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At least 703 records · Page 39

Influence of annealing parameters on phase evolution and recrystallization kinetics of a Mn-Al-Si alloyed duplex steel

Highlights: • Stacking fault energy calculated for Fe-9.8Mn-7.5Al-1.22Si-0.2C steel is 48.4 mJ/m{sup 2} • Austenite stability decreases with increasing temperature due to higher free energy • Mn{sub 5}(Al,Si)C precipitates evolve with concurrent disappearance of austenite at 1273 K • Decrease in austenite fraction stimulates boundary migration for recrystallization • The maximum value of Avrami exponent ~ 1 implies sluggish recrystallization kinetics - Abstract: In this study, the phase transformation and recrystallization behavior of hot-forged Fe-Mn-Al-Si-C alloyed duplex steel has been investigated in wide ranges of annealing temperatures (973-1273 K) and durations (15–150 min). The recrystallization kinetics has been evaluated employing Johnson-Mehl-Avrami-Kolmogorov model. A limited extent of phase transformation (i.e. duplex to single phase) has been found to take place during annealing in the range of 973-1173 K. However, during annealing at 1273 K, not only the transformation from duplex to ferritic microstructure accelerates, but also recrystallization is initiated in these ferrite grains. The changes in the free energy of the austenite with the annealing temperature play a pivotal role in dictating the stabilization of the corresponding phase. Moreover, the disappearance of the austenitic phase at 1273 K owing to higher free energy is compensated by the formation of Mn-Al-Si rich carbide precipitates. The phase evolution triggered by annealing at 1273 K affects the recrystallization kinetics of each of the phase constituents. A sharp rise in the Avrami exponent (n) value is noticed following annealing at 1273 K, which clearly denotes that the disappearing austenite-ferrite interfaces facilitate the migration of the ferrite boundaries that stimulate recrystallization. In spite of the increasing values of n with the annealing temperature, its maximum value (at 1273 K) remains close to 1. This is a clear indication of the sluggish nature of the recrystallization process in the developed alloy.

36 MATERIALS SCIENCE↗

A high-performance β-solidifying TiAl alloy sheet: Multi-type lamellar microstructure and phase transformation

Highlights: • A high-performance β-solidifying TiAl alloy sheet is fabricated via hot rolling. • Fine multi-type β/γ and α{sub 2}/γ lamellar structures are formed during hot-rolling. • These lamellar structures are induced by the β → γ and α + γ → α{sub 2} + γ/γ{sub T} transformations. • The nano-scaled antiphase domain is induced by α → α{sub 2} disorder-order transformation. • The fine multi-type lamellar structures contribute to the strength enhancement. - Abstract: TiAl alloys are widely used in the aerospace industry and, hence, a thorough understanding of the corresponding microstructural evolution is crucial for providing insight into the fabrication of high-performance TiAl alloy sheets. In this study, a high-performance β-solidifying Ti-43Al-9V-0.2Y alloy sheet with multi-type lamellar structures was obtained via hot-rolling at an initial rolling temperature of 1260 °C. Owing to the temperature drop and reheat associated with multi-pass rolling, relatively fine irregular β/γ and regular α{sub 2}/γ lamellar microstructures (average size: ~25 μm) with nano-scaled antiphase domains (APDs) were generated by the β → γ and α + γ → α{sub 2} + γ/γ{sub T} phase transformations. These two lamellar structures have different formation mechanisms. The results of electron backscatter diffraction and transmission electron microscopy revealed that the nucleation and growth of (i) β/γ and (ii) α{sub 2}/γ lamellar structures are induced mainly by (i) stress and (ii) a combination of the stress and temperature drop during hot-rolling, respectively. Thin γ{sub T} precipitates from the α/α{sub 2} or γ phases. This precipitation is induced by the higher stress and lower temperature associated with the later stage (compared with those occurring in the initial stages) of hot-rolling. Moreover, compared with the corresponding as-forged alloy, the as-rolled TiAl alloy sheet exhibits better performance at both room and elevated temperatures. The improvement in the tensile properties is attributed to the duplex microstructure consisting of fine multi-type lamellar structures with nano-scaled APDs. The interface boundaries of β/γ, α{sub 2}/γ and APDs, which are effective in retarding dislocation motion, contribute mainly to strengthening of the alloy sheet.

36 MATERIALS SCIENCE↗

Non-equilibrium approach to prediction of microstructure evolution for metals undergoing severe plastic deformation

Highlights: • New consistent physically-based model of dynamic recrystallization. • The model is based on evolution of fraction of high-angle grain boundaries. • Possibility to predict the evolution of dislocation cells and grain boundaries. • The model is implemented for FEM simulations. • Results demonstrate inhomogeneous distribution of strain within the sample. - Abstract: Available models of dynamic recrystallization have a number of disadvantages that in most cases make them inapplicable for practical predictions of material microstructure evolution. Both the microstructural and the empirically based approaches do not reflect physical processes leading to evolution of material defect structure in the process of plastic deformation. This work presents an attempt to develop a consistent physically-based model of dynamic recrystallization. This model, accounting for physical nature of processes of material defect structure evolution, should provide a possibility to predict evolution of several different experimentally measurable parameters of material microstructure without introduction of big number of fitting parameters. It is suggested that such a model should be based on equation for evolution of fraction of high-angle grain boundaries (HAGBs) in the process of deformation. It is shown, that the new model gives a possibility to predict the evolution of dislocation cells and grain boundaries in copper-based alloys providing good coincidence with experimental observations. Full 3-dimensional numerical simulation of multidirectional forging of copper is performed utilizing the developed dynamic recrystallization model. The same 3D simulations demonstrate new noteworthy effects connected to inhomogeneous distribution of plastic strain within the bulk of the material and material strain hardening.

36 MATERIALS SCIENCE↗

Grain boundary inter-connections in polycrystalline aluminum with random orientation

Highlights: • The GBICs in a pure aluminum are not random, showing remarkable preference on the planes of low Miller index. • {1 1 1}/{1 1 1} is the most frequent GBIC in pure aluminum. • {1 1 1}/{1 1 1} GBIC is mainly coming from the GBs formed by rotations around , and axes. • {1 1 1}/{1 1 1} GBIC possesses higher PCSD and definite dislocation structures compared to the general GBs. • To pursue {1 1 1}/{1 1 1} GBIC is a pint-cut for the GBE research in high stacking fault energy FCC materials. - Abstract: Grain boundary inter-connection (GBIC) is the matching of two crystallographic planes from two abutting grains ending on the grain boundary (GB) position in polycrystalline materials, which can be expressed as {h_1k_1l_1}/{h_2k_2l_2}. GBIC is the critical parameter that intrinsically defines the character and properties of a GB. In current work, a zone-melted polycrystalline aluminum bar with a purity higher than 99.99% (mass fraction) was subjected to a multi-directional forging (MDF) with a true strain of 4 followed by a recrystallization annealing at 360 °C. Such process repeated at least 4 times until an equiaxed-grain microstructure with random orientation and averaged grain size approximate 30 μm was achieved. Then the GBICs were determined by electron backscatter diffraction (EBSD) measurement and stereology-based five-parameter analysis (FPA) coupled with crystallographic analysis after the grain boundaries (GBs) were filtered according to their misorientations (e.g. angle/axis pair). The results revealed that the GBICs for any group of GBs with a given misorientation are not random, showing remarkable preference on the planes of low Miller index forming mixed and twist GBs. The work also demonstrated that among the high angle boundaries (HABs), {1 1 1}/{1 1 1}, including coherent ∑3 boundaries, is the most frequent GBIC, mainly due to the GBs formed by rotations around <1 1 1>, <1 2 2> and <1 1 2> axes. Near coincidence site (NCS) and O-lattice theory analyses indicate that the {1 1 1}/{1 1 1} GBICs usually possess higher planar coincidence site density (PCSD) and definite dislocation structures compared to the general GBs, implying their more structural stability when only crystallography is taken into account. This result agrees very well with the recent results obtained by molecular dynamic simulations. It is significant to the grain boundary engineering (GBE) in the high stacking fault energy (SFE) face-centered cubic (FCC) materials such as aluminum and its alloys.

36 MATERIALS SCIENCE↗

Thermo-mechanical processing window for β phase recrystallization inTi-5Al-5Mo-5V-3Cr alloy

Highlights: • A processing window has been developed to obtain fine uniform recrystallized grains. • High deformation (90%) with annealing at intermediate temperature (950 °C) suggested • Dynamic recrystallization (Drx) should be avoided. • DRx reduces driving force for static rx. It gives bimodal distribution of grains. • Final deformation step should be in the α + β phase field. Ti-5Al-5Mo-5V-3Cr (Ti-5553) is a high strength β titanium alloy. It is now commonly used in thick section aerospace components. In general, the thermo-mechanical processing (TMP) of β titanium alloys done at high temperature to obtain uniformly recrystallized fine grain structure is one of the major challenges. Through this work, a TMP window for Ti-5553 (through systematic variation in % reduction and post deformation annealing temperature) has been developed to obtain fine uniformly recrystallized β grains. Grain size has been quantified on EBSD generated orientation maps, by applying stereological methods, image processing and automated reconstruction. Effects of % deformation and post deformation annealing temperature, as well as that of initial ingot size prior to deformation and the capacity of the forge on the static and dynamic recrystallization behavior, which eventually determine the final grain size distribution, have been illustrated.

36 MATERIALS SCIENCE↗

Effect of aging on failure mechanism of Alloy 709 at various temperatures

Alloy 709 is a novel austenitic stainless steel with high temperature creep strength, weldability, and corrosion resistance. These properties make the material suitable for applications in the structure of next-generation nuclear power plants. Enduring high temperatures for an extended period of time in the harsh environments of a nuclear power plant results in thermal aging of the material. Therefore, it is imperative to study the effect of thermal aging on the microstructure and mechanical properties of Alloy 709 before its application in the next generation power plants. In this study, hot-processed (forged + rolled), annealed and quenched ingots of Alloy 709 are aged at 650 °C for 2000 h in air and then tested at various temperatures up to 850 °C in an in-situ heating-loading Scanning Electron Microscope (SEM) equipped with Energy Dispersive Spectroscopy (EDS) and Electron Backscatter Diffraction (EBSD). The effect of testing temperature and aging on microstructural evolutions during tensile testing of as-received and aged samples are studied. Furthermore, both as-received and aged samples displayed serrations and drop in ductility at elevated temperatures, due to the effect of dynamic strain aging (DSA). The occurrence of DSA activity was found within temperatures range of 500 °C–750 °C in as-received and 550 °C - 650 °C in aged samples. The aged samples showed less elongation accompanied by shallower dimples on the fractured surface, indicating less ductile failure mechanism compared to as-received samples. Failure mechanism observations on the fracture surface using SEM fractography are correlated to the observations made on the sample surface using in-situ SEM to achieve a complementary set of information to better understand the failure mechanism of this novel alloy.

36 MATERIALS SCIENCE↗

Process-structure-property considerations for wire-based directed energy deposition of Ti-6Al-4V

Directed energy deposition (DED) is an attractive additive manufacturing (AM) process for large structural components. The rapid solidification and layer-by-layer process associated with DED results in non-ideal microstructures, such as large grains with strong crystallographic textures. These non-ideal microstructures can lead to severe anisotropy in the mechanical properties. Despite these challenges, DED has been identified as a potential solution for the manufacturing of near net shape Ti-6Al-4V preforms, replacing lost casting and forging capabilities. Two popular wire-based directed energy deposition (W-DED) processes were considered for the manufacturing of Ti-6Al-4V with assessments on their respective metallurgical and mechanical properties, as compared to a conventionally processed material. The two W-DED processes explored were wire arc additive manufacturing (WAAM) and electron beam additive manufacturing (EBAM). High throughput inspection and tensile testing procedures were utilized to generate statistically relevant data sets related to each process and sample orientation. The 2 AM technologies produced material with remarkably different microstructures and mechanical properties. Importantly, results revealed key differences in strength and ductility for the two disparate processes which were found to be related to differences in the metallurgical properties.

36 MATERIALS SCIENCE↗

High strength W/TiNi micro-laminated composite with transformation-mediated ductility

A laminated W/TiNi composite is fabricated by hot pressing under vacuum and subsequent forging. The W and TiNi constituents are about 250 μm and 80 μm respectively in thicknesses and their interfaces are chemically sharp with negligible intermixing. The material exhibits two yielding plateaus and excellent strength-ductility combination during compression tests. In situ X-ray technique is employed to demonstrate that the unusual yielding phenomenon is related to the reversible thermoelastic phase transformation of TiNi layers. Furthermore, such mechanisms also contribute to the damage tolerance of the materials by inhibiting crack propagation in W.

36 MATERIALS SCIENCE↗

Conductive nanolamellar Cu/martensite wire with high strength

Cu wires can be greatly strengthened without losing much conductivity if a continuous nanolamellar structure with Cu and a strong second constituent is achieved. Here, we report on a nanolamellar Cu/steel wire fabricated by repetitive hot-pressing, forging, rolling and subsequent wire drawing. Austenization and quenching in liquid nitrogen resulted in a Cu/martensite structure, exhibiting tensile strength of 1220 MPa. The electrical conductivity of the wire was measured to be about 60% International Annealed Copper Standard (IACS), which was comparable with Cu/Fe fabricated by alloying and casting. In situ tensile tests under high energy X-ray diffraction were utilized to explore the deformation behavior of the wire. It was discovered that the martensite carried about 60% of the load, accounting for the high strength.

36 MATERIALS SCIENCE↗

An isothermal forming process with multi-stage variable speed for magnesium component assisted by sensitivity analysis

We have developed a multi-stage variable speed (MSV) isothermal forming process based on strain rate sensitivity (SRS) analysis, and successfully produced a large size of rib-web component of magnesium alloy from a cylindrical billet. The obtained rib-web component has been processed into parts for mechanical properties examination and the examination results met the standard of being safely used in aircrafts. The process parameters of the forming technology and microstructure change were explicitly linked by the SRS coefficient. The finite element (FE) simulation and SRS distribution were implemented to identify the relationship among process parameters, shaping characteristics, and microstructure development. The MSV speed process was employed for reducing the forming load, refining grain sizes and increasing the strength of the component. With the selected process parameters the maximum forming load was reduced to be less than 20 MN, which is 55.3% lower than that used in the same process with the initial constant speed unchanged. Fine dynamic recrystallization (DRX) were observed from all parts of the forged cover plate including the convex, ribs, and web region. It was also found that higher strain resulted in more uniform distribution of fine ß-Mg17Al12 precipitates and larger DRX volume fraction. Importantly the developed isothermal forming process with severe plastic deformation can be applied for obtaining grain refinement so improving the mechanical properties of Mg products.

Magnesium alloy, Isothermal forming, Multi-stage v↗

Friction surface layer deposition of triple-phase Al 10 Cr 12 Fe 35 Mn 23 Ni 20 high entropy alloy: Process optimization and microstructural evolution

A high-strength Co-free triple-phase Al 10 Cr 12 Fe 35 Mn 23 Ni 20 high-entropy alloy (HEA) was successfully fabricated using Friction Surface Layer Deposition (FSLD), a bulk manufacturing method. Multiple single-layer deposits were produced by varying forging force (F) and traverse speeds (T r ) to optimize the process parameters. The optimized conditions (F = 40 kN & T r = 200 mm/min) were then applied to manufacture a scaled-up multi-layer specimen. The initial microstructure of the HEA consisted of coarse grains of the soft FCC-phase, long columnar dendrites of the hard BCC-phase, and small precipitates of the harder B2-phase within the BCC-dendrites. During FSLD, the FCC-matrix underwent continuous dynamic recrystallization due to high-temperature severe plastic deformation, forming finer equiaxed grains. Simultaneously, the BCC-dendrites fractured into smaller fragments, some of which experienced partial growth and coarsening under applied stress, resulting in an hourglass morphology. In contrast, the small B2-precipitates within the BCC-fragments dissolved during the elevated temperatures of FSLD and reprecipitated as substantially finer precipitates during continuous cooling post-FSLD. Additionally, the orientation relationships between the FCC and BCC/B2 phases were completely destroyed by the severe thermoplastic deformation inherent to FSLD. The microstructural refinements led to a substantial improvement in hardness from 177 HV to 283 HV, driven by Hall-Petch strengthening. The increased number of interfaces, including coherent BCC-B2 interfaces, potentially enhances the sink strength and radiation tolerance of the HEA, making it a promising candidate for nuclear applications. In conclusion, this study also highlights FSLD as a versatile technique for achieving tunable properties in HEAs, with detailed schematics illustrating the complex mechanisms of phase transformations during processing.

Additive Manufacturing↗

Microstructure and mechanical behavior of a TiC nanoprecipitate strengthened V Alloy

The V-4Cr-4Ti (V44) alloys have been proposed as the prime candidate structural material for self-cooled liquid Li blanket and other designs for fusion energy applications. However, the applications of the V44 alloy are limited to a narrow operation temperature window, due to reduction in creep strength at or above 700 °C and susceptibility to irradiation hardening and embrittlement when irradiated below 400 °C. Here, in this work, we explore the feasibility of designing a novel V alloy to form a high number density of TiC nanoprecipitates, in order to simultaneously improve creep strength and provide defect sinks to mitigate irradiation hardening. Computational thermodynamics was used to design a new alloy (V44C) to achieve our goal of high TiC nanoprecipitates density within the alloy V44 matrix. To ensure scalability, the new alloy was made through arc-melting and ingot-casting followed by hot forging, cold rolling and heat treatments of homogenization and precipitation aging. The microstructure was characterized by SEM, TEM, XRD and APT, confirming the existence of nanoprecipitates predicted in the thermodynamic calculations. In addition to microstructural evaluation tensile properties at room temperature and 700 °C, and Charpy impact energy at room temperature were measured. The microstructure and mechanical properties were then compared with those from a historic reference V44 alloy. The tensile strength improvement in V44C was rationalized based on particle and solid solution strengthening mechanism. The fracture behavior was discussed based on the fractography results and necking deformation behavior.

Alloys development↗

Role of geometric dynamic recrystallization in nanocrystalline alloys

Nanocrystalline and near-nano-grained metals are plagued with an overall lack of ductility and formability. This is in part due to their inability to support the dislocation mechanisms or undergo the same types of transformations that conventional coarse-grained metals access in order to increase their workability. Therefore, despite their advanced properties such as high strength, the manufacturing of such fine-grained metals, which exposes them to multi-axial states of stress in operations such as rolling, drawing, extrusion, forging, and bending, has not been possible. In this work, we address this limitation and highlight an important aspect of geometric dynamic recrystallization (GDRX) in nanocrystalline materials as a way to improve manufacturability. In particular, using two different alloy compositions and two different processing techniques, this study points to the fact that if nanocrystalline or near nano metals can be truly stabilized, they can repeatedly undergo the same types of processes that conventional coarse-grained metals endure, increasing both their formability and hence manufacturability. The results reveal that due to a large number of initial high-angle grain boundaries and large applied compressive strains, GDRX is activated in the absence of any discontinuous dynamic recrystallization (DDRX) or continuous dynamic recrystallization (CDRX). This is a unique aspect of stabilized nanocrystalline materials, as traditionally fine-grained metals are not microstructurally stable enough to accommodate such an event.

36 MATERIALS SCIENCE↗

Experiment design for the neutron irradiation of $\mathrm{PM-HIP}$ alloys for nuclear reactors

Here, this article describes the design of an Advanced Test Reactor (ATR) drop-in neutron irradiation experiment aiming to directly compare the performance of nuclear structural alloys fabricated by powder metallurgy with hot isostatic pressing (PM-HIP) against conventional casting or forging. There is growing interest in PM-HIP alloys for nuclear applications because of their microstructural uniformity, superior mechanical properties, and reduced dependence on welding and machining, compared to cast/forged alloys. Nuclear code-qualification of PM-HIP alloys requires neutron irradiation testing to demonstrate performance under relevant conditions. In this experiment, six nuclear structural alloys were irradiated: Ni-based alloys 625 and 690, Grade 91 ferritic steel, SA508 pressure vessel steel, and 304L and 316L austenitic stainless steels. The experiment is assembled into seven capsules in four test trains and irradiated in three ATR inboard A positions. Both the PM-HIP and cast/forged versions of each alloy were irradiated under nearly identical conditions for comparative purposes, to target doses of 1 ± 0.2 and 3 ± 0.2 dpa at temperatures of 300 ± 50 °C and 400 ± 50 °C. A thorough description of the experiment design and thermal, structural and neutronic analyses performed to ensure the targeted irradiation conditions are met is provided. Specimens were configured as small disks, compact tension specimens and tensile bars to facilitate post-irradiation examination (PIE) that will include mechanical testing, microstructure characterization, and fracture toughness testing. Given the considerations for ASTM standardized mechanical testing, comparative fluence and temperature across specimen pairs, and comprehensive PIE planning herein, this work serves as a template for future nuclear materials qualification experiment designs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

The effect of oxygen enrichment on soot formation and thermal radiation in turbulent, non-premixed methane flames

Non-premixed oxy-fuel combustion of natural gas is used in industrial applications where high-intensity heat is required, such as glass manufacturing and metal forging and shaping. In these applications, the high flame temperatures achieved by oxy-fuel combustion increase radiative heat transfer to the surfaces of interest and soot formation within the flame is desired for further augmentation of radiation. However, the high cost of cryogenic air separation has limited the penetration of oxy-fuel combustion technologies. New approaches to air separation are being developed that may reduce oxygen production costs, but only for intermediate levels of oxygen enrichment of air. To determine the influence of oxygen enrichment on soot formation and radiation, we developed a non-premixed coannular burner in which oxygen concentrations and oxidizer flow rates can be independently varied, to distinguish the effects of turbulent mixing intensity from oxygen enrichment on soot formation and flame radiation. Local radiation intensities, soot concentrations, and soot temperatures have been measured using a thin-film thermopile, planar laser-induced incandescence (LII), and two-color imaging pyrometry, respectively. The measurements show that soot formation increases as the oxygen concentration decreases from 100% to 50%, helping to moderate a decrease in overall flame radiation. An increase in turbulence intensity has a marked effect on flame height, soot formation and thermal radiation, leading to decreases in all of these. The soot temperature decreases with a decrease in the oxygen concentration and increases with an increase in turbulent mixing intensity. Altogether, the results suggest that properly designed oxygen-enriched burners that enhance soot formation for intermediate levels of oxygen purity may be able to achieve thermal radiation intensities as high as 85% of traditional oxy-fuel burners utilizing high-purity oxygen.

03 NATURAL GAS↗

Alloy selective optical sorting of mixed post-consumer aluminum scrap streams

Shredded post-consumer non-ferrous scrap stream, also known as Zorba, contains a mixture of cast and wrought aluminum pieces with very different compositions. Cast Al pieces, with their high Si, Cu and Fe content, are a major contaminant in wrought scrap fraction, which results in downcycling of the mixed cast + wrought scrap into non-structural cast Al alloys and parts. Here, in this paper, we introduce a chemical treatment method to color-code scrap aluminum pieces by alloy family and demonstrate low-cost optical sorting of cast from wrought pieces to upgrade the scrap stream. We utilized non-acidic chemical solutions that react with (i.e., etch) the scrap pieces to produce colors based on the Al alloy chemistry of a given piece. Cast pieces with high Si and Cu fractions turned black, whereas the much leaner wrought pieces remained unreacted. We showed > 95% sorting efficiency of mixed cast and wrought pieces using a repurposed low-cost optical sorter originally designed for food sorting. We also colored wrought Al pieces by alloy families, such as 5xxx and 6xxx, using a two-step chemical etching technique, which has the potential to create a circular supply chain in which wrought aluminum alloys are sorted from the mixed scrap stream and recycled back to high-value wrought products such as sheets, extrusions, and forgings with minimal contamination from cast scrap.

Aluminum↗

Evolution of cellular dislocation structures and defects in additively manufactured austenitic stainless steel under ion irradiation

Here, the evolution of irradiation-induced defects in additively manufactured (AM) austenitic stainless steel was explored in situ by 1 MeV Kr ion irradiation at 450 and 600 °C in a transmission electron microscope. Cellular dislocation structure in AM steel act as sink/trap sites for the irradiation-induced defects, resulting in the lower density and smaller dislocation loops in AM steel than conventional forged (CF) steel at 450 °C. The higher stacking fault energy and local stress concentration induced by cellular dislocation structure in AM steel promotes the unfaulting process and the formation of network dislocation at 600 °C.

36 MATERIALS SCIENCE↗