Processing,deformation, and failure in superplastic aluminum alloys: Applications of orientation-imaging microscopy

The importance of grain size refinement in enabling superplasticity is reviewed, and the current understanding of grain boundary characteristics is summarized. The application of orientation-imaging microscopy (OIM) methods to the processing response and the deformation and failure modes in superplastic aluminum alloys are illustrated through microtexture analysis and determination of grain boundary characteristics in selected commercial materials. Continuous and discontinuous recrystallization reactions exhibit distinct microtextures and grain boundary characteristics. The application of OIM and microtexture analysis to the evaluation of both deformation and failure mechanisms during superplastic forming is illustrated. This paper was presented at the International Symposium on Superplasticity and Superplastic Forming, sponsored by the Manufacturing Critical Sector at the ASM International AeroMat 2004 Conference and Exposition, June 8–9, 2004, in Seattle, WA. The symposium was organized by Daniel G. Sanders, The Boeing Company.     

Effects of different metallurgical processing on microstructures and mechanical properties of inconel alloy 783

Different metallurgical processing, including the standard heat treatment, heat treatment without β aging, addition of high amount of Cr, and long-term isothermal exposure, was conducted on superalloy Inconel 783. For these processed materials, the tensile property and hardness at room temperature and stress relaxation behavior at 650 °C were examined. The testing results showed that isothermal exposure and heat treatment without β aging slightly enhanced the yield strength of alloy 783 at room temperature as well as all metallurgical processing in this study produced an identical stress relaxation behavior at 650 °C. The microstructure variation with different processing was analyzed using optical microscope, scanning electron microscopy (SEM), and transmission electron microscopy (TEM).     

Examination of superplastic forming combined with diffusion bonding for titanium: Perspective from experience

Superplastic forming (SPF) combined with diffusion bonding (DB) has been used successfully for the fabrication of titanium aerospace hardware. Many of these applications have been for military aircraft, whereby a complex built-up structure has been replaced with monolithic parts. Several methods for applying the two- and four-sheet titanium SPF/DB processes have been devised, including the welding of sheets prior to forming and the use of silk-screened stop-off (yttria) to prevent bonding where it is undesirable. Very little progress has been made in the past few years toward understanding and modeling the SPF/DB process using constitutive equations and data by laboratory testing. Concerns that engineers face in designing for fatigue life, acceptable design loads, and damage tolerance are currently being studied, but the database is very limited. This is a summary of past work found in the literature and forms the foundation for additional research. This paper was presented at the International Symposium on Superplasticity and Superplastic Forming sponsored by the Manufacturing Critical Sector at the ASM International AeroMat 2004 Conference and Exposition, June 8–9, 2004, in Seattle, WA. The symposium was organized by Daniel G. Sanders, The Boeing Company.     

The characteristics of a low-power-consumption plasma jet and ceramic coatings

The effects of the composition of plasma gases (Ar-N₂, Ar-H₂), arc current, and voltage on the temperature and velocity of a low-power (5 kW) plasma torch in the arc field free region has been investigated using an enthalpy probe. Coatings of Al₂O₃-13TiO₂ were deposited under different conditions. The results show that in the Ar-N₂ plasma, the enthalpy, temperature, and velocity change little with arc current and voltage when regulating the nitrogen proportion in the plasma gas. The hardness of the resulting coatings is 800 to 900 kg/mm² HV.300. For Ar-H₂ plasma, however, increases in the H₂ content in the mixture of the gases remarkably enhanced the velocity and heat transfer ability of the plasma jet, with the result that the coatings showed high hardness up to 1200 HV.     

Effect of austenitization on austempering of copper alloyed ductile iron

A ductile iron containing 0.6% copper as the main alloying element was austempered at a fixed austempering temperature of 330 °C for a fixed austempering time of 60 min after austenitization at 850 °C for different austenitization periods of 60, 90, and 120 min. The austempering process was repeated after changing austenitization temperature to 900 °C. The effect of austenitization temperature and time was studied on the carbon content and its distribution in the austenite after austenitization. The effect of austenitization parameters was also studied on austempered microstructure, structural parameters like volume fraction of austenite, X _γ , carbon content C _γ , and X _γ C _γ , and bainitic ferrite needle size, d _α after austempering. The average carbon content of austenite increases linearly with austenitization time and reaches a saturation level. Higher austenitization temperature results in higher carbon content of austenite. As regards the austempered structure, the lowering austenitization temperature causes significant refinement and more uniform distribution of austempered structure, and a decrease in the volume fraction of retained austenite.     

Influence of the Workpiece Stiffness on the Electromagnetic Sheet Metal Forming Process into Dies

Electromagnetic sheet metal forming is a high speed forming process using pulsed magnetic fields to form metals with high electrical conductivity such as aluminum. Thereby, workpiece velocities of more than 300 m/s are achievable, which can cause difficulties when forming into a die. The kinetic energy, which is related to the workpiece velocity, must be dissipated in a short time slot when the workpiece hits the die; otherwise undesired effects, for example rebound can occur. One possibility to handle this shortcoming is to locally increase the stiffness of the workpiece. A modal analysis is carried out in order to determine the stiffness of specific regions of the workpiece so that an estimation concerning the feasibility of the desired geometry is possible in advance without doing cost and time consuming experiments. Thereby, the desired geometry of the workpiece will be fractionized in significant sectors. This approach has to define the internal force variables acting on the cutting edge, which are required to constrain the numerical model. Finally, a method will be developed with the objective of calculating the stiffness of each sector. The numerical results will be verified by experiments. This article was presented at Materials Science & Technology 2006, Innovations in Metal Forming symposium held in Cincinnati, OH, October 15-19, 2006.     

Copper-nickel superalloys as inert alloy anodes for aluminum electrolysis

The superalloys Cu-Ni-Al, Cu-Ni-Fe, and Cu-Ni-Cr were studied as anodes for aluminum electrolysis. The alloys were tested for corrosion in acidic electrolyte molten salt and for oxidation in both air and oxygen. The results showed that the Cu-Ni-Al anodes possess excellent resistance to oxidation and corrosion, and the oxidation rates of Cu-Ni-Fe and Cu-Ni-Al anodes were slower than those of pure copper or nickel. During electrolysis, the cell voltage of the Cu-Ni-Al anode was affected most by the concentration of alumina in cryolite molten salt. The Cu-Ni-Fe anode exhibited corrosion resistance in electrolyte molten salt. Comparatively, the Cu-Ni-Cr anode showed poor resistance to oxidation and corrosion. The testing found that further study is warranted on the use of Cu-Ni-Al and Cu-Ni-Fe as inert alloy anodes. For more information, contact Zhongning Shi, Northeastern University, School of Materials and Metallurgy, WenhuiRoad No. 3, Shenynag, Liaoning 110004 China; e-mail znshi@163.com     

Properties of Induction Plasma Sprayed Iron Based Nanostructured Alloy Coatings for Metal Based Thermal Barrier Coatings

Metal-based thermal barrier coatings (MBTBCs) have been produced using high frequency induction plasma spraying (IPS) of iron-based nanostructured alloy powders. The study of MBTBCs has been initiated to challenge issues associated with current TBC materials such as difficult prediction of their “in-service” lifetime. Reliability of TBCs is an important aspect besides the economical consideration. Therefore, the study of MBTBCs, which should posses higher toughness than the current TBC materials, has been initiated to challenge the mechanical problems of ceramic-based TBCs (CBTBCs) to create a new generation of TBCs. The thermal diffusivity (TD) (α) properties of the MBTBCs were measured using a laser flash method, and density (ρ) and specific heat (C _p) of the MBTBCs were also measured for their thermal conductivity (k) calculation (k = αρ C _p).