Abstract: Application of hulls processing technologies, based on high-concentrated energy sources (laser and plasma technologies), allow improve shipbuilding production. It is typical for high-speed vessels construction using steel and aluminum alloys with high precision hulls required. Report describes high-performance technologies for plasma welding (using direct current of reversed polarity), laser, and hybrid laser-arc welding of hulls structures developed by JSC “SSTC”
Abstract: High temperature deformation behavior of cast
Fe-20Cr-5Al alloy has been investigated in this study by performing
tensile and compression tests at temperatures from 1100 to 1200oC.
Rectangular ingots of which the dimensions were 300×300×100 in
millimeter were cast using vacuum induction melting. Phase
equilibrium was calculated using the FactSage®, thermodynamic
software and database. Tensile strength of cast Fe-20Cr-5Al alloy was
4 MPa at 1200oC. With temperature decreased, tensile strength
increased rapidly and reached up to 13 MPa at 1100oC. Elongation
also increased from 18 to 80% with temperature decreased from
1200oC to 1100oC. Microstructure observation revealed that M23C6
carbide was precipitated along the grain boundary and within the
matrix.
Abstract: Al-Si-Mg-Ni(-Cu) alloys are widely used in the automotive industry. They have the advantage of low weight associated with low coefficient of thermal expansion and excellent mechanical properties – mainly at high temperatures. The corrosion resistance of these alloys in coastal area, particularly sea water, however is not yet known. In this investigation, electrochemical impedance spectroscopy (EIS) and potentiodynamic polarization have been used to evaluate the corrosion resistance of Al-6Si-0.5Mg-2Ni (-2Cu) alloys in simulated sea water environments. The potentiodynamic polarization curves reveal that 2 wt% Cu content alloy (Alloy-2) is more prone to corrosion than the Cu free alloy (Alloy-1). But the EIS test results showed that corrosion resistance or charge transfer resistance (Rct) increases with the addition of Cu. Due to addition of Cu and thermal treatment, the magnitude of open circuit potential (OCP), corrosion potential (Ecorr) and pitting corrosion potential (Epit) of Al-6Si-0.5Mg-2Ni alloy in NaCl solution were shifted to the more noble direction.
Abstract: Biometallic materials are the most important materials for use in biomedical applications especially in manufacturing a variety of biological artificial replacements in a modern worlds, e.g. hip, knee or shoulder joints, due to their advanced characteristics. Titanium (Ti) and its alloys are used extensively in biomedical applications based on their high specific strength and excellent corrosion resistance. Beta-Ti alloys containing completely biocompatible elements are exceptionally prospective materials for manufacturing of bioimplants. They have superior mechanical, chemical and electrochemical properties for use as biomaterials. These biomaterials have the ability to introduce the most important property of biochemical compatibility which is low elastic modulus. This review examines current information on the recent developments in alloying elements leading to improvements of beta Ti alloys for use as biomaterials. Moreover, this paper focuses mainly on the evolution, evaluation and development of the modulus of elasticity as an effective factor on the performance of beta alloys.
Abstract: Metal matrix composites (MMCs) have gained a
considerable interest in the last three decades. Conventional powder
metallurgy production route often involves the addition of reinforcing
phases into the metal matrix directly, which leads to poor wetting
behavior between ceramic phase and metal matrix and the
segregation of reinforcements. The commonly used elements for
ceramic phase formation in iron based MMCs are Ti, Nb, Mo, W, V
and C, B. The aim of the present paper is to investigate the effect of
sintering temperature and V-B addition on densification, phase
development, microstructure, and hardness of Fe–V-B composites
(Fe-(5-10) wt. %B – 25 wt. %V alloys) prepared by powder
metallurgy process. Metal powder mixes were pressed uniaxial and
sintered at different temperatures (ranging from 1300 to 1400ºC) for
1h. The microstructure of the (V, B) Fe composites was studied with
the help of high magnification optical microscope and XRD.
Experimental results show that (V, B) Fe composites can be produced
by conventional powder metallurgy route.
Abstract: The impact deformation and fracture behaviour of cobalt-based Haynes 188 superalloy are investigated by means of a split Hopkinson pressure bar. Impact tests are performed at strain rates ranging from 1×103 s-1 to 5×103 s-1 and temperatures between 25°C and 800°C. The experimental results indicate that the flow response and fracture characteristics of cobalt-based Haynes 188 superalloy are significantly dependent on the strain rate and temperature. The flow stress, work hardening rate and strain rate sensitivity all increase with increasing strain rate or decreasing temperature. It is shown that the impact response of the Haynes 188 specimens is adequately described by the Zerilli-Armstrong fcc model. The fracture analysis results indicate that the Haynes 188 specimens fail predominantly as the result of intensive localised shearing. Furthermore, it is shown that the flow localisation effect leads to the formation of adiabatic shear bands. The fracture surfaces of the deformed Haynes 188 specimens are characterised by dimple- and / or cleavage-like structure with knobby features. The knobby features are thought to be the result of a rise in the local temperature to a value greater than the melting point.
Abstract: In this study, Electrical Discharge Machining (EDM) is used to modify the surface of high carbon steel En31 with the help of tool electrode (Copper-Chromium-Nickel) manufactured by powder metallurgy (PM) process. The effect of EDM on surface roughness during surface alloying is studied. Taguchi’s Design of experiment (DOE) and L18 orthogonal array is used to find the best level of input parameters in order to achieve high surface finish. Six input parameters are considered and their percentage contribution towards surface roughness is investigated by analysis of variances (ANOVA). Experimental results show that an hard alloyed surface (1.21% carbon, 2.14% chromium and 1.38% nickel) with surface roughness of 3.19µm can be generated using EDM with PM tool. Additionally, techniques like Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscopy (EDS) are used to analyze the machined surface and EDMed layer composition, respectively. The increase in machined surface micro-hardness (101%) may be related to the formation of carbides containing chromium.
Abstract: Effect of 2wt% Cu addition on tensile properties and
fracture behavior of Al-6Si-0.5Mg-2Ni alloy at various strain rates
were studied. The solution treated Al-6Si-0.5Mg-2Ni (-2Cu) alloys,
were aged isochronally for 1 hour at temperatures up to 300oC. The
uniaxial tension test was carried out at strain rate ranging from 10-4s-1
to 10-2s-1 in order to investigate the strain rate dependence of tensile
properties. Tensile strengths were found to increase with ageing
temperature and the maximum being attained ageing for 1 hr at
225oC (peak aged condition). Addition of 2wt% Cu resulted in an
increase in tensile properties at all strain rates. Evaluation of tensile
properties at three different strain rates (10-4, 10-3 and 10-2 s-1)
showed that strain rates affected the tensile properties significantly.
At higher strain rates the strength was better but ductility was poor.
Microstructures of broken specimens showed that both the void
coalescence and the interface debonding affect the fracture behavior
of the alloys
Abstract: Laser beam welding has wide acceptability due to least welding distortion, low labour costs and convenient operation. However, laser welding for dissimilar titanium and aluminium alloys is a new area which is having wider applications in aerospace, aircraft, automotive, electronics and other industries. The present study is concerned with welding parameters namely laser power, welding speed, focusing distance and type of shielding gas and thereby evaluate welding performance of titanium and aluminium alloy thin sheets. This paper reviews the basic concepts associated with different parameters of Ti/Al sheet joint using Laser beam welding.
Abstract: This work details the generation of thin films of
structured zeolite catalysts (ZSM–5 and Y) onto the surface of a
metal substrate (FeCrAlloy) using in-situ hydrothermal synthesis. In
addition, the zeolite Y is post-synthetically modified by acidified
ammonium ion exchange to generate US-Y. Finally the catalytic
activity of the structured ZSM-5 catalyst films (Si/Al = 11, thickness
146 0m) and structured US–Y catalyst film (Si/Al = 8, thickness
230m) were compared with the pelleted powder form of ZSM–5 and
USY catalysts of similar Si/Al ratios.
The structured catalyst films have been characterised using a range
of techniques, including X-ray diffraction (XRD), Electron
microscopy (SEM), Energy Dispersive X–ray analysis (EDX) and
Thermogravimetric Analysis (TGA). The transition from oxide-onalloy
wires to hydrothermally synthesised uniformly zeolite coated
surfaces was followed using SEM and XRD. In addition, the
robustness of the prepared coating was confirmed by subjecting these
to thermal cycling (ambient to 550oC).
The cracking of n–heptane over the pellets and structured catalysts
for both ZSM–5 and Y zeolite showed very similar product
selectivities for similar amounts of catalyst with an apparent
activation energy of around 60 kJ mol-1. This paper demonstrates that
structured catalysts can be manufactured with excellent zeolite
adherence and when suitably activated/modified give comparable
cracking results to the pelleted powder forms. These structured
catalysts will improve temperature distribution in highly exothermic
and endothermic catalysed processes.
Abstract: SiC reinforced Aluminum samples were produced by stir casting of liquid AA1200 aluminum alloy at 600-650ºC casting temperature. 83µm SiC particles were rinsed in 10g/l, 20g/l and 30g/l molar concentration of Sncl2 through cleaning times of 0, 60, 120, and 180 minutes. Some cast samples were tested for mechanical properties and some were subjected to heat treatment before testing. The SnCl2 rinsed SiC reinforced aluminum exhibited higher yield strength, hardness, stiffness and elongation which increases with cleaning concentration and time up to 120 minutes, compared to composite with untreated SiC. However, the impact energy resistance decreases with cleaning concentration and time. The improved properties were attributed to good wettability and mechanical adhesion at the fiber-matrix interface. Quenching and annealing the composite samples further improve the tensile/yield strengths, elongation, stiffness, hardness similar to those of the as-cast samples.
Abstract: This paper aims at experimental and numerical investigation of springback behavior of sheet metals during L-bending process with emphasis on Stribeck-type friction modeling. The coefficient of friction in Stribeck curve depends on sliding velocity and contact pressure. The springback behavior of mild steel and aluminum alloy 6022-T4 sheets was studied experimentally and using numerical simulations with ABAQUS software with two types of friction model: Coulomb friction and Stribeck friction. The influence of forming speed on springback behavior was studied experimentally and numerically. The results showed that Stribeck-type friction model has better results in predicting springback in sheet metal forming. The FE prediction error for mild steel and 6022-T4 AA is 23.8%, 25.5% respectively, using Coulomb friction model and 11%, 13% respectively, using Stribeck friction model. These results show that Stribeck model is suitable for simulation of sheet metal forming especially at higher forming speed.
Abstract: Joining of 1mm thick aluminum 6061 to titanium TC4
was conducted using Bypass-current MIG welding-brazed, and stable
welding process and good bead appearance were obtained. The Joint
profile and microstructure of Ti/Al joints were observed by optical
microscopy and SEM and then the structure of the interfacial reaction
layers were analyzed in details. It was found that the intermetallic
compound layer at the interfacial top is in the form of columnar
crystal, which is in short and dense state. A mount of AlTi were
observed at the interfacial layer near the Ti base metal while
intermetallic compound like Al3Ti, TiSi3 were formed near the Al base
metal, and the Al11Ti5 transition phase was found in the center of the
interface layer due to the uneven distribution inside the weld pool
during the welding process. Tensile test results show that the average
tensile strength of joints is up to 182.6 MPa, which reaches about
97.6% of aluminum base metal. Fracture is prone to occur in the base
metal with a certain amount of necking.
Abstract: The design of multi stage deep drawing processes requires the evaluation of many process parameters such as the intermediate die geometry, the blank shape, the sheet thickness, the blank holder force, friction, lubrication etc..These process parameters have to be determined for the optimum forming conditions before the process design. In general sheet metal forming may involve stretching drawing or various combinations of these basic modes of deformation. It is important to determine the influence of the process variables in the design of sheet metal working process. Especially, the punch and die corner for deep drawing will affect the formability. At the same time the prediction of sheet metals springback after deep drawing is an important issue to solve for the control of manufacturing processes. Nowadays, the importance of this problem increases because of the use of steel sheeting with high stress and also aluminum alloys.
The aim of this paper is to give a better understanding of the springback and its effect in various sheet metals forming process such as expansion and restreint deep drawing in the cup drawing process, by varying radius die, lubricant for two commercially available materials e.g. galvanized steel and Aluminum sheet. To achieve these goals experiments were carried out and compared with other results. The original of our purpose consist on tests which are ensured by adapting a U-type stretching-bending device on a tensile testing machine, where we studied and quantified the variation of the springback.
Abstract: Tensile specimens of nonflammable AZ91D Mg alloy were fabricated in this study via cold chamber die-casting process. Dimensions of tensile specimens were 25mm in length, 4mm in width, and 0.8 or 3.0mm in thickness. Microstructure observation was conducted before and after tensile tests at room temperature. In the die casting process, various injection distances from 150 to 260mm were employed to obtain optimum process conditions. Distribution of Al12Mg17 phase was the key factor to determine the mechanical properties of die-cast Mg alloy. Specimens with 3mm of thickness showed superior mechanical properties to those with 0.8mm of thickness. Closed networking of Al12Mg17 phase along grain boundary was found to be detrimental to mechanical properties of die-cast Mg alloy.
Abstract: High temperature deformation behavior of cast 310S stainless steel has been investigated in this study by performing tensile and compression tests at temperatures from 900 to 1200oC. Rectangular ingots of which the dimensions were 350×350×100 in millimeter were cast using vacuum induction melting. Phase equilibrium was calculated using the FactSage®, thermodynamic software and database. Thermal expansion coefficient was also measured on the ingot in the temperature range from room temperature to 1200oC. Tensile strength of cast 310S stainless steel was 9 MPa at 1200oC, which is a little higher than that of a wrought 310S. With temperature decreased, tensile strength increased rapidly and reached up to 72 MPa at 900oC. Elongation also increased with temperature decreased. Microstructure observation revealed that s phase was precipitated along the grain boundary and within the matrix over 1200oC, which is detrimental to high temperature elongation.
Abstract: The fatigue crack growth is stochastic because of the fatigue behavior having an uncertainty and a randomness. Therefore, it is necessary to determine the probability distribution of a grown crack size at a specific fatigue crack propagation life for maintenance of structure as well as reliability estimation. The essential purpose of this study is to present the good probability distribution fit for the grown crack size at a specified fatigue life in a rolled magnesium alloy under different specimen thickness conditions. Fatigue crack propagation experiments are carried out in laboratory air under three conditions of specimen thickness using AZ31 to investigate a stochastic crack growth behavior. The goodness-of-fit test for probability distribution of a grown crack size under different specimen thickness conditions is performed by Anderson-Darling test. The effect of a specimen thickness on variability of a grown crack size is also investigated.
Abstract: Electron Beam Melting (EBM) process was used to prepare porous scaffolds with controlled porosity to ensure optimal levels of osteointegration for different trabeculae sizes. Morphological characterization by means of SEM analyses was carried out to assess pore dimensions; tensile, compression and adhesion tests have been carried out to determine the mechanical behavior. The results indicate that EBM process allows the creation of regular and repeatable porous scaffolds. Mechanical properties greatly depend on pore dimension and on bulk-pore ratio. Adhesion resistance meets the normative requirements, and the overall performance of the produced structures is compatible with potential orthopaedic applications.
Abstract: Chromium bearing Austempered Ductile Iron (ADI) has been recently in the news for its improved wear performance over the ADI. The work presented below was taken up to study the effect of different austenitisation temperatures on the microstructure and wear performance of the Carbidic Austempered Ductile Iron (CADI). In this investigation Cr bearing ductile iron was subjected to austempering treatment to obtain an ausferritic microstructure. Two different austenitisation temperatures were selected whereas, the austempering temperature and time was kept unchanged. Microstructure and wear performance of this alloy, austenitized at two different temperatures was studied.
Abstract: This paper present a mechanical characteristics on fatigue crack propagation in Aluminium Plate based on strain and stress distribution using the abaqus software. The changes in shear strain and stress distribution during the fatigue cycle with crack growth is identified. In progressive crack in the strain distribution and the stress is increase in the critical zone. Numerical Modal analysis of the model developed, prove that the Eigen frequencies of aluminium plate were decreased after cracking, and this reduce is nonlinear. These results can provide a reference for analysts and designers of aluminium alloys in aeronautical systems.
Therefore, the modal analysis is an important factor for monitoring the aeronautic structures.