Surface alloying of carbon tool steels using laser heating

The problems of surface hardening of high-carbon steels by alloying using laser radiation are considered. The effect of the laser treatment parameters on the thickness, the structure, the phase composition, the microhardness, and the residual stresses of the surface layer is studied, and the influence of alloying elements on the strength of the surface layer in carbon steels and their wear resistance is investigated.     

Effect of Shot Blasting and Shot Peening Parameters on Residual Stresses Induced in Connecting Rod

This paper investigates the effect of shot blasting and shot peening parameters on residual stresses induced in connecting rod. Compressive residual stresses are induced using shot peening to increase fatigue life of connecting rod. Shot peening is also responsible for increase in surface roughness. Surface roughness is detrimental for fatigue life of the connecting rod. This necessitates shot blasting to reduce surface roughness. Shot peening and shot blasting processes are analysed to find optimum process parameters which will induce required value of compressive residual stress on the surface of connecting rod. Compressive residual stresses induced in the connecting rod specimen have been experimentally measured using X-ray stress analyser. The experimental results have been analysed using grey relational analysis to find optimum values of process parameters for target value of compressive residual stress and surface roughness. The experimental investigation and the analysis of it have resulted in achieving the desired value of compressive residual stress, which is 10.5% higher over the existing connecting rod. Surface roughness also decreases to 3.84 Ra which is 8.5% lesser than specified value to achieve better fatigue life.     

硬质合金基体上金刚石膜粘附性能的影响因素探讨

采用压痕试验法的临界开裂（或剥落）载荷PCr和抗裂性参数dP/dX两指标系统,评定了硬质合金基体经不同预处理工艺和沉积工艺参数全盛的金刚石膜的粘附性能。探讨了粘附性能指标与基体表面钴相含量、表面粗糙度、主要沉积工艺参数（如甲烷浓度、沉积气压、沉积功率）、膜中残余应力之间的内在关系。适当的基体表面预处理、合适的甲烷浓度、较低的沉积气压、较高的沉积功率、适中的残余应力均有利于改善硬质合金基体上金刚石膜的粘附性能。     

Residual stresses in high-velocity oxy-fuel metallic coatings

X-ray based residual stress measurements were made on type 316 stainless steel and Fe₃Al coatings that were high-velocity oxy-fuel (HVOF) sprayed onto low-carbon and stainless steel substrates. Nominal coating thicknesses varied from 250 to 1500 μm. The effect of HVOF spray particle velocity on residual stress and deposition efficiency was assessed by preparing coatings at three different torch chamber pressures. The effect of substrate thickness on residual stress was determined by spraying coatings onto thick (6.4 mm) and thin (1.4 mm) substrates. Residual stresses were compressive for both coating materials and increased in magnitude with spray velocity. For coatings applied to thick substrates, near-surface residual stresses were essentially constant with increasing coating thickness. Differences in thermal expansion coefficient between low-carbon and stainless steels led to a 180 MPa difference in residual stress for Fe₃Al coatings. Deposition efficiency for both materials is maximized at an intermediate (∼600 m/s) velocity. Considerations for X-ray measurement of residual stresses in HVOF coatings are also presented.     

Residual stress-affected diffusion during plasma nitriding of tool steels

Plasma nitriding of tool materials is common practice to improve the wear resistance and lifetime of tools. Machining-induced compressive residual stresses in shallow layers of some tenths of microns are observed accompanied by other characteristic properties of machined surfaces in these high-strength materials. After plasma nitriding of M2 high-speed steel, previously induced compressive residual stresses remain stable and the depth of diffusion layers decreases with increasing compressive residual stresses. This article reports investigations of plasma nitrided samples with different levels of residual stresses induced prior to the nitriding process. For comparison, experiments with bending load stresses during plasma nitriding have also been carried out. The plasma nitriding treatment was performed at constant temperature of 500 °C with a gas mixture of 5 vol pct N₂ in hydrogen. Nitriding time was varied from 30 to 120 minutes. All samples were characterized before and after plasma nitriding concerning microstructure, roughness, microhardness, chemical composition, and residual stress states. Experimental results are compared with analytical calculations on (residual) stress effects in diffusion and show a clear effect of residual and load stresses in the diffusion of nitrogen in a high-strength M2 tool steel.     

Bauschinger effect and residual phase stresses in two ductile-phase steels: Part II. The effect of microstructure and mechanical properties of the constituent phases on Bauschinger effect and residual phase stresses

A finite-element method has been employed to calculate the effect of the prestrain, particle size, volume fraction, and yield strength ratio of the constituent phases on the Bauschinger effect (BE) and residual phase stresses for ferrite-martensite two-phase steels. The relationships be-tween the BE parameters and residual phase stresses are given, and the basics of inelastic un-loading and the effect of reverse deformation on the BE and residual phase stresses are also discussed. Based on the decaying of the residual phase stresses (commonly called “back stresses”) during reverse loading, the relationship between back stresses and permanent softening has been elucidated. Some of the calculated results are compared with experimental ones, and good agree-ment between them is found.     

Induction Heat Treatment of Sheet‐Bulk Metal‐Formed Parts Assisted by Water–Air Spray Cooling

In order to produce components with massive secondary functional elements from sheet metal bulk forming operations, termed sheet‐bulk metal forming, can be applied. Owing to high, three‐dimensional stress and strain states present during sheet‐bulk metal forming, ductile damage occurs in the form of micro‐voids. Depending on the material flow properties, tensile residual stresses can also be present in the components' formed functional elements. During service, the components are subjected to cyclic loading via these functional elements, and tensile residual stresses exert an unfavorable influence on crack initiation and crack growth, and therefore on the fatigue life. Following the forming process, temperature and microstructurally related compressive residual stresses can be induced by local heat treating of the surface. These residual stresses can counteract potential crack initiation on the surface or in the subsurface regions. In the present study, the adjustability of the residual stress state is investigated using a workpiece manufactured by orbital cold‐forming, which possesses an accumulation of material in its edge region. Based on residual stress measurements in the workpiece's edge region using x‐ray diffractometry, it is possible to verify the compressive residual stresses adjusted by varying the cooling conditions.     

Residual stresses in ground steels

A new X-ray method for the evaluation of three dimensional (residual) stress states is demonstrated by studies of the effect of grinding on Armco iron and a medium carbon steel. Although the penetration depth of the Cr-radiation employed in this study is only 5 μm, there is evidence of residual stresses normal to the surface (normal and shear components). In the past it has been assumed that these stress components can be neglected. Shear stresses normal to the surface are small in Armco iron, but significant (± 60 MPa) in steel. From the sign of the shears, the direction of final grinding can be determined. Cooling decreases the tensile stresses parallel to the surface in steel; surprisingly, the opposite result is found in Armco iron.     

Roentgenographic Determination of Residual Stresses in Carbonitrided Layers

The aim of the current investigation is to examine the influence of carbonitriding in low-temperature plasma on forming macroresidual stresses in the surface layer of the materials. Particular modes of ion carbonitriding are considered in which layers of different depth and different surface microhardness are obtained. The residual stresses in the α-Fe in carbonitride layers are determined by the method of “sin²Ψ.” The results show that at different modes of ion carbonitriding, residual macrostresses are obtained that have different values and depend on the qualitative characteristics of the formed carbonitrided layers.     

Fatigue crack propagation in carburized high alloy bearing steels

Fatigue cracks were propagated through carburized cases in M-50NiL (0.1 C,4 Mo, 4 Cr, 1.3 V, 3.5 Ni) and CBS-1000M (0.1 C, 4.5 Mo, 1 Cr, 0.5 V, 3 Ni) steels at constant stress intensity ranges, ΔK, and at a constant cyclic peak load. Residual compressive stresses of the order of 140 MPa (20 Ksi) were developed in the M-50NiL cases, and in tests carried out at constant ΔK values it was observed that the fatigue crack propagation rates,da/dN, slowed significantly. In some tests, at constant peak loads, cracks were stopped in regions with high compressive stresses. The residual stresses in the cases in CBS-1000M steel were predominantly tensile, probably because of the presence of high retained austenite contents, andda/dN was accelerated in these cases. The effects of residual stress on the fatigue crack propagation rates are interpreted in terms of a pinched clothespin model in which the residual stresses introduce an internal stress intensity, K_i where K_i, = σ_id _i ^1/2 (σ_i = internal stress, d_i = characteristic distance associated with the internal stress distribution). The effective stress intensity becomes K_e = K_a + K_i where K_a is the applied stress intensity. Values of K_i were calculated as a function of distance from the surface using experimental measurements of σ_i and a value of d_i = 11 mm (0.43 inch). The resultant values of K_e were taken to be equivalent to effective ΔK values, andda/dN was determined at each point from experimental measurements of fatigue crack propagation obtained separately for the case and core materials. A reasonably good fit was obtained with data for crack growth at a constant ΔK and at a constant cyclic peak load. The carburized case depths were approximately 4 mm, and the possible effects associated with the propagation of short cracks were considered. The major effects were observed at crack lengths of about 2 mm, but the contributions of short crack phenomena were considered to be small in these experiments, since the two steels were at high strength levels, and short cracks would be expected to be of the order of 10 μm. Also, the two other steels behaved differently and in a way which followed the residual stress patterns. Both M-50NiL and CBS-1000M have a high fracture toughness, with K_lc = 50 MPa · m^1/2 (45 Ksi · in^1/2), and the carburized cases exhibit excellent resistance to rolling contact fatigue. Thus, M-50NiL, carburized, may be useful for bearings where high tensile hoop stresses are developed, since fatigue cracks are slowed in the case by the residual compressive stresses, and fracture is resisted by the relatively tough core.     

Finite element simulation of shot peening of an aluminum alloy considering hardening models

Shot peening is a surface engineering process acknowledged for its potential to develop fatigue strength and erosion-corrosion resistance of metallic materials. In the present study, a 3-D finite element model is employed to predict the effective parameters through a single shot impact and the accuracy of the simulation is validated using previous literatures. In order to induce uniform compressive residual stress patterns across the specimen, processing parameters such as shot velocity, impact angle and friction coefficient should be controlled. It is observed that by increasing the shot velocity and the friction coefficient, the depth of compressive residual stress increases. Moreover, a comparative study between isotropic and kinematic hardening models is performed to evaluate the significant role of the hardening models on the compressive residual stress. It is observed that the kinematic hardening model shows better compatibility with the experimental results compared to the isotropic hardening.     

Wear of hard-turned AISI 52100 steel

High-precision machining such as hard turning changes the surface and the material properties of steel alloys. The near-surface material properties have been predicted from the known hard-turning cutting conditions. The effect of the predicted hard-turned surface and material properties on wear performance was analyzed in detail to develop a process-performance model. A sliding block-on-cylinder wear tester was used for the purpose of testing the wear performance of AISI 52100 bearing steel. The microstructure, surface roughness, residual-stress field, and loading conditions from each wear test were used to develop the process-performance model. The effect of microstructure on the wear performance of hard-turned steel showed that the white layer and overtempered martensite (OTM) had a higher wear resistance than martensite. The wear-mechanism dependence on the surface hardness was attributed to this increase in wear performance. The near-surface residual stress of the material was shown to become more compressive as the material wore down. The applied normal loads affected the surface roughness, residual stresses, and, in turn, the wear performance of the material. A process-performance model was developed to predict the wear performance of hard-turned steels, which considers the machining process and the operating conditions in sliding wear.     

Numerical Simulation of Continuous Tension Leveling Process of Thin Strip Steel and Its Application

 Cold rolled thin strip steel of high flatness quality undergoes multistage deformation during tension leveling. Thus, the parameters of set up and manipulating are more difficult. With the aid of FE code MSCMARC, the tension leveling process of thin strip steel was numerically simulated. Concentrating on the influence of the roll intermeshes in 2# anti cambering on the distribution and magnitude of residual stresses in leveled strip steel, several experiments were done with the tension leveler based on the results from the simulation. It was found from the simulation that the magnitude of longitudinal residual stresses in the cross section of the leveled strip steel regularly presents obvious interdependence with the roll intermeshes in 2# anti cambering. In addition, there is a steady zone as the longitudinal residual stresses of the surface layers in leveled strip steel vary with the roll intermeshes of 2# anti cambering, which is of importance in the manipulation of tension levelers. It was also found that the distribution of strains and stresses across the width of strip steel is uneven during leveling or after removing the tension loaded upon the strip, from which it was found that 3D simulation could not be replaced by 2D analysis because 2D analysis in this case cannot represent the physical behavior of strip steel deformation during tension leveling.     

Residual stress measurements by x-ray diffraction in the ferritic-austenitic interface weldment

A mathematical model of calculating residual stresses at the weld interface of ferritic-austenitic steels has been developed. The Kurdjumov-Sachs orientation relationship (110)_bcc[111]// (11 l)_fcc[011] was determined at the interface of the transition joint. The resultant bcc-fcc lattice misfit gives rise to significant residual stresses. The performed X-ray analysis establishes macro- and microstress profiles extending up to 22 mm and 55 μm, respectively. The profiles indicate the development of compressive and tensile stresses on either side of the weld interface. With respect to this, tensile stresses in increasing sequence were computed from the parent metal toward the interface and compressive stresses were determined from the interface inward toward the weld bead in decreasing sequence. A remarkable stress discrepancy between the two profiles was observed, with the macrostresses falling in the range of +185 to −245 MPa and the microstress level ranging between +340 and −420 MPa. While the developed interfacial residual stresses are due to the difference in the bcc-fcc lattice parameters, the discrepancy observed in the determined stress level has its origin in the varying percentage of the two phases involved within a narrow mixing zone at the weld interface.     

Mapping Residual Stress Distributions at the Micron Scale in Amorphous Materials

Residual stresses in crystalline or glassy materials often play a key role in the performance of advanced devices and components. However, stresses in amorphous materials cannot easily be determined at the micron scale by diffraction, or by other conventional laboratory methods. In this article, a technique for mapping residual stress profiles in amorphous materials with high spatial definition is presented. By applying a focused ion beam (FIB)–based semidestructive mechanical relaxation method, the stresses are mapped in a peened and fatigued bulk metallic glass (BMG) (Zr₅₀Cu₄₀Al₁₀ at. pct). The residual stresses are inferred using finite element analysis (FEA) of the surface relaxations, as measured by digital image correlation (DIC), that occur when a microslot is micromachined by FIB. Further, we have shown that acceptable accuracy can in most cases be achieved using a simple analytical model of the slot. It was found that the fatigue cycling significantly changes the distribution of compressive residual stresses with depth in the plastically deformed surface layer. Our observations point to the scalability of this method to map residual stresses in volumes as small as 1 × 1 × 0.2 μm³ or less.     

辊弯成形方形型钢的残余应力

 残余应力对于型钢产品的使用性能有重要影响。应用X射线衍射方法对方形型钢的残余应力进行了测量,分析了残余应力在型钢各个部位的分布情况,探讨了不同成形工艺、尺寸、厚度材料生产的方形型钢产品残余应力分布的差异。研究结果表明型钢焊缝处的残余应力最大,残余应力在外表面为拉应力,内表面为压应力,不同成形工艺与外形尺寸对于残余应力的分布有较大影响。研究结果可为工艺设计人员和型钢使用人员提供有益的参考。     

Thermal-tempering analysis of bulk metallic glass plates using an instant-freezing model

The viscoelastic nature of bulk metallic glasses (BMGs), their low thermal conductivity, and the fast cooling used in their processing subject them to thermal tempering. This process leads to a residual stress state in which compression on the surface is balanced by tension in the interior. For the first time, we have calculated such stresses in metallic glasses by adapting an analytical instant-freezing model previously developed for silicate glasses. This model has been demonstrated to be reasonably accurate in predicting the final residual stresses, although, due to its very nature, it neglects transient effects. For an infinite plate geometry and employing processing parameters often used for metallic glasses, we predict that significant residual stresses can be generated in these materials during thermal tempering. Preliminary measurements conducted using the layer-removal method yield compressive residual stress values close to model predictions.     

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MS980 is one of advanced high-strength steels, which has a great potential for producing square tubes. Residual stress plays a significant role in determining roll-formed members?? behavior and strength. An experimental study on transverse residual stress of roll-formed shape with square section was conducted via X-ray diffraction method. The distribution of transverse residual stresses at different position in sections was measured and studied, and influence of cold-rolled-sheet and hot-rolled-sheet, different fillet radius, different processes, and different pickling time on circumferential residual stress distribution for square section was investigated. The experimental results show the transverse residual stresses are compressive stress in the corner portion and the tensile stress in the straight edge. Fillet radius, sheet, and process have a significant impact on the distribution of residual stress, but the conventional pickling hardly affects residual stress.     

A variant selection model for predicting the transformation texture of deformed austenite

The occurrence of variant selection during the transformation of deformed austenite is examined, together with its effect on the product texture. A new prediction method is proposed based on the morphology of the austenite grains, on slip activity, and on the residual stresses remaining in the material after rolling. The aspect ratio of pancaked grains is demonstrated to play an important role in favoring selection of the transformed copper ({311}〈011〉 and {211}〈011〉) components. The extent of shear on active slip planes during prior rolling is shown to promote the formation of the transformed brass ({332}〈113〉 and {211}〈113〉) components. Finally, the residual stresses remaining in the material after rolling play an essential part by preventing growth of the {110}〈110〉 and {100}〈uvw〉 orientations selected by the grain shape and slip activity rules. With the aid of these three variant selection criteria combined, it is possible to reproduce all the features of the transformation textures observed experimentally. The criteria also explain why the intensities of the transformed copper components are sensitive to the pancaking strain, while those of the transformed brass are a function of the cooling rate employed after hot rolling.     

Residual Stress Analysis in Deep Drawn Twinning Induced Plasticity (TWIP) Steels Using Neutron Diffraction Method

In Twinning Induced Plasticity (TWIP) steels, delayed fracture occurs due to residual stresses induced during deep drawing. In order to investigate the relation between residual stresses and delayed fracture, in the present study, residual stresses of deep drawn TWIP steels (22Mn-0.6C and 18Mn-2Al-0.6C steels) were investigated using the finite element method (FEM) and neutron diffraction measurements. In addition, the delayed fracture properties were examined by dipping tests of cup specimens in the boiled water. In the FEM analysis, the hoop direction residual stress was highly tensile at cup edge, and the delayed fracture was initiated by the separation of hoop direction and propagated in an axial direction. According to the neutron diffraction analysis, residual stresses in 18Mn-2Al-0.6C steel were about half the residual stresses in 22Mn-0.6C steel. From the residual strain measurement using electron back-scatter diffraction, formation of deformation twins caused a lot of grain rotation and local strain at the grain boundaries and twin boundaries. These local residual strains induce residual stress at boundaries. Al addition in TWIP steels restrained the formation of deformation twins and dynamic strain aging, resulting in more homogeneous stress and strain distributions in cup specimens. Thus, in Al-added TWIP steels, residual stress of cup specimen considerably decreased, and delayed fracture resistance was remarkably improved by the addition of Al in TWIP steels.