Abstract: This paper studies a failure case of a fuel pressure supply tube from an aircraft engine. Multiple fracture cases of the fuel pressure control tube from aircraft engines have been reported. The studied set was composed by the mentioned tube, a welded connecting pipe, where the fracture has been produced, and a union nut. The fracture has been produced in one of the most critical zones of the tube, in a region next to the supporting body of the union nut to the connector. The tube material was X6CrNiTi18-10, an austenitic stainless steel. Chemical composition was determined using an X-Ray fluorescence spectrometer (XRF) and combustion equipment. Furthermore, the material was characterized mechanically, by a hardness test, and microstructurally using a stereo microscope and an optical microscope. The results confirmed that the material was within specifications. To determine the macrofractographic features, a visual examination and an observation using a stereo microscope of the tube fracture surface were carried out. The results revealed a tube plastic macrodeformation, surface damaged and signs of a possible corrosion process. Fracture surface was also inspected by scanning electron microscopy (FE-SEM), equipped with an energy-dispersive X-ray microanalysis system (EDX), to determine the microfractographic features in order to find out the failure mechanism involved in the fracture. Fatigue striations, which are typical from a progressive fracture by a fatigue mechanism, were observed. The origin of the fracture was placed in defects located on the outer wall of the tube, leading to a final overload fracture.
Abstract: The paper presents the influence of non-metallic inclusions on the multi-stage forging process and the mechanical properties of the dodecagon socket bolt used in the automotive industry. The detected metallurgical defect was so large that it directly influenced the mechanical properties of the bolt and resulted in failure to meet the requirements of the mechanical property class. In order to assess the defect, an X-ray examination and metallographic examination of the defective bolt were performed, showing exogenous non-metallic inclusion. The size of the defect on the cross section was 0.531 mm in width and 1.523 mm in length; the defect was continuous along the entire axis of the bolt. In analysis, a finite element method (FEM) simulation of the multi-stage forging process was designed, taking into account a non-metallic inclusion parallel to the sample axis, reflecting the studied case. The process of defect propagation due to material upset in the head area was analyzed. The final forging stage in shaping the dodecagonal socket and filling the flange area was particularly studied. The effect of the defect was observed to significantly reduce the effective cross-section as a result of the expansion of the defect perpendicular to the axis of the bolt. The mechanical properties of products with and without the defect were analyzed. In the first step, the hardness test confirmed that the required value for the mechanical class 8.8 of both bolt types was obtained. In the second step, the bolts were subjected to a static tensile test. The bolts without the defect gave a positive result, while all 10 bolts with the defect gave a negative result, achieving a tensile strength below the requirements. Tensile strength tests were confirmed by metallographic tests and FEM simulation with perpendicular inclusion spread in the area of the head. The bolts were damaged directly under the bolt head, which is inconsistent with the requirements of ISO 898-1. It has been shown that non-metallic inclusions with orientation in accordance with the axis of the bolt can directly cause loss of functionality and these defects should be detected even before assembling in the machine element.
Abstract: Wind turbines are equipment of great importance for generating clean energy in countries and regions with abundant winds. However, complex loadings fluctuations to which they are subject can cause premature failure of these equipment due to the material fatigue process. This work evaluates fatigue failures in small AISI 304 stainless steel turbine shafts. Fractographic analysis techniques, chemical analyzes using energy dispersive spectrometry (EDS), and hardness tests were used to verify the origin of the failures, characterize the properties of the components and the material. The nucleation of cracks on the shafts' surface was observed due to a combined effect of variable stresses, geometric stress concentrating details, and surface wear, leading to the crack's propagation until the catastrophic failure. Beach marks were identified in the macrographic examination, characterizing the probable failure due to fatigue. The sensitization phenomenon was also observed.
Abstract: This paper summarizes the work conducted to assess the root cause of the failure of a medium commercial vehicle leaf spring failed in service. Macro- and micro-fractographic analyses by scanning electron microscope as well as material verification tests were conducted in order to understand the failure mechanisms and root cause of the failure. Findings from the fractographic analyses indicated that failure mechanism is fatigue. Crack initiation was identified to have occurred from a point on the top surface near to the front face and to the left side. Two other crack initiation points were also observed, however, these cracks did not propagate. The propagation mode of the fatigue crack revealed that the cyclic loads resulting in crack initiation and propagation were unidirectional bending. Fractographic analyses have also showed that the root cause of the fatigue crack initiation and propagation was loading the part above design stress. Material properties of the part were also verified by chemical composition analysis, microstructural analysis by optical microscopy and hardness tests.
Abstract: The mineral in human bone is not pure stoichiometric calcium phosphate (Ca/P) as it is partially substituted by in organic elements. In this study, the copper ions (Cu2+) substituted hydroxyapatite (CuHA) powder has been synthesized by the co-precipitation method. The CuHA powder has been used to fabricate CuHA fiber scaffolds by sol-gel process and the following sinter process. The resulted CuHA fibers have slightly different microstructure (i.e. porosity) compared to HA fiber scaffold, which is denser. The mechanical properties test was used to evaluate CuHA, and the results showed decreases in both compression strength and hardness tests. Moreover, the in vitro used endothelial cells to evaluate the angiogenesis of CuHA. The result illustrated that the viability of endothelial cell on CuHA fiber scaffold surfaces tends to antigenic behavior. The results obtained with CuHA scaffold give this material benefit in biological applications such as antimicrobial, antitumor, antigens, compacts, filling cavities of the tooth and for the deposition of metal implants anti-tumor, anti-cancer, bone filler, and scaffold.
Abstract: In the recent years, aluminum metal matrix composites were most widely used, which are finding wide applications in various field such as automobile, aerospace defense etc., due to their outstanding mechanical properties like low density, light weight, exceptional high levels of strength, stiffness, wear resistance, high temperature resistance, low coefficient of thermal expansion and good formability. In the present work, an effort is made to study the effect of heat treatment on mechanical properties of aluminum 7075 alloy reinforced with constant weight percentage of naturally occurring mineral beryl and varying weight percentage of graphene. The hybrid composites are developed with 0.5 wt. %, 1wt.%, 1.5 wt.% and 2 wt.% of graphene and 6 wt.% of beryl by stir casting liquid metallurgy route. The cast specimens of unreinforced aluminum alloy and hybrid composite samples were prepared for heat treatment process and subjected to solutionizing treatment (T6) at a temperature of 490±5 oC for 8 hours in a muffle furnace followed by quenching in boiling water. The microstructure analysis of as cast and heat treated hybrid composite specimens are examined by scanning electron microscope (SEM). The tensile test and hardness test of unreinforced aluminum alloy and hybrid composites are examined. The wear behavior is examined by pin-on disc apparatus. The results of as cast specimens and heat treated specimens were compared. The heat treated Al7075-Beryl-Graphene hybrid composite had better properties and significantly improved the ultimate tensile strength, hardness and reduced wear loss when compared to aluminum alloy and as cast hybrid composites.
Abstract: This work describes an investigation on the effect of filler metals diameter to weld joint, and low alloy carbon steel A516 Grade 70 is the base metal. Commercially SA516 Grade70 is frequently used for the manufacturing of pressure vessels, boilers and storage tank, etc. In fabrication industry, the hardness of the weld joint is between the important parameters to check, after heat treatment of the weld. Submerged arc welding (SAW) is used with two filler metal diameters, and this solid wire electrode is used for SAW non-alloy and for fine grain steels (SFA 5.17). The different diameters were selected (Ø = 2.4 mm and Ø = 4 mm) to weld two specimens. Both specimens were subjected to the same preparation conditions, heat treatment, macrograph, metallurgy micrograph, and micro-hardness test. Samples show almost similar structure with highest hardness. It is important to indicate that the thickness used in the base metal is 22 mm, and all specifications, preparation and controls were according to the ASME section IX. It was observed that two different filler metal diameters performed on two similar specimens demonstrated that the mechanical property (hardness) increases with decreasing diameter. It means that even the heat treatment has the same effect with the same conditions, the filler metal diameter insures a depth weld penetration and better homogenization. Hence, the SAW welding technique mentioned in the present study is favorable to implicate for the industry using the small filler metal diameter.
Abstract: Ledeburitic tool steel Vanadis 6 has been subjected to sub-zero treatment (SZT) at -140 °C and -196 °C, for different durations up to 48 h. The microstructure and hardness have been examined with reference to the same material after room temperature quenching, by using the light microscopy, scanning electron microscopy, X-ray diffraction, and Vickers hardness testing method. The microstructure of the material consists of the martensitic matrix with certain amount of retained austenite, and of several types of carbides – eutectic carbides, secondary carbides, and small globular carbides. SZT reduces the retained austenite amount – this is more effective at -196 °C than at -140 °C. Alternatively, the amount of small globular carbides increases more rapidly after SZT at -140 °C than after the treatment at -140 °C. The hardness of sub-zero treated material is higher than that of conventionally treated steel when tempered at low temperature. Compressive hydrostatic stresses are developed in the retained austenite due to the application of SZT, as a result of more complete martensitic transformation. This is also why the population density of small globular carbides is substantially increased due to the SZT. In contrast, the hardness of sub-zero treated samples decreases more rapidly compared to that of conventionally treated steel, and in addition, sub-zero treated material induces a loss the secondary hardening peak.
Abstract: In this study, the effects of B4C and SiC particle reinforcements on wear properties of magnesium matrix metal composites produced by pressure infiltration method were investigated. AZ91 (9%Al-1%Zn) magnesium alloy was used as a matrix. AZ91 magnesium alloy was melted under an argon atmosphere. The melt was infiltrated to the particles with an appropriate pressure. Wear tests, hardness tests were performed respectively. Microstructure characterizations were examined by light optical (LOM) and scanning electron microscope (SEM). The results showed that uniform particle distributions were achieved in both B4C and SiC reinforced composites. Wear behaviors of magnesium matrix metal composites changed as a function of type of particles. SiC reinforced composite has better wear performance and higher hardness than B4C reinforced composite.
Abstract: In this work, obtaining methods of ultrafine alumina
powdery composites and high temperature pressing technology of
matrix ceramic composites with different compositions have been
discussed. Alumina was obtained by solution combustion synthesis
and sol-gel methods. Metal carbides containing powdery composites
were obtained by homogenization of finishing powders in nanomills,
as well as by their single-step high temperature synthesis .Different
types of matrix ceramics composites (α-Al2O3-ZrO2-Y2O3, α-Al2O3-
Y2O3-MgO, α-Al2O3-SiC-Y2O3, α-Al2O3-WC-Co-Y2O3, α-Al2O3-
B4C-Y2O3, α-Al2O3- B4C-TiB2 etc.) were obtained by using OXYGON
furnace. Consolidation of powders were carried out at 1550-
1750°C (hold time - 1 h, pressure - 50 MPa). Corundum ceramics
samples have been obtained and characterized by high hardness and
fracture toughness, absence of open porosity, high corrosion
resistance. Their density reaches 99.5-99.6% TD. During the work,
the following devices have been used: High temperature vacuum
furnace OXY-GON Industries Inc (USA), Electronic Scanning
Microscopes Nikon Eclipse LV 150, Optical Microscope NMM-
800TRF, Planetary mill Pulverisette 7 premium line, Shimadzu
Dynamic Ultra Micro Hardness Tester DUH-211S, Analysette 12
Dynasizer.
Abstract: The impact of boron doping on the internal friction (IF) and shear modulus temperature spectra of Si1-xGex(x≤0,02) monocrsytals has been investigated by reverse torsional pendulum oscillations characteristics testing. At room temperatures, microhardness and indentation modulus of the same specimens have been measured by dynamic ultra microhardness tester. It is shown that boron doping causes two kinds effect: At low boron concentration (~1015 cm-3) significant strengthening is revealed, while at the high boron concentration (~1019 cm-3) strengthening effect and activation characteristics of relaxation origin IF processes are reduced.
Abstract: The sintering step in powder metallurgy (P/M) processes is very sensitive as it determines to a large extent the properties of the final component produced. Spark plasma sintering over the past decade has been extensively used in consolidating a wide range of materials including metallic alloy powders. This novel, non-conventional sintering method has proven to be advantageous offering full densification of materials, high heating rates, low sintering temperatures, and short sintering cycles over conventional sintering methods. Ti6Al4V has been adjudged the most widely used α+β alloy due to its impressive mechanical performance in service environments, especially in the aerospace and automobile industries being a light metal alloy with the capacity for fuel efficiency needed in these industries. The P/M route has been a promising method for the fabrication of parts made from Ti6Al4V alloy due to its cost and material loss reductions and the ability to produce near net and intricate shapes. However, the use of this alloy has been largely limited owing to its relatively poor hardness and wear properties. The effect of sintering temperature on the densification, hardness, and wear behaviors of spark plasma sintered Ti6Al4V powders was investigated in this present study. Sintering of the alloy powders was performed in the 650–850°C temperature range at a constant heating rate, applied pressure and holding time of 100°C/min, 50 MPa and 5 min, respectively. Density measurements were carried out according to Archimedes’ principle and microhardness tests were performed on sectioned as-polished surfaces at a load of 100gf and dwell time of 15 s. Dry sliding wear tests were performed at varied sliding loads of 5, 15, 25 and 35 N using the ball-on-disc tribometer configuration with WC as the counterface material. Microstructural characterization of the sintered samples and wear tracks were carried out using SEM and EDX techniques. The density and hardness characteristics of sintered samples increased with increasing sintering temperature. Near full densification (99.6% of the theoretical density) and Vickers’ micro-indentation hardness of 360 HV were attained at 850°C. The coefficient of friction (COF) and wear depth improved significantly with increased sintering temperature under all the loading conditions examined, except at 25 N indicating better mechanical properties at high sintering temperatures. Worn surface analyses showed the wear mechanism was a synergy of adhesive and abrasive wears, although the former was prevalent.
Abstract: Hard coatings are widely used in cutting and forming
tool industries. Titanium Nitride (TiN) possesses good hardness,
strength, and corrosion resistance. The coating properties are
influenced by many process parameters. The coatings were deposited
on steel substrate by changing the process parameters such as
substrate temperature, nitrogen flow rate and target power in a D.C
planer magnetron sputtering. The structure of coatings were analysed
using XRD. The hardness of coatings was found using Micro
hardness tester. From the experimental data, a regression model was
developed and the optimum response was determined using Response
Surface Methodology (RSM).
Abstract: Friction stir welding and tungsten inert gas welding
techniques were employed to weld armor grade aluminum alloy to
investigate the effect of welding processes on tensile behavior of
weld joints. Tensile tests, Vicker microhardness tests and optical
microscopy were performed on developed weld joints and base metal.
Welding process influenced tensile behavior and microstructure of
weld joints. Friction stir welded joints showed tensile behavior better
than tungsten inert gas weld joints.
Abstract: Ceramic obtained on the base of aluminum oxide has
wide application range, because it has unique properties, for example,
wear-resistance, dielectric characteristics, and exploitation ability at
high temperatures and in corrosive atmosphere. Low temperature
synthesis of α-Al2O3 is energo-economical process and it is topical
for developing technologies of corundum ceramics fabrication. In the present work possibilities of low temperature transformation
of oxyhydroxides in α-Al2O3, during the presence of small amount of
rare–earth elements compounds (also Th, Re), have been discussed.
Aluminum unstable oxyhydroxides have been obtained by hydrolysis
of aluminium isopropoxide, nitrates, sulphate, and chloride in
alkaline environment at 80-90ºC temperatures. β-Al(OH)3 has been
received from aluminum powder by ultrasonic development. Drying
of oxyhydroxide sol has been conducted with presence of various
types seeds, which amount reaches 0,1-0,2% (mas). Neodymium,
holmium, thorium, lanthanum, cerium, gadolinium, disprosium
nitrates and rhenium carbonyls have been used as seeds and they
have been added to the sol specimens in amount of 0.1-0.2% (mas)
calculated on metals. Annealing of obtained gels is carried out at 70–
1100ºC for 2 hrs. The same specimen transforms in α-Al2O3 at
1100ºC. At this temperature in case of presence of lanthanum and
gadolinium transformation takes place by 70-85%. In case of
presence of thorium stabilization of γ-and θ-phases takes place. It is
established, that thorium causes inhibition of α-phase generation at
1100ºC, and at the time when in all other doped specimens α-phase is
generated at lower temperatures (1000-1050ºC). Synthesis of various
type compounds and simultaneous consolidation has developed in the
furnace of OXY-GON. Composite materials containing oxide and
non-oxide components close to theoretical data have been obtained in
this furnace respectively. During the work the following devices have
been used: X-ray diffractometer DRON-3M (Cu-Kα, Ni filter,
2º/min), High temperature vacuum furnace OXY-GON, electronic
scanning microscopes Nikon ECLIPSE LV 150, NMM-800TRF,
planetary mill Pulverisette 7 premium line, SHIMADZU Dynamic
Ultra Micro Hardness Tester, DUH-211S, Analysette 12 Dyna sizer.
Abstract: Si-Ge solid solutions (bulk poly- and mono-crystalline
samples, thin films) are characterized by high perspectives for
application in semiconductor devices, in particular, optoelectronics
and microelectronics. From this point of view, complex studying of
structural state of the defects and structural-sensitive physical
properties of Si-Ge solid solutions depending on the contents of Si
and Ge components is very important. Present work deals with the
investigations of microstructure, microhardness, internal friction and
shear modulus of Si1-xGex(x≤0,02) bulk monocrystals conducted at
room temperature. Si-Ge bulk crystals were obtained by Czochralski
method in [111] crystallographic direction. Investigated
monocrystalline Si-Ge samples are characterized by p-type
conductivity and carriers’ concentration 5.1014-1.1015cm-3.
Microhardness was studied on Dynamic Ultra Micro hardness Tester
DUH-201S with Berkovich indenter. Investigate samples are characterized with 0,5x0,5x(10-15)mm3
sizes, oriented along [111] direction at torsion oscillations ≈1Hz,
multistage changing of internal friction and shear modulus has been
revealed in an interval of strain amplitude of 10-5-5.10-3. Critical
values of strain amplitude have been determined at which hysteretic
changes of inelastic characteristics and microplasticity are observed. The critical strain amplitude and elasticity limit values are also
determined. Dynamic mechanical characteristics decreasing trend is
shown with increasing Ge content in Si-Ge solid solutions. Observed
changes are discussed from the point of view of interaction of various
dislocations with point defects and their complexes in a real structure
of Si-Ge solid solutions.
Abstract: The present work is aimed at examining carbon steel
oil pipelines corrosion using three natural extracts (Eruca Sativa,
Rosell and Mango peels) that are used as inhibitors of different
concentrations ranging from 0.05-0.1wt. %. Two sulphur compounds
are used as corrosion mediums. Weight loss method was used for
measuring the corrosion rate of the carbon steel specimens immersed
in technical white oil at 100ºC at various time intervals in absence
and presence of the two sulphur compounds. The corroded specimens
are examined using the chemical wear test, scratch test and hardness
test. The scratch test is carried out using scratch loads from 0.5 Kg to
2.0 Kg. The scratch width is obtained at various scratch load and test
conditions. The Brinell hardness test is carried out and investigated
for both corroded and inhibited specimens. The results showed that
three natural extracts can be used as environmentally friendly
corrosion inhibitors.
Abstract: In the present study, response surface methodology has been used to optimize turn-assisted deep cold rolling process of AISI 4140 steel. A regression model is developed to predict surface hardness and surface roughness using response surface methodology and central composite design. In the development of predictive model, deep cold rolling force, ball diameter, initial roughness of the workpiece, and number of tool passes are considered as model variables. The rolling force and the ball diameter are the significant factors on the surface hardness and ball diameter and numbers of tool passes are found to be significant for surface roughness. The predicted surface hardness and surface roughness values and the subsequent verification experiments under the optimal operating conditions confirmed the validity of the predicted model. The absolute average error between the experimental and predicted values at the optimal combination of parameter settings for surface hardness and surface roughness is calculated as 0.16% and 1.58% respectively. Using the optimal processing parameters, the surface hardness is improved from 225 to 306 HV, which resulted in an increase in the near surface hardness by about 36% and the surface roughness is improved from 4.84µm to 0.252 µm, which resulted in decrease in the surface roughness by about 95%. The depth of compression is found to be more than 300µm from the microstructure analysis and this is in correlation with the results obtained from the microhardness measurements. Taylor hobson talysurf tester, micro vickers hardness tester, optical microscopy and X-ray diffractometer are used to characterize the modified surface layer.
Abstract: Aluminium matrix composites with alumina
reinforcements give superior mechanical & physical properties. Their
applications in several fields like automobile, aerospace, defense,
sports, electronics, bio-medical and other industrial purposes are
becoming essential for the last several decades. In the present work,
fabrication of hybrid composite was done by Stir casting technique
using Al 6061 as a matrix with alumina and silicon carbide (SiC) as
reinforcement materials. The weight percentage of alumina is varied
from 2 to 4% and the silicon carbide weight percentage is maintained
constant at 2%. Hardness and wear tests are performed in the as cast
and heat treated conditions. Age hardening treatment was performed
on the specimen with solutionizing at 550°C, aging at two
temperatures (150 and 200°C) for different time durations. Hardness
distribution curves are drawn and peak hardness values are recorded.
Hardness increase was very sensitive with respect to the decrease in
aging temperature. There was an improvement in wear resistance of
the peak aged material when aged at lower temperature. Also
increase in weight percent of alumina, increases wear resistance at
lower temperature but opposite behavior was seen when aged at
higher temperature.
Abstract: In the present work, the alloy of Bismuth-lead is
prepared on the basis of percentage of molecular weight 9:1, 5:5 and
1:9 ratios and grown by Zone- Refining Technique under a vacuum
atmosphere. The EDAX of these samples are done and the results are
reported. Micro hardness test has been used as an alternative test for
measuring material’s tensile properties. The effect of temperature and
load on the hardness of the grown alloy has been studied. Further the
comparative studies of work hardening coefficients are reported.