Optimum Conditions for Blast Cleaning of Steel Plate

Abstract

Technological investigations are described in which practical blast cleaning of steel plate was simulated in the laboratory.

The rate of cleaning is found to increase when more abrasive per unit of time is discharged. This means that high pressure, a large nozzle and a wide valve for metering the abrasive flow are advantageous, but the actual setting of these variables should be mutually adjusted. The optimum blasting angle for removing millscale is about 45°, and the optimum nozzle-to-work distance is 55–75 cm. The smaller the abrasive grains, the quicker is the cleaning process. Under otherwise constant conditions, air consumption decreases as the abrasive transport is increased. High cleaning rates are advantageous because they lead to lower costs per unit area for labour and power, whilst for abrasive increase only slightly.     

Analysis of abrasive blasting of DOP-26 iridium alloy

The effects of abrasive blasting on the surface geometry and microstructure of DOP-26 iridium alloy (Ir—0.3% W—0.006% Th—0.005% Al) have been investigated. Abrasive blasting has been used to control emissivity of components operating at elevated temperature. The effects of abrasive blasting conditions on surface morphology were investigated experimentally using surface profilometry. A simplified model was used to estimate the effects of process parameters on surface deformation and residual strain distribution. The surface geometry is found to be insensitive to the abrasive blast process conditions of nozzle pressure and standoff distance considered in this study. Modeling results suggest that the angularity of the abrasive particle has an important role in determining surface geometry and residual strains. Abrasive blasting causes localized surface strains and localized recrystallization, but it does not affect grain size following extended exposure at elevated temperature. The dependence of emissivity of the DOP-26 alloy on mean surface slope follows a similar trend to that reported for pure iridium.     

Erosive abrasive wear behaviour of stainless steel surface produced by plasma transferred arc hardfacing

Abstract

Erosive abrasive wear is caused by high speed impact of particles entrained in a fluid system on the surfaces of components such as boilers and furnaces. Erosive abrasive wear in boilers results from the impact of hard particles such as ash or clinker entrained in flue gases and can lead to serious damage. The life of boiler and furnace components encountering erosive abrasive wear in service, which are most commonly fabricated from carbon steels, can be improved by hardfacing with a wear resistant material. The effects of wear parameters such as particle size, flux and velocity on the erosive abrasive wear behaviour of a stainless steel surface produced by the plasma transferred arc hardfacing have been investigated using an experimental design approach. The wear resistance of the stainless steel surface was found to be twice that of the carbon steel substrate.     

Experimental investigation into cutting forces and active grain density during abrasive flow machining

It is important to know cutting force components and active grain density during abrasive flow machining (AFM) as this information could be used to evaluate the mechanism involved in AFM. The results show that cutting force components and active grain density govern the surface roughness produced during AFM process. In this paper, an attempt has been made to study the influence of these two parameters, namely cutting force and active grain density, on the surface roughness. This study will help in developing a more realistic theoretical model.The present paper highlights a suitable two-component disc dynamometer for measuring axial and radial force components during AFM. The influence of three controllable variables (extrusion pressure, abrasive concentration and grain size) on the responses (material removal, reduction in surface roughness (R_a value), cutting forces and active grain density) are studied. The preliminary experiments are conducted to select the ranges of variables by using single-factor experimental technique. Five levels for abrasive concentration and six levels for extrusion pressure and abrasive grain size were used. A statistical 2³ full factorial experimental technique is used to find out the main effect, interaction effect and contribution of each variable to the machined workpiece surface roughness. The machined surface textures are studied using a scanning electron microscope.     

Effects of cold work on the oxidation behavior and carburization resistance of Alloy 800

The structure of the oxide layer formed on Alloy 800 at 600 °C in superheated steam markedly indicates the role of the grain boundaries as easy diffusion paths of Cr and Mn to the alloy/oxide interface. Increasing the number of grain boundaries by 10-90% cold work leads to increasing Cr- and Mn-content in the scale and to decreasing oxide growth rates. Variation of the grain size by different annealing treatments leads – since the Cr-content in the scale is decreasing with the grain size – to a linear relation of growth rate and grain size. The effect of cold work was also demonstrated on the protectiveness of the oxide scale towards carbon uptake and carburization of Alloy 800. After preoxidation of differently deformed specimens at 900 °C, these were exposed to a CO-CO₂H₂O-H₂ mixture at 700 °C for long time. The gas mixture was tagged with ¹⁴C so that the C-ingress into the oxide scale and into the alloy could be sensitively monitored by autoradiography and (upon stepwise polishing) radioactivity measurements of the carbon penetration. The carbon uptake is effectively reduced with cold working; in contrast a non-deformed, electropolished and preoxidized specimen shows relatively high C-content after exposure. The investigations prove the highly favorable effect of mechanical pretreatment on the formation of the oxide scale on an austenitic Fe-Ni-Cr alloy. Cold work and other methods of surface deformation (grinding, polishing, sand blasting, shot peening) generate easy diffusion paths for fast Cr-diffusion to the surface and sufficient supply of Cr to form a protective oxide layer.     

Corrosion of stainless steels under heat transfer conditions in nitric acid

Abstract

Novel test rigs are described for the study of the corrosion of metal specimens under controlled heat fluxes. In the corrosion of stainless steels in nitric acid, tests at various heat fluxes with steel surface temperature kept constant have shown that the cooler acid present at the surface under higher heat fluxes leads to slightly smaller corrosion rates than under isothermal conditions. Crevice corrosion can develop under the gasket sealing the stainless steel specimen to the test cell. This crevice corrosion can produce enhanced corrosion rates (by factors up to 100), not only on surfaces within the crevice, but also on those external to the crevice. The factors influencing the development of crevice corrosion are discussed.     

小直径磨棒磨削加工TiC颗粒增强钢基复合材料GT35

为探究TiC颗粒增强钢基复合材料GT35合理的加工参数和冷却润滑条件,研究其对切削力、表面质量及刀具磨损的影响规律,采用小直径磨棒以侧面磨削方式开展试验。结果表明：干磨削会引起磨棒烧伤,极压磨削油的润滑效果优于水基合成磨削液的;磨棒在极压磨削油润滑下,磨削工件12 min后进入稳定磨损状态,其主要磨损形式为磨粒破碎、磨粒磨耗和磨粒脱落;主轴转速对切削力的影响大于进给速度的,且转速越高,切削力越小;工件表面粗糙度主要与磨棒磨粒出露高度的平整度有关,受加工参数的影响较小。用小直径磨棒磨削加工GT35材料时,应选择极压磨削油润滑,高主轴转速、中速进给的加工方式,以获得良好的刀具寿命、工件加工表面质量及适当的加工效率。     

Intensity of hydrodynamic movements induced by ultrasounds in ultrasonic cleaning in water solutions

Abstract

The main causative agent of ultrasonic cleaning is cavitation. A helpful factor is liquid movement induced by ultrasound, but in some organic solvents, the intensity of this movement is so high that its significance for the process of cleaning is equal to and sometimes even higher than the significance of cavitation. In the present work, the intensity of hydrodynamic movement induced by ultrasound in water was assessed and compared with those in selected organic solvents used in ultrasonic cleaning.     

Influence of cooling rate and composition on orientation of primary carbides of Fe–Cr–C hardfacing alloys

Abstract

Four Fe–Cr–C hardfacing alloys with carbon contents of 3˙34–6˙5% were studied. The orientation of primary carbides in the microstructures of hardfacing layers produced by arc surfacing was investigated under controlled cooling conditions. Carbon content and cooling conditions were found to play an important role in determining overlayer microstructures. Increasing carbon content or decreasing Cr/C ratio increased the tendency for primary carbides to be oriented perpendicular to the surface of the overlayers, and the carbides in the microstructure became more compact. Under water cooling conditions, the primary carbides were preferentially oriented perpendicular to the surface, which would be expected to improve wear resistance. At lower cooling rates, primary carbides were oriented randomly.     

Surface nanocrystallisation engineering: scientific and industrial potential

Abstract

By means of surface mechanical attrition treatment (SMAT), a nanostructured surface layer with a graded grain size distribution ranging from nano-to micrometres can be synthesised on various metallic materials. In this paper, the grain refinement mechanism, mechanical and diffusion properties, and chemical reactivity of the nanostructured surface layer, are reviewed. In addition, effects of the nanostructured surface layer on the mechanical performance and surface thermochemical treatment processes of engineering materials are described. Previous investigations have indicated that the nanostructured surface layer synthesised by means of SMAT on metallic materials provides many unique opportunities in both basic scientific research and technological applications.     

磨粒刻划单晶SiC的SPH与FEM耦合仿真分析

目的 进一步理解金刚石线锯加工硬脆晶体材料的去除特性.方法 采用SPH与FEM耦合算法,分析磨粒刻划单晶碳化硅工件过程中的材料去除动态响应,研究不同磨粒压入深度与几何形状条件对磨粒接触力、工件刻划表面形貌与应力分布的影响规律,分析磨粒恒定深度刻划与变深度刻划两种方式下磨粒刻划工件材料的动态响应.结果 磨粒接触力的各方向分量均随刻划时间发生波动,其中x与z轴方向的磨粒接触力随时间的变化趋势相近,平稳刻划时段的磨粒接触力均值拟合方程分别为fx=3.0956h2.7264,fz=11.3813h2.6214.磨粒压入深度是影响刻划过程中工件刻划截面形貌及应力分布的主要因素.相较于圆锥体磨粒,球体磨粒刻划后的工件材料截面形貌更粗糙,但工件材料的变形及损伤层深度更小.在磨粒变深度刻划方式下,随着磨粒压入深度的增加,刻划过程中的工件材料发生了脆塑转变.结论 在保证材料去除率的条件下,需降低磨粒压入深度,以降低磨粒接触力,获得更平整的工件表面刻划形貌与更低的等效应力.     

Role of annealing twinning in microstructural evolution of high purity silver during friction stir welding

ABSTRACT

Friction stir welding (FSW) with a relatively large heat input was applied to high purity Ag with a low stacking fault energy, which leads to profuse twinning. The microstructural evolution was examined along the material flow path during rapid cooling FSW. The frequent formation of annealing twinning induced by the heating caused the microstructural refinement, following the transformation from twin boundaries to normal high angle boundaries. The bulging of the high angle boundary, which is one of the typical mechanisms of discontinuous dynamic recrystallisation did not occur. Irrespective of the initial grain size, the grain size obtained after the FSW was approximately 8?µm due to the dynamic balance between the grain boundary migration and the annealing twin formation.     

Use of magnetic arc oscillation for grain refinement of gas tungsten arc welds in α–β titanium alloys

Abstract

In an effort to refine the weld metal grain structure in α–β titanium alloys, gas tungsten arc welding was carried out, during which transverse oscillations of the arc were induced through the use of an alternating external magnetic field. At optimum values of oscillation amplitude and frequency in both the alloys investigated, considerable refinement of the fusion zone grain structure was achieved. This could be attributed to factors that include enhanced fluid flow, reduced temperature gradients, and a continually changing weld pool size and shape owing to the action of the imposed magnetic field. The reduction in the prior β grain size was shown to result in a notable increase in fusion zone tensile ductility. Post-weld annealing increased ductility in all cases, but the magnetically treated material continued to show a higher elongation than that of the untreated material even after post-weld heat treatment.     

Modelling and optimisation of magnetic abrasive finishing process based on a non-orthogonal array with ANN-GA approach

ABSTRACT

Magnetic abrasive finishing (MAF) is an advanced precise finishing method that achieves micro-level to nano-level surface roughness. In industries, MAF is highly recommended where zero or negligible post-process surface defects are an obligatory requirement. In the same context, process optimisation is essential for making it commercially viable. This study presents an artificial neural network and genetic algorithm (ANN-GA), a robust modelling and optimisation tool (applicable to any sort of data set orthogonal array design or non-orthogonal array design) that is applied to scrutinise and improve the performance of the magnetic abrasive finishing of stainless steel SS302. In addition, the results from ANN-GA modelling and optimisation have been compared with conclusions drawn from conventionally used Taguchi-ANOVA analysis. An L₂₇ non-orthogonal array design has been opted for as per machining set-up restriction. Abrasive size, voltage, machining gap, and rotational speed were the design variables considered in the present research work. It was found that the parametric design used in this study provides a straightforward, methodical, and proficient method of modelling and optimisation of change of surface roughness or finishing behaviour during the MAF process. Modelling and optimisation done with ANN-GA show a maximum value of (ΔR _a)_max equal to 0.256?µm, which is 7% better than the result obtained from Taguchi-ANOVA analysis.     

The Effects of Fluid Flow on Particle Pushing

Abstract

The surface energy model, which may govern particle pushing under or near equilibrium solidification conditions, is not valid when convection exists in the liquid. Experiments were carried out to show that under convection conditions, particle pushing occurred at much higher growth rates than that predicted by using the surface energy model. Several mechanisms are proposed for explaining the effects of fluid flow on particle pushing.     

Influence of Ti/N ratio on simulated CGHAZ microstructure and toughness in X70 steels

Abstract

Three API 5L X70 steels with different Ti and N contents and otherwise identical chemistry were selected to investigate the effect of Ti/N ratio on the toughness in coarse grained heat affected zone (CGHAZ). A Gleeble 3500 thermomechanical simulator was used to simulate the thermal profile of CGHAZ of double submerged arc welding process. The microstructure was examined by optical microscopy. Statistics of CGHAZ grain coarsening were compiled by measuring the prior austenite grain size. Toughness of the simulated CGHAZ regions was evaluated by Charpy V-notch testing at ?20 and ?40°C. Morphology of the impact fracture surface was investigated using SEM. Steel B with Ti/N ratio of 3·22 (slightly below stoichiometric) showed slightly higher toughness in the simulated CGHAZ due to higher volume fraction of austenite grains less than 80 μm in diameter.     

Observation of twinned martensite in weld heat affected zone of Grade 100 low carbon microalloyed steel

Abstract

The microstructural changes caused by a low nominal heat input of 0.5 kJ mm^-1 in the coarse grained heat affected zone (CGHAZ) of Grade 100 microalloyed steel were investigated. Microhardness measurements suggested that the CGHAZ was martensite of maximum theoretical hardness for the carbon content of the steel. The bulk of the CGHAZ was lath martensite containing none of the small and few of the intermediate sized Nb precipitates responsible for strength and grain size control in the steel plate. Twinned martensite was unexpectedly observed in local areas of the CGHAZ. The formation of twins, which are normally seen in steels with a higher level of carbon, is explained by a combination of the rapid heating rates, high peak temperatures, precipitate dissolution and dispersion, and rapid cooling rates.     

Erosion testing and surface preparation using abrasive water-jetting

Erosion testing and surface preparation are studied using a 3-axis Computer Numerical Control (CNC) abrasive water jetting (AWJ) apparatus. The effects of erosion time t, impingement angle α and pressure p on the erosion rate E, average surface roughness R _a, and surface hardness Rockwell C Hardness (HRC) were investigated in detail. Compared with conventional grit blasting, AWJ can reduce grit embedment in the target material due to the action of the high-pressure water. AWJ also has the advantage of generating a higher average surface roughness R _a over water jetting (WJ) due to the action of abrasive particles. In addition, AWJ increases the surface hardness HRC of the substrate material. The obtained higher degree of average surface roughness is helpful for improving the bonding strength between the coating and the substrate material. The erosion testing and the surface preparation are numerically controlled by a 3-axis CNC system; therefore precise and detailed results for various operating parameters can be obtained.     

磨粒半径对金刚石研磨加工影响机制的仿真研究

为解析金刚石磨粒尺寸变化对金刚石材料研磨质量的影响机制,利用分子动力学方法建立球形刚性金刚石磨粒研磨金刚石工件的模型,研究不同磨粒半径下的磨削力变化规律和应力、相变分布.结果表明:磨粒半径从6a增大到20a(a为金刚石晶格常数),磨削平均法向力和平均切向力均线性增加,但平均法向力增量为平均切向力的3倍;磨粒与工件间的剪...     

Comparative studies of grain refinement of commercial purity Mg by CaO and Ca addition

ABSTRACT

The comparative studies of grain refinement of commercial purity Mg by CaO/Ca addition have been investigated by using TP-1 tests, optical microscope, XRD characterisation and TEM (STEM) observation along with EDX analysis. Experimental results showed that Ca/CaO addition significantly refines the grain structure of commercial purity Mg. Compared with Ca addition, CaO exhibits finer grain size and the average grain size remains invariable with further CaO addition. CaO addition is readily reduced to Ca by Mg melt and forms Mg₂Ca on the surface of MgO particles. First-principle calculations were used to understand the nucleation of Mg₂Ca layer by a coherent interface model calculating the work of adhesion and the interface energy between Mg₂Ca and α-Mg. The combination of experiments and calculations showed that the formation of Mg₂Ca layer on MgO facilitates the nucleation of α-Mg and then refines the grain structure by Ca or CaO addition.