Influence of Temperature and Time of Post-weld Heat Treatment on Stress Relief in an 800-mm-Thick Steel Weldment

Ferritic steel weldments are invariably post-weld heat treated for relieving the residual stresses. However, the long duration of post-weld heat treatment (PWHT) required for very thick weldments can adversely affect the mechanical properties and fracture toughness. Thus, there is a need to establish the relative importance of temperature and time of PWHT with respect to stress relief. Accordingly, in the present work, the phenomenon of stress relief (due to PWHT) in an 800-mm-thick steel weldment was investigated using finite element analysis and the results were validated against experimental measurements. An analytical study was also carried out to determine the relative influence of temperature and time of PWHT on stress relief. It was found that time of PWHT plays a more significant role in case of relatively lower PWHT temperatures. It was also found that, for a given value of Hollomon parameter, different combinations of PWHT temperature and time can be employed to achieve the same level of stress relief. A mathematical relationship has been established between Hollomon parameter and magnitude of residual stress after PWHT. It has been shown that residual stress is a monotonically decreasing function of the Hollomon parameter.     

Biosorption of chromium(VI) using Bacillus subtilis SS-1 isolated from soil samples of electroplating industry

Soils around the electroplating industry are often polluted with metals. The aim of the study was to assess Cr(VI) adsorption potential of chromium-resistant bacteria isolated from soil samples collected in and around electroplating industry, Coimbatore, India. A total of six morphologically different chromium-resistant bacteria were isolated from the soil samples and assayed for resistance to Cr(VI). Isolate designated SS-1 exhibited maximum resistance to Cr(VI) (600 mg/l) and subsequently identified as Bacillus subtilis based on the morphology, phenotypic characters, and partial 16S rDNA sequences. Batch experiments were carried out as a function of time, initial Cr(VI) concentration (100 mg/l), pH (2), and biosorbent dose (0.1 g/l). The maximum percentage of Cr(VI) removal was found to be 98.7 %. The experimental data showed a better fit with Langmuir model over Freundlich model throughout the range of initial concentrations. The kinetic models were examined with pseudo-first-order and pseudo-second-order kinetics. Fourier transform infrared spectroscopy studies confirmed the involvement of carboxyl and amide groups in Cr(VI) adsorption. Scanning electron microscopic studies revealed that nature of the bioadsorbent was altered after Cr(VI) adsorption. The results revealed that Cr(VI) was considerably adsorbed onto bacterial biomass, and it could be an economical method for the removal of Cr(VI) from aqueous solution.     

A new additive manufacturing process based on friction deposition

Additive manufacturing involves layer-by-layer fabrication of three-dimensional parts under computer control. The current study demonstrates a novel concept for additive manufacturing, in which material addition is achieved in solid-state through a process that can be termed as “friction deposition.” The present work reports preliminary results on the proposed new approach. Individual layers up to a thickness of 1 to 2 mm can be added up successively by friction deposition. A solid cylinder of 20 mm dia and 50 mm height was successfully produced with austenitic stainless steel AISI 304. Microstructural studies and tensile tests were conducted to ascertain the quality of bonding between the layers. The results show that the proposed approach is indeed quite amenable for additive manufacturing and can lead to a viable commercial process.     

Characterization of friction surfaced martensitic stainless steel (AISI 410) coatings

Friction surfacing is a candidate process for depositing corrosion and wear resistant coatings. Being a solid-state process, it offers several advantages over conventional fusion welding based surfacing process. In the current work, martensitic stainless steel AISI 410 was friction surfaced over mild steel substrates. Coating microstructures were characterized using light microscopy, scanning electron microscopy and Xray diffraction. Coatings in as-deposited condition exhibited a fully martensitic microstructure and were found to be quite hard (with an average hardness of 460 HV). Bend and shear tests indicated excellent coating/substrate bonding. Overall, the current work shows that martensitic stainless steel AISI 410 can be satisfactorily friction surfaced on mild steel.     

Characterization and Low Temperature Study of Iron Telluride Thin Films Upon Ageing and Oxygen Ion Irradiation

The occurrence of superconductivity in iron telluride thin films has been observed upon ageing. The superconducting transition is found to be very robust under an application of magnetic fields up to 10 T. Infrared and Raman spectroscopic characterization of the aged films reveal the formation of Fe_1+δTeO _x upon ageing. As an alternative method of introducing oxygen in FeTe thin film, oxygen ion irradiation has also been carried out It is found that the irradiated film becomes increasingly disordered and ultimately transforms to an amorphous phase upon increasing the irradiation dose. Investigation of electrical resistivity and optical reflectivity of the irradiated FeTe films indicates an interesting possibility of an ion irradiationinduced phase change memory material in analogy to the phase change characteristics of laserirradiated FeTe films.     

Friction Buttering: A New Technique for Dissimilar Welding

This work offers a fresh perspective on buttering, a technique often considered for fusion welding of dissimilar metals. For the first time, buttering was attempted in solid state using friction deposition. Using this new “friction buttering” technique, fusion welding of two different dissimilar metal pairs (austenitic stainless steel/borated stainless steel and Al-Cu-Mg/Al-Zn-Mg-Cu) was successfully demonstrated. The results show that friction buttering can simplify a tough dissimilar welding problem into a routine fusion welding task.     

Microstructure and Mechanical Properties of Friction Stir Lap Welded Aluminum Alloy AA2014

Friction stir lap welds were produced in 3 mm thick Alclad sheets of Al alloy 2014-T4 using two different tools (with triangular and threaded taper cylindrical pins). The effects of tool geometry on weld microstructure, lap-shear performance and failure mode were investigated. The pin profile was found to significantly influence the hook geometry, which in turn strongly influenced the joint strength and the failure mode. Welds produced in alloy 2014-T4 Alclad sheets by using triangular and threaded taper cylindrical tools exhibited an average lap-shear failure load of 16.5 and 19.5 kN, respectively, while the average failure load for standard riveted joints was only 3.4 kN. Welds produced in alloy 2014-T6 Alclad sheets and in alloy 2014-T4 bare sheets (i.e., no Alclad) were comparatively evaluated with those produced in alloy 2014-T4 Alclad sheets. While the welds made (with threaded taper cylindrical tool) in T6 and T4 conditions showed very similar lap-shear failure loads, the joint efficiency of the welds made in T6 condition (43%) was considerably lower (because of the higher base material strength) than those made in T4 condition (51%). The Alclad layers were found to present no special problems in friction stir lap welding. Welds made with triangular tool in alloy 2014-T4 Alclad and bare sheets showed very similar lap-shear failure loads. The present work provides some useful insights into the use of friction stir welding for joining Al alloys in lap configuration.     

Microstructural evolution during friction surfacing of tool steel H13

Coatings of AISI H13 tool steel were made on low carbon steel by friction surfacing. Detailed microstructural studies and microhardness tests were carried out on the coatings. Studies revealed defect-free coatings and sound metallurgical bonding between the coating and the substrate. In addition, mechanical interlocking on a very fine scale was observed to occur between the coating and the substrate. Coatings exhibited martensitic microstructure with fine grain size and with no carbide particles. Coatings in as-deposited condition showed very high hardness (58 HRC) compared to the mechtrode material in annealed condition (20 HRC). Based on these findings, microstructural evolution during friction surfacing of H13 tool steel is discussed. The current work shows that friction surfaced tool steel coatings are suitable for use in as-deposited condition. Further improvements in coating microstructure and properties are possible with appropriate post-surfacing heat treatment.     

Bond formation and fiber embedment during ultrasonic consolidation

The quality of ultrasonically consolidated parts critically depends on the bond quality between individual metal foils. This necessitates a detailed understanding of interface microstructures and ultrasonic bond formation mechanisms. In this work, the interface microstructures of a variety of ultrasonically consolidated similar and dissimilar metal samples were investigated. Samples with embedded SiC fibers were also investigated. Based on detailed microstructural studies, the mechanisms of foil bonding and fiber embedment in ultrasonic consolidation have been discussed.