Numerical simulation for stress/strain distribution and microstructural evolution in 42CrMo steel during hot upsetting process

Based on experimental results, the dynamic recrystallization mathematical models of 42CrMo steel were derived. The effects of strain rates on the strain/stress distribution and microstructural evolution in 42CrMo steel during hot upsetting process were simulated by integrating the thermo-mechanical coupled finite element model. The results show that the deformation of the specimen is inhomogeneous, and the degree of the deformation inhomogeneity decreases with the increase of strain rates. The distribution of the effective stress in the specimen is also inhomogeneous, and the locus of the maximum effective stress changes with the variations of strain rates. The dynamic recrystallization volume fraction decreases with the increase of strain rates. The distribution of the dynamic recrystallization grain is inhomogeneous in the deformed specimen, and the average dynamic recrystallization grain size decreases as the strain rate is increased. A good agreement between the predicted and experimental results confirmed that the derived dynamic recrystallization mathematical models can be successfully incorporated into the finite element model to predict the microstructural evolution in the hot upsetting process for 42CrMo steel.     

Microstructural modeling and simulation for GCr15 steel during elevated temperature deformation

The microstructural evolution of GCr15 steel, one of the most commonly used bearing steels, was investigated and simulated by physical experiments and finite element method (FEM). Physical experiments were conducted on the Gleeble-3500 thermo-simulation system. Effects of initial grain size and plastic strain on the microstructural of the materials were investigated by setting different heating temperature, holding time and deformation degree, respectively. Based on the results of stress–strain curves and metallographic analysis, the constitutive equations for flow stress, austenite grain growth and dynamic recrystallization of GCr15 steel were formulated by linear regression method and genetic algorithm. In addition, the coupled thermo-mechanical finite element method integrated with the developed constitutive models was used to simulate the microstructural evolution of GCr15 steel during hot compression. Good agreement between the calculated and experimental results was obtained, which confirmed that the developed constitutive models can be successfully used to predict microstructural evolution during hot deformation process for GCr15 steel.     

低碳钢奥氏体再结晶模型的建立

为了描述低碳钢变形过程的组织演化,建立了一套完整的奥氏体动态再结晶、静态再结晶、亚动态再结晶模型.本文利用Gleeble试验机研究不同初始晶粒度、变形温度、应变和应变速率对奥氏体再结晶量和晶粒尺寸变化的影响.流变应力模型考虑了变形条件对模型系数的影响.利用测得的应力-应变曲线及晶粒度由多元非线性回归得出了奥氏体再结晶模型系数,并且由模型计算的峰值应变、稳定应变、硬化区流变应力、再结晶体积分数、晶粒尺寸和实际接近.     

Fractal based correlations for Nb microalloyed steel undergoing static recrystallization

A new elliptical function for predicting the area fraction of the nucleated sub-grains during static recrystallization has been proposed which considers the fractal based correlation between the sub-grain size and the prior austenite grain size for Nb microalloyed steel. To derive the correlation, fractal analysis of microstructural images of Nb microalloyed steel was performed. The proposed elliptical model in conjunction with the fractal based grain size model improves the prediction of the final grain size distribution for the Nb microalloyed steel and gives excellent correlation with experimental results.     

Prediction of metadynamic softening in a multi-pass hot deformed low alloy steel using artificial neural network

The metadynamic softening behaviors in 42CrMo steel were investigated by isothermal interrupted hot compression tests. Based on the experimental results, an efficient artificial neural network (ANN) model was developed to predict the flow stress and metadynamic softening fractions. The effects of deformation parameters on metadynamic softening behaviors in the hot deformed 42CrMo steel have been investigated by the experimental and predicted results from the developed ANN model. Results show that the effects of deformation parameters, such as strain rate and deformation temperature, on the softening fractions of metadynamic recrystallization are significant. However, the strain (beyond the peak strain) has little influence. A very good correlation between experimental and predicted results indicates that the excellent capability of the developed ANN model to predict the flow stress level and metadynamic softening, the metadynamic recrystallization behaviors were well evidenced.     

Microstructural evolution in 42CrMo steel during compression at elevated temperatures

In order to study the workability and to optimize the processing parameters for 42CrMo steel hot forming, the hot compressive tests of 42CrMo steel were performed in the temperature range of (850-1150) °C at strain rates of (0.01-50) s^− 1 and deformation degrees of (10-60)% on Gleeble-1500 thermo-simulation machine. The effects of processing parameters, including the strain rate, forming temperature and deformation degree, on the microstructures of 42CrMo steel were investigated by metallurgical analysis. The results show that the average grain size of the deformed 42CrMo steel increases with the forming temperature and decreases with the deformation degree and strain rate. In a word, the grain size of hot compressive 42CrMo steel is dependent on the forming temperature, strain and strain rate, also on Zener-Hollomon parameter.     

Effects of strain on the workability of a high strength low alloy steel in hot compression

Based on the experimental results from the hot compression tests of 42CrMo steel, the efficiencies of power dissipation and instability parameter were evaluated. The effects of strain on the efficiency of power dissipation and instability parameter of 42CrMo steel have been discussed in detail. Processing maps were constructed by superimposition of the instability map over the power dissipation map. The dynamic recrystallization domains and instable zones were identified in the processing map. The effects of strain on microstructural evolutions were correlated with the processing maps. According to the 3D processing maps, the optimum domain of hot deformation is in the temperature range of 1050–1150 °C and strain rate range of 0.01–3 s⁻¹, with its peak efficiency of 32% at about 1140 °C and 0.23 s⁻¹, which are the optimum hot working parameters.     

Mn18Cr18N护环钢静态再结晶组织及模型

在Gleeble-1500D热模拟机上,采用双道次热压缩试验研究Mn18Cr18N护环钢高温变形后不同停留时间内的静态软化行为,分析热变形温度、应变速率、变形程度以及初始奥氏体晶粒对静态再结晶行为的影响.通过应力补偿法计算静态再结晶软化率,并结合金相组织作了修正.建立其静态再结晶动力学模型,获得静态再结晶激活能249.3 k J/mol.研究表明:Mn18Cr18N钢静态再结晶软化曲线呈"S"形,符合Avrami方程.静态再结晶体积分数随着停留时间延长而增加,热变形温度越高,静态再结晶分数越大,而在较低温度和较小变形程度时,孕育时间较长,主要发生静态回复,将静态再结晶动力学模型的预测结果与实测值进行比较,二者吻合较好,为护环钢后续热镦粗工艺模拟提供更为详尽的模型.     

奥氏体不锈钢热轧加工性能的数学模型研究

钢的热加工性能是钢的热轧工艺设计的基础.奥氏体钢在热加工中涉及到众多的物理现象,如动态回复、动态再结晶、静态回复、亚动态再结晶、静态再结晶和晶粒长大.一个优秀的描述钢的热加工性能的数学模型可以优化热轧工艺,提高生产效率,改善产品质量.综述了奥氏体不锈钢在热加工中发生的各类物理现象及其相对应的数学模型,讨论了变形温度、变形参数与流变应力、再结晶以及再结晶晶粒度之间复杂的关系,并分析了在工业多道次轧制工艺中,如何应用这些数学模型模拟和预测轧钢过程中残余应变和其内部组织的演变过程.     

On the modeling of the static recrystallization considering the initial grain size effects

Modeling of the static recrystallization in deformed copper specimens with different initial grain sizes is carried out based on a previous dislocation–grain size interaction model and a Monte Carlo simulation. From the dislocation–grain size interaction model, the stored energy of the deformed copper is calculated considering the interaction of the dislocations due to the different initial grain sizes. Then, utilizing the stored energy and Monte Carlo simulation the kinetic of recrystallization and recrystallized grain sizes are obtained. The JMAK plots of the modeling results show that, in conditions of 2D modeling and site-saturated nucleation, the Avrami exponent is 2 ± 0.1. The time for 50% recrystallization and recrystallized grain size increase by increasing the initial grain size at a specific strain and are consistent with the experimental data.     

Hot rolling simulations of austenitic stainless steel

The dynamic, static and metadynamic recrystallization behavior of austenitic stainless steel during hot rolling was analyzed. In this approach, each of those recrystallization behaviors is described by appropriate kinetics equations. The critical strain for dynamic recrystallization was determined so that a distinction could be made between static and metadynamic recrystallization; then the amounts of strain accumulation compared with the critical strain each pass. The effects of grain size on the fraction recrystallized and of the latter on the flow stress were evaluated for each type recrystallization behavior. In this way, the dependence of the mean flow stress (MFS) on temperature could be analyzed in terms of the extent and nature of the prior or concurrent recrystallization mechanisms. Finally, an example is given of an industrial process in which DRX/MDRX can play an important role. More grain refinement can be achieved by increasing the strain rate, decreasing the interruption time and lowering the temperature of deformation.     

300M钢的热变形行为及热锻成形工艺研究现状

300M钢凭其优异的综合力学性能而被广泛应用于飞机起落架大型构件的生产。在大型构件的热锻成形过程中,材料的流动行为及组织演变受到众多因素影响,变形机制复杂。主要从300M钢的热变形本构模型、微观组织演变以及锻造工艺三方面对现有研究进行综述。在热变形本构模型方面,综述了300M钢在单道次及多道次热变形下的本构模型的研究现状。在微观演化方面,综述了300M钢热变形各个阶段所对应的组织演化机制,包括晶粒长大、动态再结晶、静态再结晶、亚动态再结晶以及相变过程。此外,从数值分析角度综述了热锻成形工艺的研究现状。最后,针对现有研究提出了后续值得继续深入研究的方向。     

Microstructural evolution of a Ni-Co based superalloy during hot compression at γ'sub-/super-solvus temperatures

The effects of strain rate on the microstructural evolution and deformation mechanism of a Ni-Co based superalloy were investigated by isothermal compression tests performed at γ'sub-solvus(1090℃)andγ'super-solvus temperatures(1150℃)with a wide strain rate range from 0.001 to 10 s-1 under a true strain of 0.693.Electron backscatter diffraction(EBSD),electron channeling contrast imaging(ECCI)and transmission electron microscope(TEM)techniques were used to characterize the microstructures.The results revealed that the dynamic recrystallization(DRX)volume fraction increased and stored energy of the γ matrix grains decreased with increasing the strain rate during γ'sub-solvus temperature defor-mation,while the opposite phenomena were observed during γ'super-solvus temperature deformation.The comprehensive effect of initial grain size,primary y'phase,twins and adiabatic temperature rise led to these results.The primary γ'particles undergone the deformation behavior within itself and obviously accelerated the DRX of the matrix.The microstructural evolution proved that discontinuous dynamic recrystallization(DDRX)was the dominant mechanism during the hot deformation carried out at both γ'sub-solvus and γ'super-solvus temperatures.Primary γ'particles obviously accelerated the nucleation step and retarded the growth step of DDRX during γ'sub-solvus temperature deformation.Besides,the acceleration effect of primary γ'particles on DDRX increased with the increase of strain rate.Continuous dynamic recrystallization(CDRX)was confirmed to be an assistant mechanism during γ'super-solvus temperature deformation and was promoted with the increase of strain rate.     

Kinetics,mechanism and modelling of microstructural evolution during thermomechanical processing of a 15Cr–15Ni–2.2Mo–Ti modified austenitic stainless steel

The paper discusses the kinetics, mechanism and modelling of the microstructural evolution of a 15Cr–15Ni–2.2Mo–0.3Ti modified austenitic stainless steel (alloy D9) during dynamic recrystallization (DRX). The experimental methodology included different hot working operations employing industrial equipment such as forge hammer, hydraulic press and rolling carried out in the temperature range 1,173–1,473 K to various strain levels. The kinetics of DRX has been investigated employing modified Johnson–Mehl–Avrami–Kolmogorov (JMAK) model. It has been found that the value of Avrami exponent varies in a close range of 1.17–1.34 which implies that D9 exhibits growth controlled DRX. Optical metallography has revealed that nucleation of DRX grains occurred along the prior grain boundaries by bulging mechanism. Microstructural characterization has shown that a significant correlation between microstructural features and processing parameters exists. However, this interrelation is ambiguous and fuzzy in nature. Therefore an artificial neural network model has been developed to predict the microstructural features, namely fraction of DRX and grain size, at different processing conditions. A good correlation between experimental findings and predicted results has been obtained. An instantaneous microstructure, therefore, can be designed in order to optimize the process parameters based on microstructural evolution.     

Formation mechanism of large grains inside annealed microstructure of GH4169 superalloy by cellular automation method

In authors’ previous work [Mater. Charact. 141 (2018) 212–222], it was found that the heterogeneous deformed microstructures can be replaced by the relatively homogeneous recrystallized grains through an annealing treatment. However, there are still some relatively large recrystallized grains. To find the reasons for the formation of large grains, some new annealing treatment tests were done, and the cellular automation (CA) simulations were carried out in the present work. The experimental results showed that the microstructural evolution during annealing treatment is significantly affected by the content of δ phase. So, the effects of δ phase on the nucleation and growth of grains are carefully considered in the CA model to accurately simulate the microstructural evolution behavior. By the CA simulation, it is found that the dislocation density rapidly decreases due to the nucleation of static recrystallization (SRX) and the growth of dynamc recrystallization (DRX) nuclei at the early stage of annealing. The high initial dislocation density can provide the high velocity for the growth of DRX nuclei, which is responsible for the formation of coarse grains. However, the growth rate of SRX nuclei is relatively small due to the low dislocation density and pinning effects of δ phase.     

基于有限元法的转向直臂锻件晶粒度预报

通过建立耦合了 42 CrMo 微观演化模型的热锻有限元模型,预报了一种转向直臂的热锻晶粒度。结果表明该热锻工艺能够得到晶粒度合格的产品。 使用该工艺进行实际生产,对锻件进行了金相分析,结果与预报晶粒度吻合。     

Finite element modelling on microstructure evolution during multi-pass hot compression for AZ31 alloys using incremental method

Based on the principle of piecewise linearization, the incremental forms of microstructure evolution models were integrated into the thermo-mechanical coupled finite element(FE) model to simulate nonlinear microstructure evolution during multi-pass hot deformation. This is an unsteady-state deformation where dynamic recrystallization(DRX), meta-dynamic recrystallization(MDRX), static recrystallization(SRX) and grain growth(GG) take place during hot deformation or deformation interval. The distributions of deformation and microstructure for cylindrical AZ31 sample during single-pass and double-pass hot compressions were quantitatively calculated and compared with the metallographic observation. It is shown that both the deformation and microstructure are non-uniformly distributed due to the presence of friction between the die and the flat end of sample. The average grain size and its standard deviation under the double-pass hot compression are slightly smaller than those under single-pass compression.The simulated average grain sizes agree well with the experiments, which validates that the developed FE model on the basis of incremental forms of microstructure evolution models is reasonable.     

Interfacial bonding and microstructural evolution of Al in kinetic spraying

Bonding and microstructural evolution of Al particles in kinetic spraying (cold gas dynamic spraying) result from ultra-high strain rate plastic deformation during supersonic single and successive collisions of the particles. The coating formation of kinetic spraying is composed of three stages (an individual particle impact + subsequent impacts + isothermal heating during full coating). When a single particle impacts, interfacial shear strain location under adiabatic state produces inter-particle bonding and grain refinement at narrow zone (<220 nm) by continuous dynamic recrystallization. After the individual particle impact, successive supersonic in-flight particle impact results in static recovery and static recrystallization at un-refined area using the heat energy converted from the kinetic energy as activation energy. In this study, the bonding state and microstructure of individually impacted Al particle and full Al coating were analyzed using a focused ion beam technique and a transmission electron microscopy. The mechanisms of interfacial bonding and microstructural evolution of Al particle during kinetic spraying were suggested.     

Abnormal grain growth in AISI 304L stainless steel

The microstructural evolution during abnormal grain growth (secondary recrystallization) in 304L stainless steel was studied in a wide range of annealing temperatures and times. At relatively low temperatures, the grain growth mode was identified as normal. However, at homologous temperatures between 0.65 (850 °C) and 0.7 (900 °C), the observed transition in grain growth mode from normal to abnormal, which was also evident from the bimodality in grain size distribution histograms, was detected to be caused by the dissolution/coarsening of carbides. The microstructural features such as dispersed carbides were characterized by optical metallography, X-ray diffraction, scanning electron microscopy, energy dispersive X-ray analysis, and microhardness. Continued annealing to a long time led to the completion of secondary recrystallization and the subsequent reappearance of normal growth mode. Another instance of abnormal grain growth was observed at homologous temperatures higher than 0.8, which may be attributed to the grain boundary faceting/defaceting phenomenon. It was also found that when the size of abnormal grains reached a critical value, their size will not change too much and the grain growth behavior becomes practically stagnant.     

Microstructural features of dynamic recrystallization in alloy 625 friction surfacing coatings

In friction surfacing (FS), material is deposited onto a substrate in the plasticized state, using frictional heat and shear stresses. The coating material remains in the solid state and undergoes severe plastic deformation (SPD) at high process temperatures (≈0.8 T_melt), followed by high cooling rates in the range of 30?K/s. Dynamic recrystallization and the thermal cycle determine the resulting microstructure. In this study, Ni-based alloy 625 was deposited onto 42CrMo4 substrate, suitable, for instance, for repair welding of corrosion protection layers. Alloy 625 is known to undergo discontinuous dynamic recrystallization under SPD, and the resulting grain size depends on the strain rate. The coating microstructure was studied by microscopy and electron backscatter diffraction (EBSD). The coatings exhibit a fully recrystallized microstructure with equiaxed grains (0.5–12?µm) and a low degree of grain average misorientation. Flow lines caused by a localized decrease in grain size and linear alignment of grain boundaries are visible. Grain nucleation and growth were found to be strongly affected by localized shear and nonuniform material flow, resulting in varying amounts of residual strain, twins and low-angle grain boundaries in different regions within a single coating layer’s cross section.

FS can be used to study dynamic recrystallization at high temperatures, strains and strain rates, while at the same time materials with a recrystallization grain size sensitive to the strain rate can be used to study the material flow during the process.