Mikrostrukturelle Veränderungen von Magnesium‐Druckgusslegierungen nach langzeitiger thermischer Beanspruchung

Microstructural Changes of Pressure Die Cast Magnesium Alloys after Long‐Term Thermic Loading The expansion of the application of pressure die cast magnesium alloys for automobiles requires the development of new alloys and the comprehensive assessment of available alloys on aggravated conditions, too. Such conditions are also given at higher temperatures, which can cause the creep of the material and lead to the component failure. Because the microstructural stability decisively depends on the thermic loading, this paper deals with the change of the microstructure and the hardness of the alloys AZ91, AM50 and AE42 after a long‐term annealing at 150 °C and 200 °C in comparison to the pressure die as‐cast condition. The results reveal clear differences of the microstructural stability of the alloys AZ91 and AM50 on the one hand and the alloy AE42 on the other hand. Due to the long‐term annealing at 150 °C the alloys AZ91 and AM50 show chiefly an intense precipitation of Mg₁₇Al₁₂ from the Al‐rich eutectic α‐phase. Furthermore at 200 °C, it is observed the coagulation and coarsening of these precipitates, too. The last appearances are connected with a weakening of the material. Regarding the alloy AE42, the changes of the precipitation state are not so intensely and do yet not lead to a microstructural weakening.     

Effect of annealing on precipitation, microstructural stability, and mechanical properties of cryorolled Al 6063 alloy

The effect of annealing on precipitation, microstructural stability, and mechanical properties of cryorolled Al 6063 alloy has been investigated in the present work employing hardness measurements, tensile test, XRD, DSC, EBSD, and TEM. The solution-treated bulk Al 6063 alloy was subjected to cryorolling to produce ultrafine grain structures and subsequently annealing treatment to investigate its thermal stability. The CR Al 6063 alloys with ultrafine-grained microstructure are thermally stable up to 250 °C as observed in the present work. Within the range of 150–225 °C, the size of small precipitate particles is <1 μm. These small precipitate particles pin the grain boundaries due to Zener drag effect, due to which the grain growth is retarded. The hardness and tensile strength of the cryorolled Al 6063 alloys have decreased upon subjecting it to annealing treatment (150–250 °C).     

Low‐temperature annealing and graphitizing of white‐solidified low‐alloy cast irons

Hypoeutectic iron‐carbon and iron‐carbon‐silicon model alloys as well as conventional cast irons GJL‐250_mod and EN‐GJS‐600‐3 have been produced and processed by different solidification techniques, i. e. mold casting, electron beam surface remelting and melt spinning. The white‐solidified alloys exhibit different degrees of microstructural refinement indicated by a secondary dendrite arm spacing of 0.3 μm–12 μm. The effects of microstructural refinement and silicon content on the hardness as well as on coarsening of cementite and graphitizing at temperatures of 540 °C to 670 °C have been investigated. The hardness of the as‐solidified alloys increases with decreasing secondary dendrite arm spacing and increasing silicon content. High silicon content effectively retards coarsening of pearlitic cementite, and thus is beneficial to retain the hardness at small thermal load. On the downside, high degree of microstructural refinement and high silicon content promote and accelerate graphitizing at temperatures > 600 °C. The results are discussed in terms of the applicability of a recently developed two‐step surface treatment for cast irons, i. e. electron beam remelting followed by nitriding.     

Faser‐ und drahtverstärkte Kupferlegierungen als Wärmesenke für Fusionsreaktoren

Fibre and wire reinforced copper alloys as heat sinks for fusion reactors The CuCr1Zr alloy is used in existing experimental fusion reactors and planned to be used as a heat sink in ITER because of his mechanical properties and thermal conductivity (at 20 °C 310–330 W/m/K). Because of aging this dispersion‐hardened alloy is limited in use to temperatures below 450 °C. A possibility to increase the service temperature (the aim is 550 °C) is to reinforce the alloy with SiC‐fibres or W‐wires. With the aid of SiC (SCS‐6) fibres and W‐wires (diameter ～150 μm for both) coated with the CuCr1Zr‐alloy, Cu‐MMCs are produced and their properties (tensile strength, thermal conductivity, fibre/matrix interface properties) are determined. Processing (Hot Isostatic Pressing) causes the alloy to age, making an additional heat treatment necessary in order to optimize the properties. The tensile strength of the different Cu‐MMCs was determined as a function of the volume content of the reinforcements. Tensile strength rises with increasing volume fraction of fibres (or wires) and reaches e.g. 1000 MPa for a SiC‐fibre volume fraction of 24 % or a W‐wire volume fraction of 27 %. Measurements of the thermal conductivity, performed by laser flash, show that the thermal conductivity is reduced with increasing fibre volume fraction (e.g. 200 W/m/K for a fibre volume fraction of 30 %). The W‐wire reinforced CuCr1Zr alloy has been selected because of its better thermal conductivity and interfacial properties to estimate the potential of this Cu‐MMC in a first design study of heat sinks on the basis of different divertor construction types.     

Effect of Initial Annealing Temperature on Microstructural Development and Microhardness in High‐Purity Copper Processed by High‐Pressure Torsion

The effect of the initial annealing temperature on the evolution of microstructure and microhardness in high purity OFHC Cu is investigated after processing by HPT. Disks of Cu are annealed for 1 h at two different annealing temperatures, 400 and 800 °C, and then processed by HPT at room temperature under a pressure of 6.0 GPa for 1/4, 1/2, 1, 5, and 10 turns. Samples are stored for 6 months after HPT processing to examine the self‐annealing effects. Electron backscattered diffraction (EBSD) measurements are recorded for each disk at three positions: center, mid‐radius, and near edge. Microhardness measurements are also recorded along the diameters of each disk. Both alloys show rapid hardening and then strain softening in the very early stages of straining due to self‐annealing with a clear delay in the onset of softening in the alloy initially annealed at 800 °C. This delay is due to the relatively larger initial grain size compared to the alloy initially annealed at 400 °C. The final microstructures consist of homogeneous fine grains having average sizes of ≈0.28 and ≈0.34 µm for the alloys initially annealed at 400 and 800 °C, respectively. A new model is proposed to describe the behavior of the hardness evolution by HPT in high purity OFHC Cu.     

The influence of post‐heat treatments on the tensile strength and surface hardness of selectively laser‐melted AlSi10Mg

To improve the mechanical properties of cast aluminium alloys several post‐heat treatments are known. However, these treatments cannot directly be transposed to additively via selective laser melting manufactured aluminium alloys, e. g., aluminium‐silicon‐magnesium (AlSi10Mg). Therefore, this study aims to determine suitable post‐heat treatments to optimise the mechanical properties of SLM‐built AlSi10Mg specimen. The influence of various post‐heat treatment conditions on the material characteristics was examined through hardness and tensile tests. The findings indicate that the Vickers hardness and ultimate tensile strength could not be improved via secondary precipitation hardening, whereas the fracture elongation shows a value which is distinctly higher than the values of a comparable cast alloy. Solution annealing at 525 °C reduces the hardness and the ultimate tensile strength by about 40 % and increases the fracture elongation three times. A subsequent precipitation hardening allows recovery of 80 % of the as‐built hardness, and 90 % of the previous ultimate tensile strength combined with maintaining an improved fracture elongation of about 35 % compared to the respective as‐fabricated condition.     

Comparison of superplastic forming abilities of as‐cast AZ91 magnesium alloy prepared by twin roll casting and WE43 magnesium alloy

This paper describes and compares the superplastic behaviour and microstructural evolution of twin roll cast AZ91 and WE43 rolled sheet alloys. Tests were carried out in uniaxial tension on both alloys across a range of temperatures (300 °C–525 °C) and strain rates (1?10^‐4 s^‐1–1?10^‐1 s^‐1). In the case of WE43 gas bulge testing was employed at 400 °C and 0.6 MPa to offer a better analogy to superplastic forming than uniaxial tensile testing. Elongations of over 400 % were observed within WE43 when tested at 450 °C and 1?10^‐3 s^‐1 strain rate, and over 200 % within AZ91 when tested at 350 °C and 1?10^‐3 s^‐1 strain rate. A peak cone height of 41 mm was achieved with WE43 at a temperature of 400 °C and pressure of 0.6 MPa. Electron back scattered detection technique was employed to analyse the microstructural evolution of the two alloys during the forming process. Both WE43 and AZ91 were observed to undergo dynamic recrystallization during elevated temperature tensile testing and failed at low strain rates mainly by means of coalescence of cavitation, in the case of AZ91 at high strain rates cracking of Al₁₂Mg₁₇ intermetallic particles was the dominating failure mechanism. Both alloys were seen to achieve good levels of superplastic ductility over 200 % elongation, which would be industrially useful in niche vehicle and aerospace manufacturing.     

Impact Toughness of Ultrafine‐Grained Commercially Pure Titanium for Medical Application

This study aims at achieving the best combination of strength, ductility, and impact toughness in ultrafine‐grained (UFG) Ti Grade 4 produced by equal‐channel angular pressing via Conform scheme (ECAP‐C) with subsequent cold drawing. UFG structures with various parameters (e.g., size and shape of grains, dislocation density, conditions of boundaries) are formed by varying the treatment procedures (deformation temperature and speed at drawing, annealing temperature). The tensile and impact toughness tests were performed on samples with a V‐shaped notch and different structures of commercially pure Ti Grade 4 in the coarse‐grained and UFG states. The results demonstrated that grain refinement, higher dislocation density, and their elongated shape were obtained as a result of drawing at 200 °С, which led to a decrease in both the uniform elongation at tension and the impact toughness of Ti Grade 4. Short‐term annealing at 400–450 °C could improve the impact toughness of UFG Ti with a non‐significant decrease in strength. This short‐term annealing contributes to the dislocation density decrease without considerable grain growth as a result of the recovery and redistribution of dislocations. The dependence of impact toughness on the strain hardening ability of UFG Ti was discussed.

     

Werkstoffverhalten unter zügiger elastischer Beanspruchung

Material properties by continuous elastic straining Within the scope of a common research project of the steel and automotive industry, 20 sheet steels have been investigated to obtain input data for FE‐analysis. In detail, characteristical elastic, plastic and fatique values were determined by several testing institutes for a period of 3 years. Knowledge of dependency of Young’s modulus from temperature and orientation is important for spring back at the press shop and stiffness of parts for automotive. Young’s modulus was determined by tensile tests in delivered state, after prestraining, heat treatment at room temperature and –40 °C and 100 °C. Young’s modulus is dependent from the orientation to rolling direction and can be classified in groups. Young’s modulus of ferritic steels is decreased about 10 % by prestraining of 2 % but recovered after annealing at 170 °C. Temperature dependency well known from non destructive tests are confirmed.     

Experimental characterisation of a CuAg alloy for thermo‐mechanical applications. Part 2: Design strain‐life curves estimated via statistical analysis

Strain‐life fatigue data on copper alloys, especially type CuAg, are seldom available in the literature. This work fills this gap by estimating the strain‐life curves of a CuAg alloy used for thermo‐mechanical applications, from isothermal low‐cycle fatigue tests at 3 temperatures (room temperature, 250°C, 300°C). Regression analysis is used to estimate the median fatigue curves at 50% survival probability. The comparison of median curves with the Universal Slopes Equation model, calibrated on monotonic tensile properties, shows a fairly good agreement. Design strain‐life curves with a lower failure probability and given confidence are estimated by several approximate statistical methods (“Equivalent Prediction Interval,” univariate tolerance interval, Owen's tolerance interval for regression). When higher survival probabilities are considered, the results show a marked decrease in the allowable design strain at a prescribed fatigue life. The suggested procedure thus improves the durability analysis of components loaded thermo‐mechanically.     

Study of high temperature mechanical behavior of the thermally oxidized Ti‐6Al‐4V alloy

The influence of oxidation of a Ti‐6Al‐4V alloy at 800 °C on its tensile properties at 600 °C has been studied. Specimens of this alloy were oxidized at 800 °C for 0.5, 1, 5, 10, 20 and 40 h. Tensile tests at 600 °C were carried out and the fracture surfaces were also examined. Oxidation of the specimens resulted in the formation of an oxide layer that spalled and another oxide layer that adhered to the substrate. Oxide formation increased with increase in duration of oxidation. In this investigation, density curves of the oxide layer as a function of duration of oxidation at 800 °C were used to identify a parabolic oxide growth law. The results of this study revealed coherence between the experimental data and calculations based on the Pilling‐Bedworth law. The mechanical strength of the Ti‐6Al‐4V alloy did not vary significantly with oxidation, but reduction in cross sectional area with increase in oxide layer thickness, as well as the slope of the stress‐strain curve decreased beyond the ultimate tensile strength. Fracture of the tensile tested specimens was predominantly ductile with microcavities. At certain regions of the oxide layer, brittle fracture with radial cracks was observed indicating intergranular fracture.     

The influence of defect and temperature on the fatigue behaviours of Al‐Si‐Cu‐Mg‐Ni alloy

High‐cycle fatigue (HCF) properties of two Al‐Si‐Cu‐Mg‐Ni alloys with different defect sizes named as alloys A (smaller ones) and B (bigger ones) were investigated at 350°C and 425°C, respectively. The results indicate that fatigue strengths of both alloys decrease as the temperature increases. Fatigue cracks originated from pores and oxide films at both temperatures. They propagated preferentially through cracked matrix at 350°C and debonded interface and grain boundary at 425°C. Alloy A exhibits higher fatigue life and fatigue strength than alloy B at 350°C due to its smaller pore sizes. However, it has slightly worse fatigue properties than alloy B at 425°C because the fatigue crack initiation is controlled by oxide film at this temperature and is not affected by its size. This indicates that there is a transition of predominant initiation site from pores to oxide films when the temperature increases. The fatigue strength estimated through defect size is consistent with the experimental results at 350°C, while unsuitable at 425°C.     

Aluminium based metal matrix composites for improved elevated temperature performance

Abstract

The thermal performance of six commercially available particulate reinforced metal matrix composites (MMCs) has been investigated, including the effects of continuous thermal exposure and thermal cycling on ambient and elevated temperature tensile properties, toughness, and fatigue. Additionally, accelerated creep tests and thermal cycling tests under load were carried out. Some aspects of the performance of these MMCs were very promising, particularly strength up to 200°C and good retained strength after extended exposure at up to 260°C, while resistance to creep and thermal cycling under load was generally not as good. The results were used as a basisfor selected tests on some development MMCs aimed at improvements to particular aspects of thermal performance. The use of 2618 type aluminium alloys as a matrix for powder route SiC reinforced MMCs, in place of 2124, had no significant effect, but initial results suggest that the use of ultrafine oxides as reinforcement in aluminium alloys may improve strength above 200°C.     

Stability of Microstructure of Ultrafine‐Grained Copper Under Fatigue and Thermal Exposition

Abstract: Effect of cyclic loading and thermal exposition on microstructure of bulk ultrafine‐grained Cu prepared by equal channel angular pressing was experimentally investigated by means of electron backscattering diffraction and by transmission electron microscopy. Stability of the microstructure under stress‐controlled cyclic loading with a tensile mean stress of 200 MPa was shown to be high. Neither dynamic grain coarsening nor development of bimodal microstructure was observed. However, annealing at 250 °C for 30 min resulted in formation of bimodal microstructure. Consequently, fatigue strength of annealed specimens was low.     

The effect of high‐temperature annealing on tensile strength and its mechanism of Hi‐Nicalon SiC fibres under inert atmosphere

Hi‐Nicalon SiC (silicon carbide) fibres were annealed in an argon flow for 10 h at 1400 °C, 1600 °C and 1800 °C. The strength of the fibres was determined by a monofilament tensile testing machine, their fracture surfaces were analysed by SEM (scanning electron microscope) and their microstructure was characterized by a TEM (transmission electron microscope) and XRD (X‐ray diffractometer). The results indicated that the strength of the fibres obeyed the Weibull distribution and the tensile strength decreased with the increase of annealing temperatures. The specimens showed brittle/flat fracture; most of the cracks initiated at the inner region of the fibres. After being annealed at 1800 °C for 10 h, the specimens showed cleavage and transcrystalline fracture. Statistical analysis revealed that the defects at the surface of the fibres had a negligible effect on their strength.     

Microstructure and Mechanical Properties of Al25 − xCr25 + 0.5xFe25Ni25 + 0.5x (x = 19, 17, 15 at%) Multi‐Component Alloys

A series of Al_{25 ? x}Cr_{25 + 0.5x}Fe₂₅Ni_{25 + 0.5x} (x = 19, 17, 15 at%) multi‐component alloys are prepared by arc‐melting and rapid solidification of copper molds. The technique of thermal‐mechanical processing is further applied to the master alloys to improve their mechanical properties. These alloys consist of face‐centered cubic (FCC) and body‐centered cubic (BCC) structure. The volume fraction of the BCC phase increases as Al content increase and Cr and Ni contents decrease, accompanied with a microstructural evolution from dendritic structure to lamella‐like structure. Due to the increase of volume fraction of BCC phase, the master alloys exhibit an increased strength and a declined ductility as Al content increases. The rapid solidified alloys have more BCC phase compared with the master alloys, which enhances the strength and decreases the ductility. After homogenization, hot‐rolling, and annealing at 1000 °C, the Al₈Cr_33.5Fe₂₅Ni_33.5 alloy displays excellent combination of strength (yield strength is ～635 MPa and fracture strength is ～1155 MPa) and ductility (tension strain is ～11%).

     

Werkstoffkennwerte für die Lebensdauerberechnung von Strukturen aus Stahlfeinblechen für den Automobilbau

Materials Data for Fatigue Life Calculation of Steel Sheet Structures for Automotive Engineering Within a joint project of the steel and automotive industry 17 steel sheet materials for automotive engineering in various delivery and forming conditions at temperatures of –40 °C, 22 °C and 100 °C were investigated. In the course of 37 test series strain controlled fatigue curves to crack initiation and stress‐strain‐curves under monotonic and cyclic loading were determined. All experimental data, hysteresis loops and determined cyclic properties are available in a database. A correlation between the mechanical properties from tensile tests and the properties from strain controlled cyclic experiments seems to be possible.     

Wrought Ni‐Base Superalloys for Steam Turbine Applications beyond 700 °C

The development of a new steam turbine generation for use in advanced coal fired power plants with prospective operating temperatures beyond 700 °C and a projected thermodynamic efficiency of about 55 % requires, amongst other innovations, the partial substitution of ferritic steels by wrought Ni‐base superalloys. Although Ni‐base alloys are already widely used in the aerospace industry, they are faced with demands regarding component size and operation temperature, which by far exceed current aero‐engine requirements. In this article, the potential of selected alloys for 700 °C steam turbine applications is discussed with respect to their manufacturability and mechanical performance. Hereby, the focus is on the steam turbine rotor, which probably is the most critical component. It is concluded that material solutions are available for operation conditions around 600 °C but not for temperatures of 700 °C and above. Based on these results, alloy development strategies are suggested in order to close this gap and two new alloys, DT 706 and DT 750, are introduced.     

High‐Temperature Corrosion of NiTi‐Shape‐Memory Alloys

Semi‐finished products and components made of NiTi‐shape‐memory alloys (NiTi‐SMA) are often subjected to heat treatment after their fabrication. During this heat treatment, oxide layers begin to form which contain a high amount of titanium. In this investigation special attention was drawn to the selective oxidation of Ti because a TiO_X‐layer can represent a Ni‐barrier and may therefore be of special use for medical applications. A comparison of the following three samples was carried out: A sample oxidised at room temperature, another that was heat‐treated in ambient air (600 °C/1min) and a third sample that was subjected to a heat treatment (600 °C/1min) in an atmosphere that oxidises titanium but reduces NiO in order to achieve a selective oxidation of the titanium. The analysis of the oxide layers was carried out by means of x‐ray photoelectron spectroscopy (XPS). It was shown that the ratio of titanium to nickel in the oxide layer can be substantially increased when performing the annealing treatments in a partial reducing atmosphere. Furthermore, a thermo‐gravimetric investigation of the material was carried out at 600 °C in dry air in order to estimate the growth of the oxide layers.     

Stability of Several Oxide Dispersion Strengthened Alloys and a directionally solidified y/y′ -α eutectic alloy in a thermal gradient

Thermal gradient testing of three oxide dispersion strengthened alloys (two Ni-base alloys, MA 754 and MA 6000E, and the Fe-base MA 956) and the directionally solidified eutectic alloy, γ/γ′-α, have been conducted. Experiments were carried out with maximum temperatures up to 1200°C and thermal gradients on the order of 100°C/mm. The oxide dispersion strengthened alloys were difficult to test because the thermal stresses promoted crack nucleation and growth; thus the ability of these alloys to maintain a thermal gradient may be limited. The stability of individual fibers in γ/γ′-α was found to be excellent; however, microstructural changes were observed in the vicinity of grain boundaries. Similar structures were also observed in isothermally annealed material; therefore thermal gradients do not affect the microstructure of γ/γ′-α in any significant manner.