed specimen after removal at selected intervals and tensile testing. One of the nanostructured Al-Mg alloys exhibited significantly superior pitting resistance when compared to conventional microstructured AA 5083. Under conditions where pitting corrosion showed up as local tunnels toward phase inclusions, transgranular cracking was observed, whereas under conditions when pitting corrosion evolved along grain boundaries, intergranular cracking inside the pit was observed. Pit initiation resistance of the nano alloys appears to be better than that of the conventional alloys. However, long-term pit propagation is a concern and warrants further study. The objective of this investigation was to obtain information regarding the role that ultra-fine microstructures play in their degradation in marine environments and to provide insight into the corrosion mechanisms and damage processes of these alloys.

Assessment of the Effect of Microstructure on the Magnetic Behavior of Structural Carbon Steels Using an Electromagnetic Sensor

Abstract: The magnetic properties of four carbon steels were evaluated using an electromagnetic sensor and correlated with their microstructures. Their composition, microstructure features (such as ferrite volume fraction, grain size, inclusions, etc), and hardness were compared with their saturated magnetic flux density, retentivity, and coercivity. The four steel rods used in this study were hot-rolled AISI 1010, AISI 1018, AISI 1045, and AISI 1045-high manganese/“stress proof.” The results show that microstructures have a notable effect on the magnetic properties of the steels. In addition, the effect of variations in cross-section area of the steel rods on the magnetic response was investigated. The steel rods diameters were systematically reduced by machining and then magnetically evaluated. Consistent relationships between metallurgical characteristics of the structural carbon steels and their magnetic properties measured with the electromagnetic sensor were obtained. In addition, the sensor was found to be able to detect changes in magnetic properties due to variations in cross-section area. These results reveal that the electromagnetic sensor has the potential to be used as a reliable nondestructive tool to detect and monitor microstructural and morphological changes occurring during the different stages of steel manufacturing or alterations caused by a degradation mechanism.

Electrochemical Corrosion Behavior of Dental/Implant Alloys in Artificial Saliva

Abstract: The corrosion behavior and passive film characteristics of various dental alloys such as Co-Cr, Ni-Cr, Cu-Ni-Al, and commercially pure Ti (c.p. Ti) were evaluated in artificial saliva medium by utilizing electrochemical impedance spectroscopy (EIS), Tafel polarization, and cyclic polarization studies. EIS studies were carried out for various durations viz. 1 h, 1 day, and 7 days to evaluate the stability of passive film and change in corrosion characteristics with respect to time. Electrochemical parameters such as Ecorr, icorr, corrosion rate, passive film characteristics with respect to time were obtained from various studies mentioned above. The corrosion resistance decreased in the order Cu-Ni-Al > cp Ti > Co-Cr (Commercial) > Ni-Cr > Co-Cr (DRDO developed) in artificial saliva solution.

Pulse TIG Welding of Two Al-Mg-Si Alloys

Abstract: This article reports the influence of pulse tungsten inert gas (TIG) welding parameters on the microstructure, hardness and tensile strength of weld joints of two Al-(0.5-0.8%)Si-(0.5-0.6%)Mg alloy (T4) produced by using three pulse frequencies (25, 33, and 50 Hz) and two duty cycles (40 and 50%). It has been observed that the mechanical properties (hardness and tensile strength) are sensitive to microstructure of weld metal, which is appreciably affected by the pulse parameters. Low frequency produced higher strength and hardness than high pulse frequency under identical welding conditions. Weld metal and HAZ were found stronger than the base metal. SEM study showed that the fracture of weldment was mostly brittle type.

Effect of Micro Arc Oxidation Coatings on Corrosion Resistance of 6061-Al Alloy

Abstract: In the present study, the corrosion behavior of micro arc oxidation (MAO) coatings deposited at two current densities on 6061-Al alloy has been investigated. Corrosion in particular, simple immersion, and potentiodynamic polarization tests have been carried out in 3.5% NaCl in order to evaluate the corrosion resistance of MAO coatings. The long duration (up to 600 h) immersion tests of coated samples illustrated negligible change in weight as compared to uncoated alloy. The anodic polarization curves were found to exhibit substantially lower corrosion current and more positive corrosion potential for MAO-coated specimens as compared to the uncoated alloy. The electrochemical response was also compared with SS-316 and the hard anodized coatings. The results indicate that the overall corrosion resistance of the MAO coatings is significantly superior as compared to SS316 and comparable to hard anodized coating deposited on 6061 Al alloy.

The Effect of Time, Temperature and Composition on Boron Carbide Synthesis by Sol-gel Method

Abstract: To minimize free carbon residue in the boron carbide (B4C) powder, a modified sol-gel process is performed where the starting materials as boric acid and citric acid compositions are adjusted. Because of boron loss in the form of B2O2(g) during the reduction reaction of the stoichiometric starting composition, the final B4C powders contain carbon residues. Thus, an excess H3BO3 is used in the reaction to compensate the loss and to obtain stoichiometric powders. Parameters of production have been determined using x-ray diffraction analysis and particle size analyses. The synthesized B4C powder using an excess boric acid composition shows no trace of carbon.

Degradation Characteristics of Elastomeric Gasket Materials in a Simulated PEM Fuel Cell Environment

Abstract: Polymer electrolyte membrane (PEM) fuel cell stack requires gaskets and seals in each cell to keep the reactant gases (hydrogen and oxygen) within their respective regions. The stability of the gaskets/seals is critical to the operating life as well as the electrochemical performance of the fuel cell. The time-dependant chemical and mechanical degradation of two commercially available silicones-based elastomeric gasket materials in a simulated fuel cell environment was investigated in this work. Two temperatures based on actual fuel cell operation were selected and used in this study. Using optical microscopy, the topographical damage on the sample surface due to the acidic environment was revealed. Atomic adsorption spectrometer analysis shows that silicon, calcium, and magnesium were leached from the materials into the soaking solution. Attenuated total reflection Fourier transform infrared (ATR-FTIR) spectroscopy and X-ray photoelectron spectroscopy (XPS) were employed to study the surface chemistry of the elastomeric gasket materials before and after exposure to the simulated fuel cell environment over time. The ATR-FTIR and XPS test results indicate that the surface chemistry changed significantly and the chemical degradation mechanism is de-crosslinking and chain scission in the backbone. The microindentation test results show that the mechanical properties of the silicone materials changed significantly after exposure to the simulated PEM fuel cell environment over time.

Synthesis & Characterization of PVA/STA Composite Polymer Electrolyte Membranes for Fuel Cell Application

Abstract: Chemically cross-linked composite membranes consisting of poly(vinyl alcohol) (PVA) and silicotungstic acid (STA) have been prepared by solution casting and evaluated as proton-conducting polymer electrolytes. The proton conductivity of the membranes was investigated as a function of blending composition, cross-linking density, and temperature. The conductivity mechanism was investigated by using Impedance spectroscopy in the region between 40 Hz and 10 MHz. Membranes were also characterized by FTIR spectroscopy to confirm the crossl-inking reaction and differential scanning calorimetry (DSC) to assess the thermal stability. Membrane swelling decreased with increase in cross-linking density accompanied by improvement in mechanical properties. The proton conductivity of the membranes was of the order of 10−3 S/cm and showed similar resistance to methanol permeability as Nafion 117 under the same measurement conditions.

Implementation of a Robust Algorithm for Prediction of Forming Limit Diagrams

Abstract: In this article, a robust algorithm for prediction of forming limit diagrams (FLD) has been presented. The presented model is based on the “Marciniak and Kuczynski” (M-K) theory. Solution to the system of equations has been obtained by applying the Newton’s method. Since the Newton’s method usually has nonconverging problem, a particular backtracking algorithm has been developed and applied. In this algorithm, a technique for step length selection in the frame of gradient descent method has been implemented. Also for the convergence criterion the so-called “Armijo” condition has been used. For verification of the results, BBC2000 yield function and Swift hardening law for AK steel metal have been used. To obtain the necking angle, the effect of groove orientation on the left- and right-hand sides of FLD has been considered. Finally, the predicted FLD has been compared with the published experimental results.

Nanoquenchants for Industrial Heat Treatment

Abstract: The present work outlines the possibility of using nanofluids for industrial heat treatment. Development of nanoquenchants having (i) high quench severity for enhancement of heat transfer for thick sections with low quench sensitivity and (ii) low cooling severity for thin sections with high quench sensitivity would be extremely useful to the heat treating community. The temperature dependent heat transfer coefficient and the wettability of the medium are the two important parameters that can be used to characterize a nanoquenchant to assess its suitability for industrial heat treatment.

Effect of Postweld Aging Treatment on Fatigue Behavior of Pulsed Current Welded AA7075 Aluminum Alloy Joints

Abstract: This article reports the effect of postweld aging treatment on fatigue behavior of pulsed current welded AA 7075 aluminum alloy joints. AA7075 aluminum alloy (Al-Zn-Mg-Cu alloy) has gathered wide acceptance in the fabrication of light weight structures requiring high strength-to weight ratio, such as transportable bridge girders, military vehicles, road tankers, and railway transport systems. The preferred welding processes of AA7075 aluminum alloy are frequently gas tungsten arc welding (GTAW) process and gas metal arc welding (GMAW) process due to their comparatively easier applicability and better economy. Weld fusion zones typically exhibit coarse columnar grains because of the prevailing thermal conditions during weld metal solidification. This often results inferior weld mechanical properties and poor resistance to hot cracking. In this investigation, an attempt has been made to refine the fusion zone grains by applying pulsed current welding technique. Rolled plates of 10 mm thickness have been used as the base material for preparing multipass welded joints. Single V butt joint configuration has been prepared for joining the plates. The filler metal used for joining the plates is AA 5356 (Al-5Mg (wt.%)) grade aluminum alloy. Four different welding techniques have been used to fabricate the joints and they are: (i) continuous current GTAW (CCGTAW), (ii) pulsed current GTAW (PCGTAW), (iii) continuous current GMAW (CCGMAW), and (iv) pulsed current GMAW (PCGMAW) processes. Argon (99.99% pure) has been used as the shielding gas. Rotary bending fatigue testing machine has been used to evaluate fatigue behavior of the welded joints. Current pulsing leads to relatively finer and more equi-axed grain structure in GTA and GMA welds. Grain refinement is accompanied by an increase in fatigue life and endurance limit. Simple postweld aging treatment applied to the joints is found to be beneficial to enhance the fatigue performance of the welded joints.

Quality of Trimming and its Effect on Stretch Flanging of Automotive Panels

Abstract: Traditional trimming requires accurate alignment of the die shearing edges, typically 5–10% of the blank thickness. Increasing the clearance above the recommended value often leads to generation of burrs on the trimmed surface. These burrs may create difficulties for flanging and hemming operations. Details of trimming technology for panels made out of aluminum sheet AA6111-T4 with elastic offal support will be discussed, including such factors as die radii of the tooling, effect of tooling wear, and trimming angle on the quality of trimmed surface. Also, imperfections on the trimmed edge of the panel may result in reduced formability in stretched flanging and hemming operations. Experimental results quantifying the behavior of trimmed surface in stretching will be provided for both a conventional trimming process and a newly developed process.

The Effects of Laser Peening and Shot Peening on Mechanical Properties in Friction Stir Welded 7075-T7351 Aluminum

Abstract: Peening techniques like laser peening and shot peening were used to modify the surface of friction stir welded 7075-T7351 Aluminum Alloy specimens. The tensile coupons were machined such as the loading was applied in a direction perpendicular to the weld direction. The peening effects on the global and local mechanical properties through the different regions of the weld were characterized and assessed. The surface hardness levels resulting from various peening techniques were also investigated for both sides of the welds. Shot peening resulted in an increase to surface hardness levels, but no improvement was noticed on the mechanical properties. In contrast, mechanical properties were improved by laser peening when compared to the unpeened material.

Controlling End-Grain Corrosion of Austenitic Stainless Steels

Abstract: SS 304L is widely used as a structural material in applications handling nitric acid such as nuclear fuel processing plants and nuclear waste management facilities. Bar, wire, and tubular products of this material are especially susceptible to end-grain corrosion in nitric acid environment. Such an attack takes place on the tubular and forged surfaces that are perpendicular to the hot-working direction and occurs as localized pitting type attack. This study shows that the possible reasons for the directional nature of end-grain attack are the manganese sulfide inclusions aligned along the hot-working direction and/or segregation of chromium along the flow lines during the fabrication stage itself. It has been shown in this study that controlled solution annealing, laser surface remelting, and weld overlay can be used to avoid/minimize end-grain corrosion. Different annealing heat-treatments were carried out on two heats of SS 304L tube and susceptibility to corrosion was measured by ASTM A 262 practice C and electrochemical potentiokinetic reactivation (EPR) test. Solution annealing at 950 °C for 90 min has been shown to increase the resistance to end-grain corrosion. Laser surface remelting using continuous wave CO2 laser under argon shield and weld deposition (overlay) using SS 308L material were done on the end faces of the tubes. These samples were completely resistant to end-grain corrosion in nitric acid environments.

Effect of Slurry Composition on Plate Weight in Ceramic Shell Investment Casting

Abstract: This paper deals with the study of the effect of primary slurry parameters on the plate weight (ceramic retention test) in ceramic shell investment casting process. Four controllable factors of the zircon flour and fused-silica powder based slurries were studied at three levels each by Taguchi’s parametric approach and single-response optimization of plate weight was conducted to identify the main factors controlling its stability. Variations in coating thickness with plate weight were calculated for each slurry and ceramic shell moulds were made on wax plate using primary slurry and coarse fused-silica sand as stucco. The Scanning Electronic Microscopy (SEM) technique has been used to study the surface morphology of zircon flour and fused silca powder particles as well as primary coating (shell surface). X-ray Diffraction (XRD) analysis was done to identify the various phases present in the ceramic slurry coating. Optical profilometer has been used to measure the surface roughness of the shells. The result reveals that the surface condition of shell can be improved by increasing the plate weight, corresponding to higher filler loading in the slurry. Confirmation experiments were conducted at an optimal condition showed that the surface quality of the ceramic shell mould were improved significantly. Castings were produced using Al-7%Si alloy in recommended parameters through ceramic shell investment casting process. Surface roughness of the produced casting were measured and presented in this paper.

Effect of the Current Density on Morphology, Porosity, and Tribological Properties of Electrodeposited Nickel on Copper

Abstract: In the steel industry, nickel coating on copper has increased the lifespan of continuous ingot casting molds. The objective of this work is to estimate the porosity of nanocrystalline nickel electrodeposited onto copper. Characteristics of nickel coating such as hardness, wear resistance, porosity, morphology, and adhesion are very important for maximum performance of molds. The effective porosity in nickel coating was determined by using anodic voltammetry. The porosity of electrodeposited nickel onto copper increased from 0.16% up to 6.22% as the current density increased from 1.5 up to 8.0 A dm−2. The morphology of the nickel electrodeposited at lower current densities was more compact. Tribological properties were studied using hardness measurements, and calotest. Results of calotest indicated a wear coefficient of 10−6 for all samples. An extremely low friction coefficient of 0.06-0.08 was obtained for the sample deposited with a current density of 1.5 A dm−2, and a friction coefficient of 0.15-0.21 was measured for the nickel coating electrodeposited at a current density of 5 A dm−2. Effects of the current density of the electrodeposition process on the morphology, porosity, and tribological properties were evaluated.

Uniaxial Tensile and Simple Shear Behavior of Resistance Spot-Welded Dual-Phase Steel Joints

Abstract: Small test coupons were machined from single spot welds in a dual-phase steel (DP600) to investigate deformation and failure of weld joints in both tension and shear. Quasi-static ( $$ \ifmmode\expandafter\dot\else\expandafter\.\fi{\upvarepsilon } \sim 10^{{ - 4}} \,1/{\text{s}} $$ ) testing was conducted in a miniature tensile stage with a custom image acquisition system. Strain accumulation in each weld was analyzed where fracture occurred, which was typically outside the fusion zone. A few shear test coupons that failed in the fusion zone were found to have the same spheroidal defects noted in previous work, and thus, severely limited weld strength and ductility. A novel strain mapping method based upon digital image correlation was employed to generate two-dimensional deformation maps, from which local stress-strain curves to failure were computed. As an important first step toward incorporation of material models into weld simulations, a preliminary finite element analysis of a tension test successfully reproduced the experimental results with material models for the base, heat-affected, and fusion zone materials generated from prior work.

Investigations on Heat Treatment of a High-Speed Steel Roll

Abstract: High-carbon high-speed steels (HSS) are very abrasion-resistant materials primarily due to their high hardness MC-type carbide and high hardness martensitic matrix. The effects of quenching and tempering treatment on the microstructure, mechanical properties, and abrasion resistance of centrifugal casting high-carbon HSS roll were studied. Different microstructures and mechanical properties were obtained after the quenching and tempering temperatures of HSS roll were changed. With air-cooling and sodium silicate solution cooling, when the austenitizing temperature reaches 1273 K, the metallic matrix all transforms into the martensite. Afterwards, the eutectic carbides dissolve into the metallic matrix and their continuous network distribution changes into the broken network. The second hardening temperature of high-carbon HSS roll is around 793 K. No significant changes in tensile strength and elongation percentage are observed unless the tempering temperature is beyond 753 K. The tensile strength increases obviously and the elongation percentage decreases slightly beyond 753 K. However, the tensile strength decreases and the elongation percentage increases when the tempering temperature exceeds 813 K. When the tempering temperature excels 773 K, the impact toughness has a slight decrease. Tempering at 793-813 K, high-carbon HSS roll presents excellent abrasion resistance.