Mechanical properties of alloy Ti–6Al–4V and of stainless steel 316L processed by selective laser melting: influence of out-of-equilibrium microstructures

Abstract

Ti–6Al–4V and stainless steel 316L have been processed by selective laser melting under similar conditions, and their microstructures and mechanical behaviours have been compared in details. Under the investigated conditions, Ti–6Al–4V exhibits a more complex behaviour than stainless steel 316L with respect to the occurrence of microstructural and mechanical anisotropy. Moreover, Ti–6Al–4V appears more sensitive to the build-up of internal stresses when compared with stainless steel 316L, whereas stainless steel 316L appears more prone to the formation of ‘lack of melting’ defects. This correlates nicely with the difference in thermal conductivity between the two materials. Thermal conductivity was shown to increase strongly with increasing temperature and the thermophysical properties appeared to be influenced by variations in the initial metallurgical state.     

Mathematical model of the thermal processing of steel ingots: Part II. Stress model

A mathematical model has been developed to predict the internal stresses generated in a steel ingot during thermal processing. The thermal history of the ingot has been predicted by a finite-element, heat-flow model, the subject of the first part of this two-part paper, which serves as input to the stress model. The stress model has been formulated for a two-dimensional transverse plane at mid-height of the ingot and is a transient, elasto-viscoplastic, finite-element analysis of the thermal stress field. Salient features of the model include the incorporation of time-temperature and temperature-dependent mechanical properties, and volume changes associated with nonequilibrium phase transformation. Model predictions demonstrate that the development of internal stresses in the ingot during thermal processing can be directly linked to the progress of the phase transformation front. Moreover, the low strain levels calculated indicate that metallurgical embrittlement must be very important to the formation of cracks in addition to the development of high tensile stresses. B. G. THOMAS, formerly a Graduate Student at the University of British Columbia     

Compound materials by PM-HIP

Abstract

There are many applications where compound materials can be of interest, for example when different properties are needed in different parts of a component. Compound materials can be produced by hot isostatic pressing (HIP) of powder metallurgical materials. One aspect that should be considered in the design is the quality of the interface between the two different material compositions. Diffusion during HIP can cause formation of brittle phases in the interface or deteriorate properties by diffusion of alloying elements. The present work shows results from a study where different steel types were joined (quench and temper steel/air hardening steel/bearing steel with a tool steel/corrosion resistant martensitic steel). The evaluation was performed by computational predictions and by small scale HIP experiments that were evaluated by microstructure analysis and chemical analysis.     

Modelling Transformation Induced Plasticity – an Application to Heavy Steel Plates

The time‐dependent inhomogeneous temperature distribution during the cooling of steel plates gives rise to thermal strains which, in turn, generate plastification and thus residual stresses. Moreover, transformation from the parent austenite phase into a product phase typically entails not only metallurgical strains but also accounts for transformation induced plasticity (TRIP), which again generates transformation related residual stresses. It is the goal of this paper to build a unified model that takes into account all relevant contributions to the total strain rate, i.e., elastic, plastic, thermal, metallurgical and TRIP strain contributions. The material parameters relevant for TRIP are determined by means of dilatometric tests as well as by purely numerical means. For the evolution of the product phase a kinetic relationship will be presented that allows differentiating between different local cooling rates. It is set up with an Avrami‐like approach, specially designed for complex cooling histories. The material model is implemented into the commercial finite element package ABAQUS, which allows to simulate the evolution of the residual stresses in heavy steel plates after complete cool‐down to room temperature.     

Ni-based superalloy as a potential tool material for thixoforming of steels

Abstract

Semisolid processing, already a well established manufacturing route for the production of intricate, thin walled aluminium and magnesium parts with mechanical properties as good as forged grades, faces a major challenge in the case of steels. The tool materials must withstand complex load profiles and relatively higher forming temperatures for thousands of forming cycles for this near-net shape process to be attractive for steels on an industrial scale. The potential of a Ni-based superalloy, Inconel 617, reported to exhibit superior thermal fatigue resistance in demanding tooling applications, was investigated. The response to thermal cycling of this alloy at high temperatures was compared with that of X38CrMoV5 hot work tool steel widely used in the manufacture of conventional forging dies. The favourable thermophysical properties of the latter were completely negated by its limited temper resistance, while the Inconel 617 alloy responded to thermal cycling by the usual heat cracking mechanism.     

Composition control in the direct laser-deposition process

Laser-engineered net shaping (LENS) is a solid freeform fabrication process that has the capability of producing functionally graded material (FGM) components by selectively depositing different powder materials in the melt pool at specific locations in the structure during part buildup. The composition in each layer of an FGM is dependent upon the degree of dilution between the substrate (or previous layer) and powder material. A study on the effects of LENS processing parameters (laser power, travel speed, and powder mass flow rate) on dilution was conducted for deposits of H-13 tool steel and copper powder on H-13 tool steel substrates. When varying a single processing parameter while holding all others constant, the dilution was found to increase with increasing laser input power and travel speed and decrease with increasing powder mass additions into the melt pool. A method for estimating dilution in LENS deposits was developed from knowledge of LENS process efficiencies and material thermophysical properties. A reasonable correlation was shown to exist between the experimentally measured dilution and the dilution calculated from the model.     

Response to thermal cycling of tool materials under steel thixoforming conditions

Abstract

The principal failure mechanism of steel thixoforming dies is thermal fatigue owing to forging pressures much lower than those encountered in conventional forging. This makes a properly designed thermal fatigue test the best method to identify suitable tooling materials for the steel thixoforming environment. Samples of X32CrMoV33 hot work tool steel and CrNiCo alloy were cycled thermally between 450 and 750°C, every 60 s for a total of 1500 cycles. While the thermal stresses generated at the surfaces of the two materials were very similar, their responses to thermal cycling were markedly different. The X32CrMoV33 steel was softened by nearly 40% after only 400 cycles, raising serious concerns over its temper resistance under steel thixoforming conditions. The extensive oxidation and subsequent spalling of oxide scales suffered by the X32CrMoV33 hot work tool steel is also a major shortcoming. The performance of the CrNiCo alloy, on the other hand, was judged to be satisfactory with a much thinner heat affected zone and a much better oxidation resistance. Lack of evidence for heat checking in this alloy after 1500 cycles is an encouraging sign.     

Friction Stir Welding in HSLA-65 Steel: Part I. Influence of Weld Speed and Tool Material on Microstructural Development

A systematic set of single-pass full penetration friction stir bead-on-plate and butt-welds in HSLA-65 steel were produced using a range of different traverse speeds (50 to 500?mm/min) and two tool materials (W-Re and PCBN). Microstructural analysis of the welds was carried out using optical microscopy, and hardness variations were also mapped across the weld-plate cross sections. The maximum and minimum hardnesses were found to be dependent upon both welding traverse speed and tool material. A maximum hardness of 323?Hv(10) was observed in the mixed martensite/bainite/ferrite microstructure of the weld nugget for a welding traverse speed of 200?mm/min using a PCBN tool. A minimum hardness of 179?Hv(10) was found in the outer heat-affected zone (OHAZ) for welding traverse speed of 50?mm/min using a PCBN tool. The distance from the weld centerline to the OHAZ increased with decreasing weld speed due to the greater heat input into the weld. Likewise for similar energy inputs, the size of the transformed zone and the OHAZ increased on moving from a W-Re tool to a PCBN tool probably due to the poorer thermal conductivity of the PCBN tool. The associated residual stresses are reported in Part II of this series of articles.     

Influence of Powder Morphology and Chemical Composition on Metallic Foams produced by SlipReactionFoamSintering (SRFS)‐ Process

The SlipReactionFoamSintering (SRFS)‐ process is a metallurgical method to produce open‐cell metallic foams of iron based materials, steels and nickel based materials. In this process several chemical reactions take place. Through the most influential parameter, the morphology of the metallic powder, different properties of the foam can be adjusted, such as the viscosity of the slip, the cell structure and the mechanical properties. Several examples are presented in this paper. Moreover, the thermal conductivity of three foams is measured with the transient‐heat‐source‐technique.     

Structural materials for fusion reactors

Fusion Reactors will require specially engineered structural materials, which will simultaneously satisfy the harsh conditions such as high thermo mechanical stresses, high heat loads and severe radiation damage without compromising on safety considerations. The fundamental differences between fusion and other nuclear reactors arise due to the 14MeV neutronics of structural materials. There exists considerable uncertainty in the nuclear data at such energies because there aren’t any strong enough sources for such neutrons except fusion reactors themselves! We thus encounter a problem of iterative nature in which we must try several experiments with the available materials in the near term. The development of such structural materials is thus going to require the experimental data of the kind that may be generated on reactors like ITER, high-performance modeling and a penetrating metallurgical insight to overcome technological challenges in terms of achieving required properties such as low activation by controlling the impurities, good thermo-mechanical properties by microstructure engineering, good chemical compatibility and high radiation resistance. These materials need to withstand a neutron wall load of the order of 2–3 MW/m², which can lead up to 30 dpa of radiation damage and 300 appm helium production per full power year in DEMO like reactors. Such conditions lead to unprecedented events related to the failure of materials due to irradiation creep, Ductile-Brittle Transition Temperature (DBTT) shift and helium embrittlement. The development of fusion materials program is oriented towards fulfilling the requirements of Test Blanket Modules, various prototype activities of SST-2 and DEMO reactor. The materials identified for first wall and blanket modules for Indian DEMO are LAFMS and ODS steels. The development program plan for these materials include (i) Manufacturing of LAFMS steel through VIM/VAR methods by controlling the impurities such as S, P and Si. (ii) ODS steel development with nano-size Y₂O₃ dispersoids in ferritic martensitic matrix by powder metallurgy route. The advanced structural materials like SiC_f /SiC composites and SiC_f /n-SiC are planned under National Fusion Program projects for indigenous development. An overview of the planned program in this direction will be presented.     

Residual stresses after orthogonal machining of AlSl 304: numerical calculation of the thermal component and comparison with experimental results

Residual stresses due to the thermal influence of orthogonal machining have been calculated with a finite element model using stationary workpiece temperatures during cutting calculated with the finite difference method. Calculated results are compared with experimental data obtained with the X-ray diffraction method. In this way, the thermal and mechanical/frictional influences of the machining operation on the workpiece residual stress state can be separated. The influence of cutting speed and cutting depth on machining residual stresses is discussed. It is shown that the thermal as well as the mechanical impact of the orthogonal cutting process causes tensile residual stresses. The mechanical impact of the machining operation causing tensile residual stresses is due to (a) compressive plastic deformation in the surface layer ahead of the advancing tool and (b) greater elastic relaxation upon unloading with respect to the underlying material of a thin, strongly work-hardened surface layer. CHRISTOPH WIESNER, formerly Research Assistant with the Laboratoire de Métallurgie Mécanique, Ecole Polytechnique Fédérale de Lausanne, MX-D Ecublens, 1015 Lausanne, Switzerland.     

粉末冶金生产工艺的两大发展

粉末冶金是节能、高效、环境友好、适合大批量生产的金属成形工艺,又因其工艺特点,创造了一系列特殊性能和用途的新材,有着广阔的发展前景.但是传统粉末冶金工艺制备的材料均含有残余孔隙,影响了性能的提高,其生产的零件的形状复杂性也受到限制.以粉末冶金高速工具钢为代表的完全致密化工艺是粉末冶金生产工艺的一大发展,粉末注射成形则是...     

Design of corners of mould in square billet casting

Abstract

In continuous casting, heat flow optimisation in the mould is key to improving the quality of the product and production savings. The heat flow influences, and is influenced by, several phenomena of a mechanical or metallurgical nature, so its optimisation should include these. In particular, shrinkage of the strand and solid phase formation are among the most influencing factors affecting the cooling of the solidifying product. The present paper describes a model implemented by a software tool that can carry out simulation of shell formation of carbon steel within the mould, for rectangular shapes. The first aim of the software is to simulate formation of the solid shell in the strand and the deformations to which this solid is subjected. Deformations are a result of both thermal shrinkage, related to phase changes, and stresses caused by metallostatic pressure or the mould-shell interaction. The output of the model consists of temperature maps of the strand, maps of formation of the shell and the ideal mould contour.     

Coupled temperature,stress, phase transformation calculation

The quenching of steels involves thermal, mechanical, and structural phenomena and their couplings. In this paper, a coupled thermal, phase transformation, internal stresses calculation model is presented. Especially, the stress-phase transformation interactions (transformation plasticity and kinetics modifications through internal stresses) are taken into account in this model, not only for martensitic transformation but also for diffusion dependent transformation. Using a specific case, the cooling of a cylinder made of eutectoid carbon steel, an analysis of how the stress phase transformation interactions affect the internal stresses, and plastic strain evolutions during cooling are performed. The calculated results show that internal stresses have an important effect on the kinetics of pearlitic transformation. These changes in transformation kinetics modify the levels of the internal stresses themselves and the residual stresses.     

Consequences of transformation plasticity on the development of residual stresses and distortions during martensitic hardening of SAE 4140 steel cylinders

Residual stresses and distortions developing during martensitic hardening of steel can be quantitatively determined by finite element calculations, if the underlying processes are adequately modelled and the materials and process data necessary are known. In this context also transformation plasticity effects have to be taken into account. Model calculations for SAE 4140 steel cylinders demonstrate the influence of these effects on the developing residual stresses. Using a special device which allows martensitic transformation under constant external loads, for SAE 4140 the transformation plasticity constant K = 4.2 · 10^?5mm²/N is determined. With this constant and assuming realistic heat transfer conditions, the development of residual stresses and distortions of SAE 4140 cylinders with a diameter of 30 mm and a length of 90 mm is modelled. The calculated results are in good agreement with experimental findings.     

Impact of in Situ Heat Treatment Effects during Laser-Based Powder Bed Fusion of 1.3343 High-Speed Steel with Preheating Temperatures up to 700 °C

For laser-based powder bed fusion (PBF-LB) of high carbon steels, preheated build platforms can reduce thermal stresses and crack formation inside the generated material. Furthermore, the heat distribution during PBF-LB is affected by laser energy input and heat transfer into the surrounding area. Depending on the preheating temperature and the thermal conditions during PBF-LB, thermal gradients and different thermal exposure times of the manufactured layers can lead to in situ heat treatment effects. As a result, gradients in microstructures and properties are observed in the manufactured material. The effects are investigated on AISI M2 high-speed steel (1.3343). Specimens are manufactured at platform preheating temperatures between 200 and 700 °C. Base plate and surface temperatures in the building layer are monitored by thermocouples and pyrometry. Local variations in the material microstructure and properties are determined and the effects of temperature distribution on microstructure and hardness are discussed.     

Prediction of Microstructure and Mechanical Properties of Hot Rolled Steel Strip: Part I ‐ Description of Models

A metallurgical through‐process model is presented which describes the microstructural evolution and predicts the final mechanical properties of low carbon steel during hot strip rolling. Process models concern the thermal and deformation phenomena, which take into account the strain, strain rate and temperature distribution along the length of the strip. And the metallurgical models cover five modules, which are (i) austenitization of cast slab in reheating furnace, (ii) recrystallization of austenite in hot rolling, (iii) phase transformation of austenite‐ferrite in laminar cooling on the run‐out‐table, (iv) grain growth after coiling, and (v) final structure‐mechanical properties of products. Temperature is the main parameter and has dominant influence on the microstrutural evolution and the mechanical properties. The related temperature variation in hot strip rolling concerns air cooling, scaling, water cooling, heat transmission by roll contact, heat generation by deformation and friction. These complex factors are incorporated into the thermal models to simulate the temperature distribution along the length of the strip from the reheating furnace exit to the down‐coiler. A self‐learning algorithm is employed to improve the calculation accuracy and the computational temperatures are compared with the measured ones at typical locations. In the structure‐property relationships, two key process parameters (e.g., finishing exit temperature (FT7) and coiling temperature (CT)) are introduced in the model to consider the influence of morphology of microstructure on mechanical properties.     

Thermal analysis of the arc welding process: Part II. effect of variation of thermophysical properties with temperature

This article is Part II of a two-part series on the thermal analysis of the arc welding process. In Part I, general solutions for the temperature rise distribution in arc welding of short workpieces were developed based on Jaeger’s classical moving heat source theory for a plane disc heat source with a pseudo-Gaussian distribution of heat intensity and constant values of thermophysical properties at one temperature (400 °C). This was extended in this investigation (Part II) to consider different thermophysical properties at different temperatures (from room temperature (25 °C) to 1300 °C) for a mild steel work material. The objective is to develop a rationale for the selection of an appropriate temperature for the choice of the thermophysical properties for the thermal analysis of arc welding. Since the quality of the weld for a given work material depends both on the thermodynamic and kinetic considerations, namely, the maximum temperatures and the temperature gradients (cooling rates) in appropriate sections of the welded part including the weld bead and the heat-affected zone (HAZ), they were determined in this investigation. The main output parameters from a thermal point of view are the widths and the depths of the melt pool (MP) and the HAZ at the weld joint. Although the length of the weld pool is also a consideration, if the entire length participates in the welding process, which is generally the case, then this is not such an important consideration. It is found that for welds produced in a conductive mode only (i.e., not considering the case of deep penetrating welds produced with keyhole mode), the values of the widths and the depths of the MP and the HAZs are nearly the same (within 10 to 20 pct), irrespective of the values of thermal properties for temperatures in the range of 400 °C to 1300 °C. Hence, the emphasis on the need to consider variable thermal properties with temperature in welding appears to be somewhat exaggerated. Also, based on the thermal analysis of the welding process, it appears that the room-temperature thermophysical properties may not be appropriate, as rightly pointed out by other researchers. The thermal history and the cooling rates were also determined analytically for arc welding of long workpieces, where quasi-steady-state conditions are established and the boundary effects can be ignored, as well as short workpieces, where transient conditions prevail and boundary effects need to be considered. This information can then be used in the appropriate time-temperature-transformation (TTT) diagram for a given steel work material to investigate the nature of the metallurgical transformation and the resulting microstructure in the welding process both in the weld bead and in the adjacent HAZs on either side.     

Ceramic Processing for TRIP‐Steel/Mg‐PSZ Composite Materials for Mechanical Applications

Composite materials are up‐to‐date products in a growing range of applications and markets. Due to the advantageous combination of two or more materials new generations of materials can be generated. Closely linked to expanding variations of material combinations are increasing numbers of manufacturing techniques. The combination of ductile metals with hard and brittle ceramics offers a range of applications in the field of crash‐absorber and structural products with high mechanical load. This paper deals with the challenges of powder metallurgical processing of TRIP‐steel/Mg‐PSZ composite materials. The presented results are a contribution to improvements in plastic processing especially for lightweight honeycomb structures.     

钢铁冶金流程节能空间研究

分两方面对钢铁企业全流程节能空间进行了研究.一方面把冶金全流程按照冶金功能进行了划分,分析了各工序能耗目前的能源消耗状况;计算了钢铁业正在推广的6项节能新技术(包括CDQ技术、TRT技术、高炉喷煤技术、球团矿技术、转炉负能炼钢技术、连铸坯热装热送和直接轧制技术)的节能效果.计算表明,如果这6项技术全部实施,冶金过程吨钢标煤能耗将下降132.27 kg/t;对钢铁全流程中目前还未引起重视的低温余热回收及其对钢铁全流程的能耗降低进行了计算评估,计算表明,如果这些低温余热全部回收,中国钢铁业吨钢能耗(折合标煤)将下降33.55 kg/t.