Very high cycle fatigue properties of bainitic high carbon–chromium steel

Fatigue properties of bainitic 100Cr6 (SAE 52100, JIS SUJ2) steel are investigated in the high cycle and very high cycle fatigue (VHCF) regime. Fully reversed tension–compression fatigue tests are performed with ultrasonic fatigue testing equipment. Specimens are grinded which leads to surface compression stresses and increased surface roughness. About 1/3 of the specimens failed after crack initiation at interior Al₂O₃? or TiN-inclusions and 2/3 failed after surface crack initiation at scratches or cavities. When inclusions are considered as cracks, failures can occur at minimum stress intensity range of 2.8 MPa m^1/2, and maximum stress intensity range without failure is 3.3 MPa m^1/2. Facets are visible close to the inclusion in some specimens, and the stress intensity range at the border of the facet is approximately 4.5 MPa m^1/2. Murakami’s model can well predict the endurance limit at 10⁹ cycles for internal failures considering the area of the inclusion in the evaluation. Surface fatigue crack initiation can lead to failure above 10⁸ cycles. When scratches are considered as cracks, minimum stress intensity range of 2.5 MPa m^1/2 can propagate surface cracks to failure. Fracture mechanics approach showed several similarities to literature results of the same material tested in tempered martensite condition.     

Microstructure and properties of Ti–Nb–V–Mo-alloyed high chromium cast iron

The correlations of microstructure, hardness and fracture toughness of high chromium cast iron with the addition of alloys (titanium, vanadium, niobium and molybdenum) were investigated. The results indicated that the as-cast microstructure changed from hypereutectic, eutectic to hypoeutectic with the increase of alloy contents. Mo dissolved in austenite and increased the hardness by solid solution strengthening. TiC and NbC mainly existed in austenite and impeded the austenite dendrite development. V existed in multicomponent systems in forms of V alloy compounds (VCrFe₈ and VCr₂C₂). With the increase of alloy additions, carbides size changed gradually from refinement to coarseness, hardness and impact toughness were increased and then decreased. Compared with the fracture toughness (6 J/cm²) and hardness (50·8HRC) without any alloy addition, the toughness and hardness at 0·60 V–0·60Ti–0·60Nb–0·35Mo (wt%) additions were improved and achieved to 11 J/cm² and 58·9HRC, respectively. The synergistic roles of Ti, Nb, V and Mo influenced the solidification behaviour of alloy. The refinement of microstructure and improvement of carbides morphologies, size and distribution improved the impact toughness.     

Microstructure and mechanical property of high strength Mg–Sn–Zn–Al alloys

This paper aims to reveal the microstructure and mechanical properties of as-cast and hot-rolled Mg–Sn–Zn–Al based alloys. Three alloys, Mg–5Sn–2Zn (TZ52), Mg–5Sn–2Zn–2Al (TAZ522) and Mg–5Sn–5Al–1Zn–0.2Mn (TAZM5510) alloys were studied. The results revealed that the as-cast alloys showed fine dendritic structures. The TAZM5510 alloys exhibited moderate yield strength of 98?MPa with good elongation of ～15%, which was comparable to several commercially used Mg die-castings. Mechanical properties were significantly improved after multi-pass rolling. The TZ52 sheet showed a high yield strength of 277?MPa with excellent ductility exceeding 30%, and the TAZM5510 sheet exhibited the highest tensile strength of 386?MPa while keeping desirable elongation of 16.6%. These sheets are termed as strong and ductile Mg–Sn–Zn–Al wrought alloys.     

Development of a high strain rate superplastic Al–Mg–Zr alloy

Abstract

For superplastic forming of aluminium to break out of the niche market that it currently occupies, alloys will be required to possess a higher strain rate capability, appropriate in service properties, and a significantly lower price and to be capable of volume production. This paper describes an approach that has been developed in an attempt to address these fundamental requirements. A series of Al–Mg–Zr alloys with increasing levels of zirconium (0–1 wt-%)has been prepared via extrusion consolidation of cast particulate (solidification rate ～10³ K s^-1). The superplastic properties of the resultant cold rolled sheet have been evaluated as a function of thermomechanical treatment and zirconium addition. It has been found that increasing the level of zirconium has the twofold effect of improving the superplastic properties of the alloy while significantly decreasing the concomitant flow stress. At present the optimum superplastic behaviour has been obtained at strain rates of 10^-2 s^-1, with the 1%Zr material exhibiting ductilities in excess of 600%. The manufacturing route produces a bimodal distribution of Al₃Zr comprising >1 µm primary particles in combination with nanoscale solid state precipitates. The current postulation is that this high strain rate superplasticity is conferred by a combination of particle stimulated and strain induced recrystallisation.     

Preparation of coatings with high adhesion strength and high corrosion resistance on sintered Nd–Fe–B magnets through electroless plating

Electroless Ni–P-based coatings have been deposited on sintered Nd–Fe–B magnets through applying ultrasonic irradiation and adjusting the [Cu²⁺]/[Ni²⁺] ratio in the solution. The effects of the ultrasonic power on the adhesion to the magnet substrate and the [Cu²⁺]/[Ni²⁺] ratio on the corrosion resistance of the coatings were investigated. It was found that the adhesion of the coating to the substrate could be greatly improved through applying ultrasonic irradiation. Maximum adhesion strength reached 56 MPa at 150 W. The results also showed that the addition of Cu²⁺ could improve the corrosion resistance of Ni–P-based coatings. When the [Cu²⁺]/[Ni²⁺] ratio was 0.02, the coating could be as long as 512 h free of corrosion in the neutral salt spray. The compact amorphous structure was responsible for the improved corrosion resistance of the coating.     

Structure–property relationships for high thermal conductivity carbon fibers

Previous work at Clemson University has shown that ribbon-shaped mesophase pitch-based carbon fibers graphitized at only 2400°C can develop thermal conductivities comparable with those of commercial round-shaped pitch-based carbon fibers graphitized at temperatures above 3000°C. The thermal and electronic transport properties (i.e. thermal conductivity and electrical resistivity) of ribbon-shaped carbon fibers produced at Clemson University are being studied. In addition, the structure of these fibers is being analyzed by electron microscopy and X-ray diffraction techniques. This paper will discuss the relationships between processing conditions, fiber structure and fiber properties.     

Synthesis and high temperature oxidation of Mo–Si–B–O pseudo in situ composites

In this paper, the new concept of ‘pseudo in situ composites’ is introduced into artificial composites for ultra-high temperature applications, composed of five phases, Mo, Mo₃Si, Mo₅Si₃, Mo₅SiB₂ and SiO₂. Among these phases, Mo and Mo₅Si₃ are not thermodynamically stable with each other, but they are locally equilibrated in the composites due to the formation of Mo₃Si as their reactant. Using the spark plasma sintering (SPS) technique, the Mo–Si–B–O pseudo in situ composites are successfully synthesized from Mo₃Si/Mo₅Si₃/Mo₅SiB₂ in situ composite powder, Mo and/or SiO₂ powders. The consolidated compacts are sound and fully dense, indicating that the SPS is a promising technique to synthesize the Mo–Si–B–O pseudo in situ composites. High temperature oxidation properties of the composites were examined up to 1673 K. The temperature range is divided into three with respect to the oxidation behavior; i.e. (I) below 1000 K, (II) between 1000 and 1400 K, and (III) above 1400 K. In the range II, the oxidation resistance of the composites is significantly improved by SiO₂ addition. In the range III, the oxidation resistance of the composites is good enough even at 1673 K in spite of the existence of Mo, displaying high potential for ultra-high temperature applications.     

Investigation of quench sensitivity of high strength Al–Zn–Mg–Cu alloys by time–temperature-properties diagrams

The quench sensitivity of some typical high strength Al–Zn–Mg–Cu alloys, including 7075, 7175, 7050, 7010, 7055, 7085 and 1933, was investigated by time–temperature-properties (TTP) diagrams which were from the present paper and literature. The drop in the mechanical properties due to decreased quenching rate was predicted by quench factor analysis method. The nose temperature of TTP diagrams was the highest for 7055 alloy and the lowest for 7085 alloy. The critical time at the nose temperature was the shortest for 7055 alloy and the longest for 1933 alloy. Decreased quenching rate to 10 k/s led to drop in the properties less than 2% for 7085 and 1933 alloys, but more than 20% for 7075, 7175 and 7055 alloy. Thus, 7075, 7175 and 7055 alloys were the most quench sensitive alloys, while 7085 and 1933 alloys were the least quench sensitive ones. The differences in the quench sensitivity of these alloys were explained mainly based on its chemical compositions.     

Modifying high Cr–Mn cast iron with boron and rare earth–Si alloy

Abstract

By modifying 13Cr–4Mn (wt-%) white cast iron with boron and rare earth (RE)–Si complex, the carbide morphology of the iron can be changed from interconnected, coarse clusters of rods into a parallel distribution of isolated, fine rods, and the impact toughness of the iron can reach 6–7 × 10⁴ J m^?2. In a pin wear test, the relative abrasion resistance of the iron is 1·01 and in a repeated impact abrasive wear test it is 0·95, in comparison with 15Cr–3Mo cast iron. Thus, it is stated that modifying high Cr–Mn cast iron with boron and RE–Si complex is very cost effective, and has almost the same abrasion resistance, when compared with 15Cr–3Mo cast iron.

MST/957     

Phase boundary between Na–Si clathrates of structures I and II at high pressures and high temperatures

Understanding of the covalent clathrate formation is a crucial point for the design of new superhard materials with intrinsic coupling of superhardness and metallic conductivity. It has been found that silicon clathrates have the archetype structures, which can serve an existent model compounds for superhard clathrate frameworks Si–B, Si–C, B–C and C with intercalated atoms (e.g., alkali metals or even halogens) that can assure the metallic properties. Here we report our in situ and ex situ studies of high-pressure formation and stability of clathrates Na₈Si₄₆ (structure I) and Na_24+x Si₁₃₆ (structure II). Experiments have been performed using standard Paris–Edinburgh cells (opposite anvils) up to 6 GPa and 1500 K. We have established that chemical interactions in the Na–Si system and transition between two structures of clathrates occur at temperatures below silicon melting. The strong sensitivity of crystallization products to the sodium concentration has been observed. A tentative diagram of clathrate transformations has been proposed. At least up to ~6 GPa, Na_24+x Si₁₃₆ (structure II) is stable at lower temperatures as compared to Na₈Si₄₆ (structure I).     

Properties of coatings of the Al–Cr–Fe–Co–Ni–Cu–V high entropy alloy produced by the magnetron sputtering

It has been found that coatings from an Al–Fe–Co–Ni–Cu–Cr–V high entropy equiatomic alloy produced by the magnetron sputtering have nanocrystalline microstructures, are textured, and present a solid two-phase solution, which crystallizes in the bcc (a = 2.91 Å) and fcc (a = 3.65 Å) phases. The ion bombardment of a growing coating caused by the bias voltage (0–(–200) V), which has been applied to the substrate, decreases the growth rate of a condensate and affects its composition and structure. It has been shown that the composition of coatings deposited without an ion bombardment coincides with the target composition, whereas an increase of the ion bombardment intensity leads to the depletion of the coating composition in Al, Cu, and Ni and increase the microhardness. The anisotropy of the coating produced has been revealed.     

Characterisation of two Al–Fe based high temperature alloy powders

Abstract

Aluminium alloys containing additions of iron and cerium are among the alloys being developed as potential replacements for titanium based alloys for moderately high temperature applications. Development of these alloys is possible using rapid solidification technology, which results in a very fine distribution of dispersoids in the aluminium matrix. The microstructures of two rapidly solidified high temperature alloy powders of composition (wt-%) Al–6·7Fe–5·9Ce (alloy A) and Al–6·2Fe–5·9Ce–1·63Si (alloy B) have been characterised using transmission electron microscopy and the results are explained on the basis of some of the major solidification parameters, such as nucleation undercooling and recalescence. It was observed that most of the powder particles in the +10 to ?20 μm size range contained both microcellular and cellular regions, which could be explained in terms of an initial large undercooling followed by recalescence. The decomposition of the powder microstructure after exposing the powders to temperatures of 350, 420, and 500°C for 1 h was investigated using transmission electron microscopy. This work was complemented by phase identification studies using X-ray diffraction. The equilibrium precipitates Al₁₃Fe₄, Al₈Fe₂Si, and Al₃FeSi were detected in the powder microstructure of alloy B, whereas Al₁₃Fe₄ precipitates were detected in alloy A after high temperature exposure (500°C).

MST/1571     

NLR experience with high velocity burner rig testing 1979–1989

The NLH. has two high velocity burner rigs for oxidation and hot corrosion testing. A large, custom-built rig was commissioned in 1977 to enable actual components to be tested. A smaller rig for specimen testing was purchased in 1986. Experience with these rigs over the last decade is reviewed.     

Formation of non–equilibrium alloys by high pressure melt quenching

Melt quenching under high pressure can promote the formation of metastable materials. High pressure accelerates the amorphization of Cu₆₀Ti₄₀ and Cd₄₃Sb₅₇.For an alloy systems having volume expansion after solidification, the higher the applied pressure, the lower the melting point and the higher the amorphization temperature, which promotes the formationof metallic glass. High pressure also enhances nucleation and suppresses grain growth, so solidification under high pressure can refine the crystal grains to form nanocrystalline alloys, such as Ti₆₀Cu₄₀,Cu₇₀Si₃₀ and Pd₇₈Si₁₆Cu₆ alloys.     

Phase transformations in Al–Mg–Zn alloys during high pressure torsion and subsequent heating

The structure, phase composition, and their thermal evolution were studied in case of ternary Al–Zn–Mg alloys before and after high-pressure torsion (HPT) in Bridgman anvils. The as-cast non-deformed alloys contained the fine particles of Mg₃₂(Al,Zn)₄₉ (τ phase), MgZn₂ (η phase), AlMg₄Zn₁₁ (η′ phase), and Mg₇Zn₃ phases embedded in the matrix of Al-based solid solution. During heating in differential scanning calorimeter (DSC), all these phases dissolved around 148 °C. The τ nanoparticles coherent with (Al) matrix-formed instead around 222 °C. HPT of the as-cast alloys strongly refined the grains of (Al) solid solution from 500 μm to 120–150 nm. The particles of τ, η, η′, and Mg₇Zn₃ phases fully dissolved in the (Al) matrix. During the following DSC-heating, particles of η phase appeared and grew. Their amount became maximal around 166 °C. The growth of η phase in the fine-grained HPT-treated alloys instead of τ phase in the coarse-grained ones is explained by the shift of the (Al) + η/(Al) + η + τ/(Al) + τ lines in the Al–Zn–Mg ternary phase diagram due to the grain boundary (GB) adsorption. At 166 °C the η phase formed the continuous flat layers in numerous (Al)/(Al) GBs. This corresponds to the complete GB wetting by the η phase. Other (Al)/(Al) GBs contain separated lenticular η particles (incomplete GB wetting). Increasing the temperature from 166 to 320 °C led to the disappearance of the completely wetted (Al)/(Al) GBs. In other words, the transition from complete to the incomplete wetting of (Al)/(Al) GBs by the η phase proceeds between 166 °C and 320 °C.     

Workability of Ti–6Al–4V alloy at high temperatures and strain rates

Hot workability of Ti–6Al–4V has been investigated by means of hot compression tests carried out in the 880–950 °C temperature range and 1–50 s⁻¹ strain rate range. The effect of microstructural characteristics of the deformed specimens have been studied and correlated with the test temperature, total strain and strain rate. A constitutive equation for the flow stress has been defined and the test conditions for a homogeneous deformation evaluated. The machine employed for testing allowed to reach very high strain rates by means of a uniform compression for long strains (until 0.9), whereas data extracted from the scientific literature are significantly limited in comparison. In this way, a higher accuracy could be obtained in material behaviour modelling for forging process simulation.     

Deformation behaviour of ultrafine grained Mg–7Gd–5Y–1.2Nd–0.5Zr alloy under high strain rates

The mechanical behaviour of Mg–7Gd–5Y–1.2Nd–0.5Zr (wt. %) alloy with ultrafine grains was measured by split Hopkinson pressure bar method under the strain rates of 1000, 1500, and 2000 s^?1 at room temperature. Dynamic tests were carried out along extrusion direction (ED), transverse direction (TD), and normal direction (ND). The results demonstrated that the flow stress increased with the increase of strain rate, showing a positive strain rate strengthening effect. There was no obvious anisotropy in dynamic compression along ED, TD, and ND, which was caused by rare earth elements and multi-pass deformation. This led to the adoption of plastic deformation mode dominated by non-basal slip and participated by tension twinning.     

Synthesis of high purity hydroxyapatite nanopowder via sol–gel combustion process

A polymeric sol–gel combustion method has been used to synthesize nanocrystalline hydroxyapatite (HA) powder from calcium nitrate and triethyl phosphate with the addition of NH₄OH. The sol–gel combustion process generates phase-pure nanocrystalline HA powder, as characterized using Fourier transform infrared (FTIR), X-ray diffraction (XRD), and transmission electron microscopy (TEM). Sintering of the HA powder compact at 1200°C for 2 h leads to a 93% theoretical dense ceramic body. This method offers an easy route for the preparation of phase-pure nanocrystalline HA powder.     

Surface integrity in high speed end milling of titanium alloy Ti–6Al–4V

Abstract

Machined titanium components, such as medical prosthesis, require the greatest reliability, which is determined by process induced surface integrity. However, surface integrity of milled titanium components easily deteriorates due to the poor machinability of titanium alloys and cyclic chip loading during milling. Milling induced surface integrity, including anisotropic surface roughness, residual stress, surface microstructure alterations and microhardness, has received little attention. In the present study, a series of end milling experiments were conducted to comprehensively characterise surface integrity at various milling conditions of titanium alloy Ti–6Al–4V with TiAlN coated carbide cutting tools. The experiments were carried out under dry cutting conditions. For a range of cutting speeds, feeds and depths of cut, analyses of machined surface roughness, residual stress, microhardness and the microstructural observations were carried out. The present work aims to evaluate the influence of different milling conditions on workpiece surface integrity.     

Reduced graphene oxide–nickel oxide composites with high electrochemical capacitive performance

Reduced graphene oxide (RGO)–NiO composites have been fabricated by a simple solvothermal route starting with graphite oxide (GO). The morphology, composition and microstructure of the as-obtained samples are systematically characterized by thermogravimetric (TG) analysis, X-ray diffraction (XRD), and field emission scanning electron microscopy (FESEM). Moreover, the electrochemical performances of composites were evaluated by cyclic voltammogram (CV) and galvanostatic charge–discharge. Interestingly, it was found that the electrochemical performance of the composites could be affected by the mass ratio between RGO and NiO. The composite with the mass ratio up to 79:21 (NiO:RGO) exhibits the highest specific capacitance of 576 F g⁻¹ at 1 A g⁻¹, which is much higher than that of pure NiO (240 F g⁻¹) and pure RGO (98 F g⁻¹). In addition, the cycling measurements showed that RGO–NiO composite exhibited excellent cycling stability with no decay in the available capacity over 1100 cycles. The enhancement in specific capacitance and cycling stability may be attributed to the increased electrode conductivity owing to RGO network, the increased effective interfacial area between NiO and the electrolyte, as well as the contact area between NiO and RGO.