Galvannealing of (High‐)Manganese‐Alloyed TRIP‐ and X‐IP®‐Steel

In this study the influence of Mn on galvannealed coatings of 1.7% Mn‐1.5% Al TRIP‐ and 23% Mn X‐IP®‐steels was investigated. It is shown that the external selective oxides like Mn, Al and Si of the TRIP steel which occur after annealing at 800 °C for 60 s at a dew point (DP) of ‐25 °C (5% H₂) hamper the Fe/Zn‐reaction during subsequent galvannealing. Preoxidation was beneficially utilized to increase the surface‐reactivity of the TRIP steel under the same dew point conditions. The influence of Mn on the steel alloy was investigated by using a 23% Mn containing X‐IP®‐steel which was bright annealed at 1100 °C for 60 s at DP ‐50 °C (5% H₂) to obtain a mainly oxide free surface prior to hot dip galvanizing (hdg) and subsequent galvannealing. As well known from the literature Mn alloyed to the liquid zinc melt stabilizes δ‐phase at lower temperatures by participating in the Fe‐Zn‐phase reactions, it was expected that the metallic Mn of the X‐IP®‐steel increases the Fe/Zn‐reactivity in the same manner. The approximation of the effective diffusion coefficient (D_eff(Fe)) during galvannealing was found to be higher than compared to a low alloyed steel reference. Contrary to the expectation no increased Fe/Zn‐reaction was found by microscopic investigations. Residual η‐ and ζ‐phase fractions prove a hampered Fe/Zn‐reaction. As explanation for the observed hampered Fe/Zn‐reaction the lower Fe‐content of the high‐Mn‐alloyed X‐IP®‐steel was suggested as the dominating factor for galvannealing.     

Spline‐Interpolation and Calculation of Machine Parameters for the Three‐Roll‐Pushbending of Spline‐Contours

Today, bending tasks become more and more complex. Not even constant bending radii are required in the industrial practice. There is a growing demand for bending spline‐contours, too. Such geometries are often produced with Freeform‐Bending procedures like Three‐Roll‐Pushbending. This paper presents a method to interpolate a given spline bending‐contour (by CAD data), in order to calculate its radii distribution, which is needed to determine the machine parameters in certain points for the Three‐Roll‐Pushbending. For the determination of the machine parameters one has to consider the different influences on the bending process. The material springback and the deflection of the bending machine per radius need to be compensated to reach a near net shape bending result. Nevertheless deviations cannot be avoided. To improve the results, a possibility to adjust the pre‐calculated machine parameters is shown. For the investigations tube profiles with constant wall thicknesses were considered. The corresponding plasticity calculations refer to tube cross‐sections. The results were validated by bending a representative spline contour on the bending machine of the Chair of Forming Technology at the University of Siegen.     

Stress‐Temperature‐Transformation and Deformation‐Temperature‐Transformation Diagrams for an Austenitic CrMnNi as‐cast Steel

Stress‐Temperature‐Transformation (STT) and Deformation‐Temperature‐Transformation (DTT) diagrams are well‐suited to characterize the TRIP (transformation‐induced plasticity) and TWIP (twinning‐induced plasticity) effect in steels. The triggering stresses for the deformation‐induced microstructure transformation processes, the characteristic temperatures, the yield stress and the strength of the steel are plotted in the STT diagram as functions of temperature. The elongation values of the austenite, the strain‐induced twins and martensite formations are shown in the DTT diagram. The microstructure evolution of a novel austenitic Cr‐Mn‐Ni (16%Cr, 6% Mn, 6% Ni) as‐cast steel during deformation was investigated at various temperatures using static tensile tests, optical microscopy and the magnetic scale for the detection of ferromagnetic phase fraction. At the temperatures above 250 °C the steel only deforms by glide deformation of the austenite. Strain‐induced twinning replaces the glide deformation at temperatures below 250 °C with increasing strain. Below 100 °C, the strain‐induced martensite formation becomes more pronounced. The kinetics of the α'‐martensite formation is described according to stress and deformation temperatures. The STT and DTT diagrams, enhanced with the kinetics of the martensite formation, are presented in this paper.     

Iso‐Work‐Rate Weighted‐Taylor Homogenization Scheme for Multiphase Steels Assisted by Transformation‐induced Plasticity Effect

A simple homogenization scheme for multiphase microstructure (composite) is developed. This scheme is based on the classical Taylor (iso‐strain‐rate) averaging scheme. Scalar multipliers are introduced as weighting parameters in order to relax the condition of uniform strain distribution used in the classical Taylor scheme. In the present work, the scalar weighting parameters are determined by satisfying the iso‐work‐rate condition, i.e., work is equally distributed in all constituent phases. In combination with micromechanical models developed for transformation‐induced plasticity (TRIP) effect, the iso‐work‐rate weighted‐Taylor scheme is applied for simulating the effective mechanical behaviour of multiphase TRIP‐assisted steel. The predictions of the iso‐work‐rate weighted‐Taylor scheme are compared with the result of the corresponding simulation with the direct finite‐element method (FEM).     

A Study of Microstructure and Performance of Quenching Fe‐V‐W‐Mo Alloy

The critical points and time temperature transformation (TTT) curves of Fe‐5%V‐5%W‐5%Mo‐5%Cr‐3%Nb‐2%Co (Fe‐V‐W‐Mo) were measured, and the effects of quenching temperature and cooling modes on the microstructure and performance of Fe‐V‐W‐Mo alloy were investigated. The results showed that the hardness of Fe‐V‐W‐Mo alloy increased until the quenching temperature reached 1025°C and dropped down as the quenching temperature exceeded 1050°C in oil cooling. The hardness obtained in air cooling and spray cooling exhibited a similar tendency as that in oil cooling, but the temperature at which the highest hardness was obtained in these slower cooling processes changed to a higher range. The hot hardness and toughness of Fe‐V‐W‐Mo alloy increased with rising quenching temperature until it reached 1150°C, and from then on the toughness began to drop. The main reasons why the structures and properties of Fe‐V‐W‐Mo alloy obviously change under different quenching conditions are particularly analysed at last.     

A Study of Microstructure and Performance of Tempered Fe‐V‐W‐Mo Alloy

Influences of tempering temperature, holding time and tempering times on the microstructure and performance of Fe‐5%V‐5%W‐5%Mo‐5%Cr‐3%Nb‐2%Co(Fe‐V‐W‐Mo) were investigated by means of metallography, optical microscopy, hardness measurements, impact tester and pin abrasion tester. The results show that the hardness of Fe‐V‐W‐Mo alloy remains constant when tempered below 350°C. The hardness decreases gradually as the tempering temperature increase until around 475°C and then it increases again to a peak at 525°C. The hardness of Fe‐V‐W‐Mo alloy reaches nearly the highest value after the first tempering and decreases after triple‐tempering. The toughness of Fe‐V‐W‐Mo alloy increases until the tempering temperature reaches 475°C and then decreases until the temperature reaches 525°C. However, it increases again when tempering is beyond that temperature. The excellent wear resistance can be obtained by tempering at 500‐550°C.     

Reoxidation of Ni‐ and Ni‐Fe‐Alloys by Al2O3‐SiO2 Refractory Materials

Reactions at the refractory/melt interface during ingot casting of Ni‐ and Ni‐Fe‐alloys were studied. The casts were performed using different alumino‐silicate bricks as refractory materials. Samples taken from the casting channel before and after casting were investigated using light and scanning electron microscopy with XPS. Thermodynamic calculations were performed with FactSage and the results were compared with the results from industrial tests. After the melt has infiltrated the surface layer of the bricks, refractory corrosion starts with an attack of Mn and Mg of the melt on SiO₂ and Fe₂O₃ of the refractory bonding matrix. Despite the presence of elements with higher oxygen affinity in the melt, low‐melting alumino‐silicate phases are predominantly built by the reaction with Mn and Mg. In a second step this liquid phase either traps non‐metallic inclusions from the melt or, at higher contents of Zr, Ti, Mg, Y etc. in the melt, causes massive reoxidation and inclusion formation. The refractory materials investigated show an increasing trend for reoxidation with an increasing amount of SiO₂ in glassy phases of the refractory bonding matrix. By the use of a refractory material with higher mullite content in the bonding matrix or by use of alumina bricks a strong reoxidation of the melt and intense inclusion formation can be avoided. These observations are also valid for other alloys with higher contents of elements with high affinity to oxygen.     

Some Thermophysical Properties of Liquid Cr‐Mn‐Ni‐Steels

In the last years new Cr‐Mn‐Ni‐TRIP/TWIP steels have been developed at the Institute of Iron and Steel Technology, Freiberg University of Mining and Technology. Within the Collaborative Research Center SFB 799, the ZrO₂‐ceramic‐TRIP‐steel composite materials are produced using the infiltration of open foam ceramics with liquid steel and using powder metallurgy with small additions of ceramic powder before sintering. The thermophysical properties of liquid steel play an important role in both production routes. They affect the infiltration efficiency in one process and the produced powder size in the other, and therefore finally determine the composite properties. In this work some of these properties were estimated, as they are not available in literature. The investigated steels contain approximately 16% chrome, 7% manganese and 3% to 9% nickel. The surface tension was estimated using two methods: the drop weight method and the maximum bubble pressure method. In the drop weight method similar conditions at the gas/metal interface exist as during the atomization or the infiltration process, where liquid metal is exposed to high volume of inert gas. In all these cases the evaporation of manganese affects the surface tension. For comparison of results and for estimation of the liquid steel density the maximum bubble pressure method was used where the evaporation of manganese is limited. The wettability on partially MgO‐stabilized ZrO₂ ceramic substrates and its change with contact time was determined using the sessile drop method.     

Viscosities of the Quaternary Al2O3‐CaO‐MgO‐SiO2 Slags

Viscosities of some quaternary slags in the Al₂O₃‐CaO‐MgO‐SiO₂ system were measured using the rotating cylinder method. Eight different slag compositions were selected. These slag compositions ranging in the high basicity region were directly related to the secondary steel making operations. The measurements were carried out in the temperature range of 1720 to 1910 K. Viscosities in this system and its sub‐systems were expressed as a function of temperature and composition based on the viscosity model developed earlier at KTH. The iso‐viscosity contours in the Al₂O₃‐CaO‐MgO‐SiO₂ system relevant to ladle slags were calculated at 1823 K and 1873 K for 5 mass% MgO and 10 mass% MgO sections. The predicted results showed good agreement with experimental values and the literature data.     

3D‐FE Modelling and Simulation of Multi‐way Loading Process for Multi‐ported Valves

Multi‐ported valves are widely used in the marine, sanitary, petrochemical and power industry. Multi‐way loading forming technology provides an efficient approach for integral forming of high strength multi‐ported valves, such as tee pipe coupling, high‐pressure cross valves, large‐scale complex valves, and so on. Since the multi‐way loading process is a very complicated plastic forming process due to the complexity of loading path, finite element numerical simulation is adopted to investigate the multi‐way loading process in order to predict and control the multi‐ported valve forming process. A reasonable model of the process is developed under DFEORM‐3D environment based on the coupled thermo‐mechanical finite element method. Then the reliability of the model is validated with respect to geometry development and forming defects. Numerical simulations of multi‐way loading forming for a tee valve and a cross valve have been carried out via using the developed model. Further, the forming processes of tee valve and cross valve have been compared. Moreover, the modelling method is also suitable for multi‐way loading processes of other complex components.     

Isothermal Microstructural Transformations of the Heat‐treatable Steel 42CrMo4 during Heat‐treatment following Hot‐forming

Apart from reducing the processing energy, hardening and tempering of near‐net shape forged components from their forging heat primarily promises shortened conventional process sequences with reduced manufacturing costs. In this case, the time‐temperature‐transformation diagrams (T‐T‐T diagrams) found in the literature can only be used to a limited extent for determining the microstructural transformations during the heat‐treatment. The reasons for this are that firstly, the deformation influences the transformation kinetics and secondly, the forming temperatures at which austenitising takes place are comparatively high. For this reason, isothermal deformation T‐T‐T diagrams for forging temperatures from 1200 °C and deformation levels of 0.3 and 0.7 were determined for the heat‐treatable steel 42CrMo4 (1.7225). These diagrams were subsequently modelled for simulating the heat‐treatment and implemented in the FE‐software ANSYS®.     

A Method for the Calculation of Retained Austenite Evolution during Heat‐Treatment of Low‐Alloy TRIP‐Assisted Steels

Summary (abstract) : Despite the critical effect of heat‐treatment, and in particular of the isothermal bainitic treatment stage, on the amount and stability of retained austenite in the microstructure of low‐alloy TRIP‐assisted steels, determination of optimum heat‐treatment conditions is still largely empirical and experiment‐dependent. This work proposes a method by which it is possible to calculate the vol. fraction of retained austenite in the microstructure as a function of intercritical annealing temperature and isothermal bainitic treatment temperature and holding time. The method assumes diffusionless lengthening of bainitic ferrite (α_B) plates in austenite (γ), and subsequent thickness‐wise C rejection from the α_B plates to the adjacent γ layers. The relative thickness of α_B plates and adjacent γ layers is determined by the T_o line of the transforming system at any given bainitic transformation temperature. The C‐concentration profiles in γ are calculated with respect to a local time‐scale, referring to any random section of any random α_B plate. Determination of the variation of C‐concentration profiles with local time in γ, together with the use of a simple austenite‐retention criterion, allows the calculation of vol. fraction retained austenite (γ_R) as a function of transformation temperature and local time. Transition from local (calculation) time to actual heat treatment time is performed by introducing a time‐scale factor, which depends on transformation temperature and initial C‐content of α_B. The calculated behaviour of vol. fraction γ_R vs. bainitic holding time conforms to the well established, experimentally observed one: vol. fraction γ_R initially increases with holding time, reaches a maximum and decreases at longer holding times. According to calculated results, the decrease is attributed to the gradual homogenization of C inside the γ layers, which leads to inadequate stabilization and transformation of γ to martensite on quenching. As regards quantitative comparison with available experimental data, calculations show reasonable agreement. Certain refinements of the method, which are underway, are reported, in order to further improve quantitative results. Nevertheless, the method in its present form provides a calculational tool, by which the effect of different heat‐treatment conditions or steel compositions can be examined and compared to each other, which can be a useful step towards optimizing alloy compositions and heat‐treating processes.     

Composition Control of CaO‐MgO‐Al2O3‐SiO2 Inclusions in Tire Cord Steel ‐ a Thermodynamic Analysis

The effect of oxide component content on the low melting point zone (LMP) in the CaO‐MgO‐Al₂O₃‐SiO₂ system has been analysed using FactSage software. The contents of dissolved elements [Si], [Mg], [O] and [Al] in liquid steel in equilibrium with the LMP inclusions in the CaO‐MgO‐Al₂O₃‐SiO₂ system have been calculated. The results show that the CaO‐MgO‐Al₂O₃‐SiO₂ system has the largest LMP zone (below 1400°C) when the Al₂O₃ content is 20% or the MgO content is 10%. The LMP zone becomes wide with the increase in CaO content (within the range of 0~30 mass%) and the decrease in SiO₂ (from 25 to 5 mass%). To obtain the LMP (below 1400°C) inclusions, the [Mg], [Al] and [O] contents must be controlled within the range of 0.2~2 ppm, 1.0~2.0 ppm and 60~100 ppm, respectively.     

Gas‐pressure Forming of an AlMg‐Alloy Sheet at Elevated Temperatures

Forming of automotive leightweight parts using aluminium offers numerous advantages. Compared to other wrought aluminium alloys, in particular AlMg‐alloys generally show a good formability which is favourable for the production of complex parts. However, forming of Mg‐containing alloys at room temperature leads to yielding patterns preventing their implementation for class‐A‐surface applications. Furthermore, the formability of steel still exceeds that of AlMg‐alloys at room temperature. Thus, in the present study, sheet metal forming is applied at a temperature range that is typical for warm forming. It is supposed to profit from the advantages of warm forming like high achievable strains and improved surface quality of the formed part, while not having the disadvantages of long production times and high energy consumption, which is correlated with superplastic forming. Applying fluid‐based sheet metal forming in this paper, nitrogen is used as fluid working medium to satisfy the demand on high temperature resistance. Concerning the blank material used, formability of Mg‐containing aluminium alloys shows strong strain rate sensitivity at elevated temperatures. To figure out the optimal strain rates for this particular process, a control system for forming processes is developed within the scope of this paper. Additionally, FE‐simulations are carried out and adapted to the experiment, based on the generated process data. FE‐investigations include forming of domes (bulging) as well as shape‐defined forming, having the objective to increase formability in critical form elements by applying optimal strain rates. Here, a closed‐loop process control for gas‐pressure forming at elevated temperatures is to be developed in the next stages of the project.     

Water Capacity Model of Al2O3‐CaO‐MgO‐SiO2 Quaternary Slag System

The focus of the present work was to develop a water capacity model for the quaternary slag system Al₂O₃‐CaO‐MgO‐SiO₂. In the model, a silicate melt was considered to consist of two ion groupings, viz. cation grouping and oxygen ion. The water capacity of a melt is supposed to depend on the interactions between the cations in the presence of oxygen ions. These interactions were determined on the basis of the experimentally measured water solubility data. Only binary interactions were employed in the model. For the system CaO‐SiO₂, disagreement in the literature data was found. Since the interaction between Ca²⁺ and Si⁴⁺ would play an important role, experiments were carried out to determine the water capacities of some CaO‐SiO₂ slags. For this purpose a thermogravimetric method was employed. Iso‐lines of water capacities at constant MgO contents were predicted by the model and compared with the experimental data from literature. The model calculations agreed well with the experimental results.     

Influence of Manganese and Nickel on the α´ Martensite Transformation Temperatures of High Alloyed Cr‐Mn‐Ni Steels

The martensite start temperature (M_s), the martensite austenite re‐transformation start temperature (A_s) and the re‐transformation finish temperature (A_f) of six high alloyed Cr‐Mn‐Ni steels with varying Ni and Mn contents in the wrought and as‐cast state were studied. The aim of this investigation is the development of the relationships between the M_s, A_s, A_f, T₀ temperatures and the chemical composition of a new type of Cr‐Mn‐Ni steels. The investigations show that the M_s, A_s and A_f temperatures decrease with increasing nickel and manganese contents. The A_f temperature depends on the amount of martensite. Regression equations for the transformation temperatures are given. The experimental results are based on dilatometer tests and microstructure investigations.