Effect of fluctuation and modification on microstructure and impact toughness of 20 wt.% Cr hypereutectic white cast iron. Einfluss durch Partikelzugaben und Modifikationen auf die Mikrostruktur und die Kerbschlagzähigkeit von übereutektischem weißen Gusseisen mit 20 Gew.‐% Cr

In the present study, Fe‐Cr‐C hypereutectic high chromium white cast iron were prepared from industry‐grade materials and subjected to the treatment of modification using Fe‐Si‐RE alloy, aluminum and a self‐made intermediate alloy, fluctuation (ferroalloy powder), and the combination of the fluctuation and the modification respectively. The structures of the treated alloy were investigated by means of the optical microscopy (OM). The impact toughness of the specimens was also examined. The fractographs of the samples were examined by scanning electron microscopy (SEM). The results showed that, with the addition of fluctuation or modifying agents, the primary carbides were refined and the impact toughness of the alloys was improved, especially with the combination of them.     

Beanspruchungsgerechte Formgebung von Umformwerkzeugen durch formgebendes Plasma‐Pulver‐Auftragschweißen

Load adjusted shaping of forming tools using build‐up PTA welding For the improvement of the mechanical‐technological properties of the forming tools (in particular medium sized component‐geometries) the build‐up plasma deposition‐welding was established as a manufacturing process. It could be proven that the thermo‐mechanical characteristics of these tools are improved by using of cobalt and nickel basis alloys. With the embedding of carbides in the cobalt basis matrix the most endangered surface regions of the tools may to be better protected and the life times significantly increase compared with the up to now with conventional materials manufactured components. With manufactured and tested segments of a transverse‐rolling tool it was possible to validate whether the won knowledge is transferable into the practice.     

Grundlagen der Werkstoffauswahl bei der Bekämpfung des Strahlverschleißes

Fundamentals of Material Selection in the Conditions of Erosive Wear Problems of proper selection of materials for parts subjected to wear by a stream of abrasive particles are discussed. Considering the main laws governing such kind of wear, the author concludes that target material selection in the case of erosion, like in any other case of abrasive wear, will depend on the ratio of abrasive grain hardness to material hardness. Special attention should be given to hard components in the abrasive. It has been established that a 10-15% content of quartz particles in the abrasive is enough to cause an abrupt fall in the wear resistance of chilled steels, white iron and hard surfacing alloys, thus making their use questionable. Finegrained WC-Co-type sintered carbides have shown the highest wear resistance in such conditions. The conclusions drawn in this paper are borne cut by a considerable body of experimental data.     

Precipitates change of ferritic‐martensitic 11 % chromium steel under short‐term creep

A ferritic‐martensitic (FM) 11 % chromium steel with final heat treatment was subjected to a short‐term creep test at a stress of 150 MPa and 600 °C for 1100 h in order to study the change of precipitates in the steel during the creep test. Except for Nb‐rich metall carbides (MC, M₂₃C₆) and Laves phases, Fe‐W‐Cr‐rich M₆C (based on Fe₃W₃C) carbides forming during the creep test were also identified in the crept steel by electron diffraction and x‐ray diffraction in combination with energy dispersive x‐ray analysis of extraction carbon replicas. The identified M₆C carbides have a fcc crystal structure, a metallic element composition of approximately 44Fe, 32 W, and 20Cr in atomic %, and large sizes ranging from 100 nm to 300 nm in diameter. The M₆C carbides are a dominant phase in the crept steel. M₆X precipitates are generally not easy to form during high temperature creep, even if it is a long‐term creep, in ferritic‐martensitic 9–12 % chromium steels with a final heat treatment. The present work provides the evidence for the M₆C carbides forming during short‐term creep in ferritic‐martensitic high chromium steels. The formation of the M₆C carbides was discussed.     

Strangpressen von verschleißbeständigen Fe‐Basis MMC

Hot extrusion of wear resistant Fe‐base metal matrix composites (MMC) Increasing demands on technical surfaces, i.e. thermal load, corrosion or wear, often prompt the development of tailored materials or coatings. In highly abrasive environments the progress in powder metallurgy has lead to the production of highly wear‐resistant materials based on metal‐matrix composites (MMC). Such materials are produced from a metal matrix (MM) based on Fe, Ni or Co and additional hard phases (HP), such as carbides, nitrides, borides or oxides. Moreover, powder metallurgical techniques can be used to adapt the particle size, the distribution and the content of the hard phases to the wear system on a large scale. HIP cladding is an established method of producing such MMC, but due to its near net shape capsule technique it is quite expensive. Because of this reason hot direct extrusion of capsules filled with powder blends was researched in a DFG‐Project as a method of producing long cylindrical products. Aiming at a high abrasive wear resistance, powder blends of hardenable steels with additions of fused tungsten carbide (WSC) or titanium carbides (TiC) were used. The extruded MMC were investigated with respect to their densification and microstructure, their bending strength and their wear resistance.     

High‐Strength Nanotwinned Al Alloys with 9R Phase

Light‐weight aluminum (Al) alloys have widespread applications. However, most Al alloys have inherently low mechanical strength. Nanotwins can induce high strength and ductility in metallic materials. Yet, introducing high‐density growth twins into Al remains difficult due to its ultrahigh stacking‐fault energy. In this study, it is shown that incorporating merely several atomic percent of Fe solutes into Al enables the formation of nanotwinned (nt) columnar grains with high‐density 9R phase in Al(Fe) solid solutions. The nt Al–Fe alloy coatings reach a maximum hardness of ≈5.5 GPa, one of the strongest binary Al alloys ever created. In situ uniaxial compressions show that the nt Al–Fe alloys populated with 9R phase have flow stress exceeding 1.5 GPa, comparable to high‐strength steels. Molecular dynamics simulations reveal that high strength and hardening ability of Al–Fe alloys arise mainly from the high‐density 9R phase and nanoscale grain sizes.     

Creep resistance of Fe–Ni–Cr heat resistant alloys for reformer tube applications

Relations between microstructure, phase transformations and creep resistance of austenitic Fe–Ni–Cr alloys are investigated. As-cast alloys with different silicon contents and an ex-service tube are submitted to laboratory agings to trigger specific phase transformations, and subsequently creep-tested at 950°C under stresses of 24–48?MPa. As-cast microstructures contain interdendritic chromium-rich M₇C₃ carbides with niobium-rich MC carbides. After aging at 950°C, primary M₇C₃ carbides transform into chromium-rich M₂₃C₆ carbides, associated to a loss in creep strength. The G phase present in the ex-service alloy is reversed into MC carbides by a heat treatment at 1100°C, associated to a slight decrease in creep resistance. Besides, the addition of silicon is highly detrimental to creep strength. Results can be used for alloy design.     

Feinst‐ und Ultrafeinkornhartmetalle: Tendenzen und Anwendungen

Submicron‐ and Ultrafine‐Grained Hardmetals: Tendencies and Applications Submicron‐ and ultrafine‐grained hardmetals are WC‐Co alloys with average WC grain diameters of ≤ 0.8 μm and ≤ 0.5 μm, respectively. The variation of grain size towards finer‐grain carbides has the advantage that both hardness and transverse rupture strength increase as grain size decreases. This combination of properties, which contrasts with the well‐known counter‐running relationship between hardness and transverse rupture strength found in conventional hardmetals, opens up a wide area of application for submicron and ultrafine grained hardmetals. Since their introduction, these hardmetals have firmly established themselves in metalcutting operations, predominantly in the areas of milling and drilling and to a lesser extent in turning and broaching. Submicron‐ and ultrafine‐grained hardmetals, particularly in combination with suitable coatings, are gaining increasingly in importance in the machining of highly heat‐treated and abrasive work materials.     

Fe-C-Cr合金定向凝固组织

对经定向凝固的共晶 Fe—2.94％C—29.1％Cr 合金及过共晶 Fe—3.12％C—35.9％Cr、Fe—2.80％C—33.1％Cr 合金的凝固组织作了研究。上述三种合金中的初晶及共晶碳化物均为(Fe,Cr)_7C_3它们都以小面状析出,其中初晶在与凝固方向垂直的截面上为六角形块。初晶碳化物在定向凝固时以六角形状进行包抄式的凝固,然后再从六角形壳向内凝固,最终生成完整六角形。随着凝固速度变小,初晶(Fe,Cr)_7C_3的截面尺寸及间距增大,且从实心的六角形棒变成空心的六角形棒。过共晶合金的液固两相区长度约为1.5mm。共晶合金凝固时,碳化物的形貌为不规则多边形棒,且在凝固速度大时,组织细小。上述三种合金,当凝固速度 R>2m/sec 时,液固界面将变得凹凸不平。     

Key Factors Achieving Large Recovery Strains in Polycrystalline Fe–Mn–Si‐Based Shape Memory Alloys: A Review

Fe–Mn–Si‐based shape memory alloys are the most favorable for large‐scale applications owing to low cost, good workability, good machinability, and good weldability. However, polycrystalline Fe–Mn–Si‐based shape memory alloys have low recovery strains of only 2–3% after solution treatment, although monocrystalline ones reach a large recovery strain of ≈9%. This review gives an overview of the improvement of recovery strains for polycrystalline Fe–Mn–Si‐based shape memory alloys. It is proposed that two fundamental aspects, that is, composition design and microstructure design, shall be satisfied for obtaining large recovery strains of above 6%. Alloying compositions determining the ceiling of recovery strains shall follow three guidelines: (i) Si content is 5–6 wt%; (ii) 20 wt% ≤ Mn ≤ 32 wt%; (iii) addition of elements strongly strengthening austenite matrix. Microstructure design includes coarsening austenitic grains and reducing twin boundaries as far as possible together with introducing a high density of stacking faults and second phases of strengthening austenite.

     

Investigation of wear resistance and microstructure of a newly developed chromium and vanadium containing iron‐based hardfacing alloy

Plasma transferred arc (PTA) welded Ni and Co‐based alloys have gained high acceptance in many industrial applications for the wear protection of components. Recently, the cost of nickel and cobalt is rising drastically. This paper presents the development of a cost‐effective high chromium and vanadium containing iron‐based hardfacing alloy with high hardness and wear resistance. The welding processing of the alloy is carried out by PTA welding of atomized powders. Investigations on powder production as well as on weldability are presented. The coatings are metallographically studied by optical microscopy, SEM, EDX and micro‐hardness measurements. The wear resistance properties of the coatings are examined using pin on disk, dry sand rubber wheel and Miller testing, the corrosion properties are determined by immersion corrosion tests. The newly developed iron‐based alloy has nearly the same wear resistance as Ni‐based alloys with fused tungsten carbides at a higher level of corrosion resistance and much lower cost.     

Microstructural Influences on Young's Modulus for Fe‐V‐C and Fe‐Mo‐C Alloys

The Young modulus E exhibits a coefficient in the Hooke's law. It is influenced by external parameters as temperature, forming forces, forming velocity, delay time, static or dynamic straining, stress state in tension or compression, and by internal, material‐related parameters as chemical composition, textures, lattice defect contents and results of occurred diffusion processes. Iron‐base alloys and steels – as here on single‐phase to three‐phase Fe‐V‐C and Fe‐Mo‐C alloys – showed the dependence of E on the microstructure (grain size and phase arrangement). The influence of annealing temperature yields grain growth with corresponding grain sizes. From this an equilibrium ratio of E to a distinct grain size D̄ after heat treatment in the γ‐range of iron alloys, dependent on the concentration of alloying elements, is adjusted. Besides the equilibrium E/−ln D̄ also non‐equilibrium states occur, and therefore the possibilities exist to reduce the Young modulus till to a concentration‐dependent minimum (equilibrium), and to raise it into the non‐equilibrium stages. The influences of texture and remaining dislocation content are small. With the specific variation of E it is possible to improve the stiffness of thin steel sheet materials, preferred this is interesting for the car industry.     

Drehen und Fräsen pulvermetallurgischer Hartlegierungen für warmgehende Werkzeuge

Turning and Milling of Powder Metallurgical Hard Alloys for Tools in Hot Working Applications Hard metals are high wear resistant materials. The microstructure of these composites consists of hard phases which are embedded in a metal matrix. The high hardness and the high content of the hard phases lead to a difficult machining of these materials. The present study investigates the turning and milling of D3 cold work steel (X210 Cr 12) and the powder metallurgical Fe‐based alloys ASP60 and ASP23 + WC/W₂C. The cutting tool materials were polycrystalline cubic boron nitrides (CBN) and ceramic inserts. The machining process could be judged by means of tool wear and machining quality (surface roughness and changes in the surface near zone). The investigations illustrate that the machinability of the different hard metals depends on the cutting speed and the cutting tool material.     

Neuentwicklungen für den Verschleiß‐ und Korrosionsschutz beim Plasma‐Pulver‐Auftragschweißen

New developments for wear an corrosion protection by weld surfacing with plasma transmitted arc process Highly wear‐resistant claddings which contain carbides can be applied by weld surfacing with the PTA process. The use of vanadium carbide prevents undesirable reactions with the matrix material. Thus, highly corrosion‐resistant Fe‐based claddings can be produced for applications in the food and marine industries, and Ni‐based claddings can be applied to components exposed to inorganic acid attack. A combined test is applied for determining the relative effect of corrosion under combined exposure to abrasive wear and corrosion and indicates the primacy of abrasive wear for behaviour in operation.     

Influence of cryogenic treatment on the metallurgy of ferrous alloys: A review

The research area “Cryogenic Treatment of Materials” has been the subject of a multitude of research studies and therefore needs a proper review article to highlight the present state of understanding and to define the future research direction. Though reviews on cryogenic processing of tool steels are available, there has not been a review that attempts to systematically discourse the effect of cryogenic treatment on the metallurgy of various ferrous alloys. While previous reviews address transformation of retained austenite and the formation of fine precipitated carbides as the major phenomena of cryogenic treatment, developments such as the refinement of pearlite matrix, formation of fine martensite, and enhancement of properties in low carbon steel and cast iron are discussed in detail in this article. In addition, the influence of individual treatment parameters, their sequence, and the effect of room temperature stabilization on the metallurgical changes are extensively addressed. Moreover, many of the contradicting observations/conclusions such as detwinning of martensite and dissolution of secondary carbides during cryogenic treatment are highlighted for further clarification. Finally, applicability of cryogenic treatment for a range of ferrous alloys is presented with an emphasis on scope for future research.     

Effect of boron concentration on solidification structure and hardness of Fe–B–C wear‐resistant alloy

Fe–B–C wear‐resistant alloy, as a new type of iron‐based wear‐resistant materials, has drawn extensive attention of the researchers in materials at home and abroad. The boron concentration plays an important role in the microstructure and mechanical properties of Fe–B–C wear‐resistant alloy. In this paper, the solidification microstructure, volume fraction of eutectic, macro and micro hardness of Fe–B–C alloy are researched. The samples are measured by optical microscopy (OM), scanning electron microscopy (SEM), Rockwell‐hardness tester, Vickers‐hardness tester. Image processing software such as image‐pro and photoshop are used. The content of boron in experiment alloys are 1.0%, 1.5%, 2.0%, 2.5% and 3.0% respectively. As a result, the solidification microstructure of as‐cast Fe–B–C mainly consists of metallic matrix and eutectic structure. The eutectic phase is continuous netlike distribution along the grain boundary. As boron concentration increases, the volume fraction of borocarbide increases in the matrix, and the size is larger. The hardness of Fe–B–C also has a tendency to rise with the increase of boron concentration.     

Gefüge und magnetische Eigenschaften von Chromgusseisen für Mahlkugeln

Microstructure and magnetic properties of white cast irons for grinding balls Many types of cast ferrous alloys are used for applications in the grinding, crushing, mineral‐handling and earthmoving industries. The finish grinding process for cement materials uses ball mills with differently sized grinding balls. This work deals with grinding balls of high chromium white cast irons with various chemical composition. Using certains thermal treatments, the influence of parameters of microstructure on abrasive and impact wear resistance has been studied. A special test system has been adapted for the assessment of the impact properties of these alloys. Examination of the carbides were performed using a transmission electron microscope. Additional microstructural examinations were made using the Scanning electron microscope. For a nondestructive inspection of the grinding balls, the possibilities of using the magnetic characteristics for determining the structural state and mechanical properties of white cast irons are analyzed. The results showed that the hardness and the dynamic fracture toughness are important for the combined impact‐abrasion resistance. It has been established that the microstructure has a decisive influence on the magnetical properties of white cast irons.     

Elucidation of Active Sites on S,N Codoped Carbon Cubes Embedding Co–Fe Carbides toward Reversible Oxygen Conversion in High‐Performance Zinc–Air Batteries

The development of high‐performance but low‐cost catalysts for the electrochemical oxygen reduction reaction (ORR) and oxygen evolution reaction (OER) is of central importance for realizing the prevailing application of metal–air batteries. Herein a facile route is devised to synthesize S, N codoped carbon cubes embedding Co–Fe carbides by pyrolyzing the Co–Fe Prussian blue analogues (PBA) coated with methionine. Via the strong metal–sulfur interaction, the methionine coating provides a robust sheath to restrain the cubic morphology of PBA upon pyrolysis, which is proved highly beneficial for promoting the specific surface area and active sites exposure, leading to remarkable bifunctionality of ORR and OER comparable to the benchmarks of Pt/C and RuO₂. Further elaborative investigations on the activity origin and postelectrolytic composition unravel that for ORR the high activity is mainly contributed by the S, N codoped carbon shell with the inactive carbide phase converting into carbonate hydroxides. For OER, the embedded Co–Fe carbides transform in situ into layered (hydr)oxides, serving as the actual active sites for promoting water oxidation. Zn–air batteries employing the developed hollow structure as the air cathode catalyst demonstrate superb rechargeability, energy efficiency, as well as portability.     

As-cast microstructures and behavior at high temperature of chromium-rich cobalt-based alloys containing hafnium carbides

Hafnium is often used to improve the high temperature oxidation resistance of superalloys but not to form carbides for strengthen them against creep. In this work hafnium was added in cobalt-based alloys for verifying that HfC can be obtained in cobalt-based alloys and for characterizing their behavior at a very temperature. Three Co–25Cr–0.25 and 0.50C alloys containing 3.7 and 7.4 Hf to promote HfC carbides, and four Co–25Cr– 0 to 1C alloys for comparison (all contents in wt.%), were cast and exposed at 1200 °C for 50 h in synthetic air. The HfC carbides formed instead chromium carbides during solidification, in eutectic with matrix and as dispersed compact particles. During the stage at 1200 °C the HfC carbides did not significantly evolve, even near the oxidation front despite oxidation early become very fast and generalized. At the same time the chromium carbides present in the Co–Cr–C alloys totally disappeared in the same conditions. Such HfC-alloys potentially bring efficient and sustainable mechanical strengthening at high temperature, but their hot oxidation resistance must be significantly improved.