Residual stresses, distortion and surface roughness produced by grinding thin wall ductile iron plates

This work deals with grinding effects on thin wall ductile iron plates. Residual stresses, shape distortion and surface roughness were measured on thin wall plates of different nodule count, ferritised and afterwards dry ground under several grinding conditions. In all cases, tensile residual stresses are maximum at the surface, and their profile decreases with depth until becoming compressive. No phase transformations can be observed at depths of up to 30 μm below surface, although plastic deformation is visible through nodules and grains enlargement. Distortion increases when the depth of cut and nodule count increase and the workspeed decreases. The mean stresses of the profile tensile zone also increase when the nodule count increases. Surface roughness improves slightly as nodule count increases and workspeed decreases. This tendency is more noticeable when depth of cut decreases. The arithmetic mean roughness (Ra) values obtained were always below 0.8 μm.     

Effect of nodule count and austempering heat treatment on segregation behavior of alloying elements in ductile cast iron

The equilibrium partition ratio, k, has been measured for Mn, Mo, Si, Ni and Cu in a ductile iron with composition(wt.%): 3.45 C, 0.25 Mn, 0.25 Mo, 2.45 Si, 0.5Ni and 0.5Cu with different nodule counts obtained from different section sizes of13, 25, 75 mm in the as cast, austenitized(at 870 °C for times 1, 4 and 6 hours) and austempered(at 375 °C for times 1 to 1,440 min) samples. Results show that Mn and Mo segregate positively at cell boundaries, but Si, Ni and Cu concentrate in an inverse manner in the vicinity ofgraphite nodules and there is a depletion ofthese elements at cell boundaries. Segregation curves for Ni and Cu are more smooth than for Si. Carbide formation has been observed at cell boundaries. Based on the results, the partition ratios for all elements decrease with increasing the nodule count. More carbide with coarser morphology has been observed in the microstructure with a lower nodule count. Austenitization for a longer time can decrease partition ratio, but cannot eliminate it entirely. Increasing the austenitization temperature has the same effect. Austenitizing parameters have no significant effect on carbides volume fraction. The kinetics ofaustempering is faster in higher nodule counts and subsequently better mechanical properties including higher ductility, strength and toughness have been observed for all austempering conditions studied.     

Influence of rare earths on shrinkage porosity in thin walled ductile cast iron

Abstract

Ductile cast iron has been cast in test bars with thickness from 2 to 10 mm. The rare earth elements La and Ce have been added to some of the castings to evaluate their influence on microstructure and shrinkage tendency. Both La and Ce increased the graphite nodule count, especially for thickness of 6 mm and below. La gave the best nodule size distribution with many small nodules. La had less shrinkage tendency than Ce in the 10 mm test bars. This tendency was less pronounced for the 6 and 4 mm test bars and other factors may have a large influence at these thicknesses. Increasing the temperature T ₁, which is controlled by the growth of off-eutectic austenite dendrites, increased the shrinkage tendency.     

残余应力对管线钢韧性断裂的影响

以弹塑性断裂力学理论为基础,应用ABAQUS有限元软件,采用固有应变法引入残余应力,并基于细观塑性损伤模型研究了残余应力对管线钢韧性裂纹扩展阻力曲线的影响.模型中选择了具有不同深浅裂纹的单边缺口弯曲（SENB）试样和DNV推荐准则中用于管线钢断裂评估的单边缺口拉伸（SENT）试样,并对这两种断裂力学试样在大范围屈服条件下的裂纹扩展阻力曲线（CTOD-R曲线）行为进行了对比分析.结果表明,对于深裂纹试样,残余应力降低了韧性裂纹扩展阻力曲线,而浅裂纹试样受残余应力的影响可忽略不计.     

Effect of residual stresses on hydrogen permeation in iron

The effect of residual stresses on electrochemical permeation in iron membrane was investigated. Four thermal and mechanical treatments were chosen to obtain different surface states in relation to the residual stresses.Residual stresses were determined by X-ray diffraction (XRD) using the Macherauch and Müller method. The results were completed by the microhardness measurements. For all iron membranes, compressive residual stresses were obtained.Electrochemical permeation experiments using a Devanathan and Stachurski cell were employed to determine the hydrogen permeation behaviour of the various iron membranes. The latter was charged with hydrogen by galvanostatic cathodic polarization in 0.1 M NaOH at 25 °C. The experimental results revealed that hydrogen permeation rate increases with increasing residual stresses introduced in iron membranes.     

The influence of cast structure on the austempering of ductile iron. Part 3. The role of nodule count on the kinetics,microstructure and mechanical properties of austempered Mn alloyed ductile iron

Austempering kinetic measurements and mechanical property measurements are reported for irons with different Mn contents and different nodule counts after austenitising at 870 °C and austempering at 375 °C. It is shown that increasing nodule count, which reduces segregation and changes the size and distribution of intercellular boundaries, increases the interphase boundary area between graphite and matrix and decreases the continuity of the unreacted austenite in the intercellular boundary. This accelerates the stage I reaction which broadens the heat treatment window and moves it to earlier austempering times. A high nodule count can be used to counter the delay of the stage I reaction caused by Mn additions used to increase the hardenability of the iron. A high nodule count produces a finer, more uniform ausferrite structure that increases the strength, ductility and impact energy of the austempered iron.     

The influence of cast structure on the austempering of ductile iron. Part 1: Modelling of the influence of nodule count on microsegregation

A numerical, non steady state microsegregation model is used to predict the extent of solute segregation in a ductile cast iron. The microsegregation of Mn and Mo to intercellular boundaries is shown to depend on the nodule count and the local solidification time. It is suggested that increased nodule count is the most effective way of reducing intercellular segregation in thicker components.     

镍基材料焊接中高温失塑裂纹DDC的生成机理及研究进展

以某电厂在役的10MnNi2MoV低合金钢管焊接接头作为研究对象,对其表面裂纹位置、形貌、组织和断口进行了系统地研究分析。结果表明,10MnNi2MoV钢管焊接接头盖面焊缝附近ЭА-395/9堆焊层中易产生锯齿状裂纹,该裂纹通常沿柱状晶生长方向扩展,同时在堆焊层近表面区域的迁移晶界中易产生条状和颗粒状析出物、T型晶界等显微组织及特征,这些组织为10MnNi2MoV低合金钢管焊接接头的高温失塑裂纹的形成提供了内在条件。对于在电厂服役时间较长的低合金钢焊接接头而言,在接头堆焊层易产生高温失塑裂纹,且该裂纹一旦形成将会快速扩展,严重威胁着电厂机组的安全运行。

     

多层多道焊接残余应力与变形三维数值模拟

大型复杂焊接结构件的主要接头形式为平板对接,开展对平板对接多层多道焊接三维数值模拟研究十分必要。通过控制网格尺寸和边界条件进行优化来平衡模拟精度和计算效率的问题,并采用试验测量和MSC.MARC有限元模拟相结合方法分析焊接残余应力与变形趋势。结果表明,该多层多道焊接数值模拟采用位移约束和弹簧约束混和边界条件,在焊缝最大网格尺寸为2 mm时,计算效率和精度匹配效果最佳,有限元计算结果与试验测量结果吻合良好,证明该有限元模型的合理性。     

BT20钛合金电子束焊接残余应力三维有限元数值模拟

研究钛合金电子束焊接构件残余应力的大小和分布，了解残余应力的形成机理，具有十分重要的理论和实际意义。作者利用ANSYS程序模拟了BT20钛合金电子束焊态和焊后电子束局部热处理的实际焊接温度场以及焊接接头应力场的变化和残余应力的分布。计算结果表明，钛合金薄板焊缝中心残余拉应力的峰值达到焊缝金属屈服强度σn的60％-70％；焊后电子束局部热处理可以降低焊缝中心处的拉伸残余应力值，降低约50％左右；用所建模型计算得到的数值结果规律与实测的残余应力值基本一致。     

多束流电子束薄板焊接应力变形数值模拟

为了减小薄板结构的焊接变形,基于电子束高频偏转扫描技术在焊缝两侧添加辅助扫描热源实现了多束流电子束焊接及焊前预热. 建立了矩形均匀加热辅助热源模型,采用热弹塑性有限元分析方法对1.5 mm厚304不锈钢薄板进行多束流电子束焊接数值模拟,并进行了试验验证. 结果表明,焊后残余应力和变形的实测结果与模拟结果吻合良好,多束流电子束焊接方法不仅可以改变熔池前方材料的受力状态,而且可以减小熔池形成瞬间熔池前方材料的压应力峰值,有利于减小熔池的前方压缩塑性应变,进而减小薄板结构的焊接变形.     

热源形状参数对薄板焊接残余应力和变形的影响

采用热-弹-塑性有限元方法模拟焊接残余应力和变形时,对于移动热源模型形状参数的选取,在大多数情况下大都是根据研究者的经验来确定.然而对于热源模型形状参数对焊接残余应力和变形的影响尚不十分明确.基于ABAQUS有限元软件,以高强钢SM490A单道TIG焊为例,通过建立三维有限元模型和采用双椭球体积移动热源模型,研究了热源模型形状参数对焊接残余应力和变形的影响.结果表明,热源模型形状参数对焊接残余应力影响较小,而对焊接变形,尤其是对角变形有一定程度的影响.     

Effect of trailing heat sink on residual stresses and welding distortion in friction stir welding Al sheets

Abstract

This paper investigates a trailing heat sink, which was designed and applied to friction stir welding (FSW) in order to control the residual stresses and welding distortion. Residual stresses, residual plastic strains and welding distortion of 2024-T3 and 5083-H321 Al sheets welded by FSW with and without the trailing heat sink were compared. The optimal placement of the heat sink was discussed. The results revealed that the reductions in peak tensile stresses were 66% for 2024-T3 and 58% for 5083-H321 by application of the trailing heat sink in FSW. In addition, the welding distortion could be reduced drastically by this method. The 5083-H321 sheet with a size of 1000×100×3·5 mm welded by this method was very flat and had almost no distortion. This method achieved in-process control of stresses and welding distortion, without additional complicated work before or after welding operation.     

淬火-预拉伸对2A12铝合金厚板残余应力的影响

采用层削法对2A12铝合金淬火厚板在预拉伸前后的残余应力进行了测定,厚板的淬火采用阵列喷淋及水浴两种方式。结果表明:两种淬火方式在厚板内部都形成了"内拉外压"的典型分布规律;喷淋方式的淬火强度相对较低,只在厚板靠近表层的地方形成了较大的残余应力,内部靠近中面的位置残余应力水平接近于0;水浴方式淬火强度更大,在厚板整个厚度上形成了单调连续分布的残余应力;预拉伸使喷淋和水浴两种淬火板内的残余应力都大幅度消减;强度更高的淬火工艺加大了板内金属力学性能的不均匀性,减弱了残余应力消减的效果。     

Micro-abrasive wear of DC and pulsed DC titanium nitride thin films with different levels of film residual stresses

In this work, six specimens with titanium nitride (TiN) thin films and cemented carbide (WC-Co) substrates were analyzed in terms of their micro-abrasive wear behavior. These specimens were obtained from a previous work, in which film depositions were conducted varying parameters such as bias (0, − 50 or − 100 V), type of target power (DC or pulsed DC) and, in the cases where substrate bias was zero, substrate condition (ground or floating). As a result, the level of film residual stresses varied from specimen to specimen, in the range from 4 to 11 GPa (compressive). In this work, micro-abrasive tests were run on these six specimens, using balls of AISI 1010 steel and an abrasive slurry with distilled water and silicon carbide particles with average particle size of 5 μm. Results were analyzed in terms of the wear mechanisms observed at the worn surface and also in terms of the wear resistance, characterized by the wear coefficient (k). Trends indicate a decrease in film wear rate with an increase in the value of film residual compressive stresses, as long as the adhesion was not impaired. Different values of film wear coefficient (k_c) were calculated for specimens obtained with ground and floating voltage substrates, although similar values of film residual stresses were measured in both cases.     

Influence of martensitic transformation on welding residual stress in plates and pipes

Martensitic filler metals with low transformation temperatures can efficiently mitigate harmful tensile welding residual stress. It is vital to clarify the difference in the influence of martensitic transformation for different shapes of welded joints. This article outlines the influence of martensitic transformation in a butt-welded plate and a butt-welded pipe which were designed to have the same dimensions of the cross-section perpendicular to weld line. A clear difference in the influence of martensitic transformation was found in these two joints. Longitudinal tensile stress in weld zone is efficiently reduced in both joints, whereas longitudinal tensile stress is formed in base metal near the weld zone in the pipe. A notably greater influence on transverse stress is found in the pipe than in the plate.     

Measurements of residual stresses in thin films deposited on silicon wafers by indentation fracture

A semi-empirical formula is proposed to assess residual stresses in SiO₂ and Cr thin films deposited on Si wafers using Vickers indentation fracture tests. The formula indicates that the ratio of the indentation load to the cubic of square root of the crack length is linearly proportional to the reciprocal of the square root of the crack length, the magnitude of the residual stress, and the film thickness. Wafer curvature measurements are conducted to calibrate the dimensionless parameters in the proposed formula. The experimental results agree well with the theoretical prediction and the residual stresses in the SiO₂ and Cr thin films are evaluated to be −358 and 1095 MPa, respectively.