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At least 163 records · Page 9

Effects of Rolling Passes on the Transport Properties of 37-Filamentary AgAu-Sheathed Bi-2223 Tapes

Thirty-seven-filamentary AgAu-sheathed Bi-2223 tapes were fabricated by a powder-in-tube (PIT) process. And, the round wires (ϕ 1.86 mm) were rolled to 0.35-mm tapes with 12, 7, 5, and 4 rolling passes through flat rolling, respectively. The influences of different rolling passes on the core density, deformation, and transport properties of Bi-2223/AgAu tapes were systematically investigated. It was noticed that after rolling, the Vickers microhardness of the superconducting core and deform homogeneity along both the horizontal and vertical directions on the cross section of seven-pass rolled tape were better than those on the tapes with other passes, which proved the larger core density and uniform deformation with the seven-pass rolling process. Meanwhile for the wires with 12 and 7 passes, the AgAu/superconducting core interfaces were much flatter. With the rolling passes decreasing from 12 to 4, the critical current density (J{sub c}) first increased and then decreased. Due to the better homogeneity and flatter interfaces, J{sub c} reached the maximum value of 17.3 kA/cm{sup 2} on the seven-pass sample. Meanwhile, the enhancement of current capacities in magnetic field applied parallel to the Bi-2223/AgAu tape surface could also be recognized as the evidence of improving intergrain connections due to the higher density in seven-pass rolled tapes.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Effect of Rolling Temperature on the Microstructure and Tensile Properties of 47Zr-45Ti-5Al-3V Alloy

The 47Zr-45Ti-5Al-3V (wt.%) alloy was solution-treated at 850 and 780 °C for 30 min and then rolled at different temperatures. The effect of rolling temperature on microstructure and tensile properties was investigated. The results showed that the microstructure contained a large amount of α phase at a rolling temperature of 600 °C. As the rolling temperature increased, the amount of α phase decreased, whereas the amount of β phase increased. When the rolling temperature was higher than 700 °C, the alloy was composed of a single β phase. The tensile properties of the alloy depended strongly on rolling temperature. The yield strength and tensile strength decreased with increasing rolling temperature, whereas the elongation increased. At a given rolling temperature, low solution treatment temperature resulted in higher strength and lower elongation than high solution treatment temperature. The fracture mode changed from cleavage fracture and quasi-cleavage fracture to dimple fracture with increasing rolling temperature.

36 MATERIALS SCIENCE↗

Effect of Hot Rolling on the Microstructure and Mechanical Properties of Nitrogen Alloyed Austenitic Stainless Steel

In the present investigation, the effect of multi-pass hot rolling in the temperature range of 700–1000 °C on the microstructure and mechanical properties of nitrogen alloyed austenitic stainless steel was studied with the aid of optical microscopy, tensile testing and x-ray diffraction measurements. The microstructural changes that occurred in the hot rolled specimens were elongation of grains in rolling direction, nucleation of new grains at the grain boundaries of elongated grains and growth of nucleated grains to form fully recrystallized grains. Elongated grains formed at lower rolling temperature (700–800 °C) due to inadequate strain/temperature for the initiation of dynamic recrystallization. At higher rolling temperature (900–1000 °C), fine grains formed due to dynamic recrystallization. Tensile properties showed strong dependency on the rolling temperature. Tensile strength increased with the decrease in the rolling temperature at the cost of ductility. Maximum strength was observed in samples hot rolled at 700 °C with yield strength of 917 MPa and ductility of 25%. This variation in the tensile properties with the rolling temperature is attributed to changes in the dislocation density and grain structure. The estimated yield strength from the dislocation density, solid solution and grain boundary strengthening closely matched with experimentally determined yield strength confirming the role of dislocation density and grain size in the strengthening.

36 MATERIALS SCIENCE↗

Numerical Investigation of the Effect of Rolling on the Localized Stress and Strain Induction for Wire + Arc Additive Manufactured Structures

Cold rolling can be used in-process or post-process to improve microstructure, mechanical properties and residual stress in directed-energy-deposition techniques, such as the high deposition rate wire + arc additive manufacturing (WAAM) process. Finite element simulations of the rolling process are employed to investigate the effect of rolling parameters, in particular rolling load and roller profile radius on the residual stress field as well as plastic strain distribution for the profiled roller. The results show the response to rolling of commonly used structural metals in WAAM, i.e., AA2319, S335JR steel and Ti-6Al-4V, taking into account the presence of residual stresses. The rolling load leads to changes in the location and the maximum value of the compressive residual stresses, as well as the depth of the compressive residual stresses. However, the roller profile radius only changes the maximum value of these compressive residual stresses. Changing the rolling load influences the equivalent plastic strain close to the top surface of the wall as well as in deeper areas, whereas the influence of the roller profile radius is negligible. The plastic strain distribution is virtually unaffected by the initial residual stresses prior to rolling. Finally, design curves were generated from the simulations for different materials, suggesting ideal rolling load and roller profile combinations for microstructural improvement requiring certain plastic strains at a specific depth of the additive structure.

36 MATERIALS SCIENCE↗

Design and Application of CSC-Roll for Heavy Reduction of the Bloom Continuous Casting Process

Center quality control is a key issue affecting large-section bloom production and product quality. The central convex roll could avoid the bloom side part and yield a high reduction amount, which benefit the implement of heavy reduction (HR) for bloom continuous casting process without upgrading the mechanical and hydraulic system of withdrawal and straightening machine. In this work, a curving surface convex roll (CSC-Roll), which could significantly improve bloom center quality, was designed by finite element simulation for a 360 mm × 450 mm #45 steel continuous casting bloom. The optimal roll surface shape of the CSC-Roll was determined based on an analysis of the distribution of the reduction amount in the bloom center and the strain of the bloom centerline and inner surface. The calculation results showed that the optimal size of the CSC-Roll was 200 mm in convex platform region length, 30 mm in convex platform region height, and 80 mm in gradient curvature region length. The bloom heat transfer and deformation behavior in the CSC-Roll reduction process were then analyzed. The results showed that in the CSC-Roll HR process, 61.71 pct of the reduction amount could be transmitted to the inner side of the porosity zone. Macrographs of the 360 mm × 450 mm #45 steel continuous casting bloom proved that the bloom center quality was significantly improved after CSC-Roll HR was applied.

36 MATERIALS SCIENCE↗

Elevated temperature tensile tests on DU–10Mo rolled foils

We report that studies were completed to obtain tensile mechanical properties for uranium-10wt.% molybdenum (U-10Mo) foils which were subjected to four different thermomechanical processing conditions. U-Mo alloy foils are being investigated to support fuel conversion of high power research reactors from their current high enriched fuel form to a low enriched fuel form. Mechanical properties of the fuel foil have an effect on irradiation performance and fuel fabrication and therefore are required to support modeling and qualification of new low-enriched uranium monolithic fuel plate designs. The data contained in this document contributes to fuel qualification by fulfilling the requirement that physical properties related to fuel meat be established. It is expected that depleted uranium-10wt% Mo (DU–10Mo) mechanical behavior is representative of the low-enriched U10-Mo to be used in actual fuel plates; therefore DU–10Mo was studied to simplify material processing, handling, and testing requirements. In this report, the different thermomechanical treatments included variations of wrought hot and cold rolling reduction and post rolling annealing. Each of the four foils was hot rolled. After hot rolling reduction, three of the four foils were further reduced by cold rolling. One of the three was reduced a further 20% by cold rolling, and the remaining two were reduced 50% by cold rolling. Following cold rolling reduction, one of the two foils which had been reduced 50% by cold rolling was annealed at 650?°C. Performing this analysis allows assessment of the impact of foil fabrication history on the resultant tensile properties DU–10Mo fuel foils. Tensile properties of DU–10Mo at room temperature through approximately 400 °C determined from the tests conducted herein suggest the material is stronger and has lower ductility than what has been reported previously in the literature. The explanation for these differences has yet to be determined, but is likely related to differences in grain size and/or impurity content, and variation in fabrication history. At the highest temperatures tested (550 °C) better agreement between the values reported here and available literature was found. As expected, yield and ultimate tensile strength decreased with increasing test temperature. Generally, the yield stress for all foil processing conditions was found to be in the range of 1100 MPa for room temperature tests, and in the range of 200 MPa for tests conducted at 550 °C. Ultimate tensile stress was in the range of 1175 MPa at room temperature, decreasing to approximately 225 MPa at 550 °C. Lastly, elongation increased significantly, from 0 to 2% at room temperature to 50% or more for the tests at 550 °C.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Carbide Particle Redistribution in U-10Mo Alloy during Hot and Cold Rolling Processes: Synthetic Microstructure-Based Finite-Element Approach

The influence of initial carbide particle distribution features on particle fracture and the evolution of stringer distribution within an alloy of uranium with 10 weight percent molybdenum during cold rolling was investigated in this study. This work will provide guidance to casting optimization work and identify actionable process changes to eliminate the surface features directly attributed to carbides. In a previous study, various synthetic microstructure-based finite-element (FE) models were generated with consideration of different parameters (i.e., particle shape, particle volume fraction, and particle distribution), and used to examine the effects of hot rolling on the microstructure evolution. In this study, microstructures after ~80% hot rolling were used as the initial microstructures for the subsequent cold rolling simulation. Plane-strain compression loading was employed in the FE models to simulate cold rolling with reductions from ~80% to ~94%. Stringer analyses with the consideration of particle fracture were then performed with the simulated cold rolling results. The results of void evolution analyses show that microstructures with elliptical particles incorporate a much larger (almost double) void volume fraction than those with circular particles, indicating that the elliptical particles are fractured more easily than the circular ones. The results from the fracture mode analyses show that, under the adopted simple compression loading assumption, almost all the particles (i.e., >99%) were fractured by tensile separation. The results of stringer analyses show that, during cold rolling, the stringer volume fractions increase substantially due to the particle fracture, especially for the microstructures with the elliptical particles, and that the stringer volume fractions from stringers comprising many particles tend to increase faster. The maximum stringer lengths for the microstructures with circular particles tend to remain constant or decrease during cold rolling, whereas those for elliptical particles tend to slightly increase after a slight decrease. The number of particles at the surface increases very rapidly due to particle fracture during cold rolling.

36 MATERIALS SCIENCE↗

Wind-tunnel investigation at supersonic speeds of a canard-controlled missile with fixed and free-rolling tail fins

A wind tunnel investigation was made at free stream Mach numbers from 1.70 to 2.86 to determine the effects of fixed and free rolling tail fin afterbodies on the static longitudinal and lateral aerodynamic characteristics of a cruciform canard controlled missile model. The effect of small canard roll and yaw control deflections was also examined. The results indicate that the fixed and free rolling tail configurations have about the same lift curve slope and longitudinal stability level at low angles of attack. For the free rolling tail configuration, the canards provide conventional roll control with no roll control reversal at low angles of attack. The free rolling tail configuration reduced induced roll due to model roll angle and canard yaw control.

Blair, A. B., Jr.↗

Computer-aided analysis and design of the shape rolling process for producing turbine engine airfoils

Mild steel (AISI 1018) was selected as model cold rolling material and Ti-6A1-4V and Inconel 718 were selected as typical hot rolling and cold rolling alloys, respectively. The flow stress and workability of these alloys were characterized and friction factor at the roll/workpiece interface was determined at their respective working conditions by conducting ring tests. Computer-aided mathematical models for predicting metal flow and stresses, and for simulating the shape rolling process were developed. These models utilized the upper bound and the slab methods of analysis, and were capable of predicting the lateral spread, roll separating force, roll torque, and local stresses, strains and strain rates. This computer-aided design system was also capable of simulating the actual rolling process, and thereby designing the roll pass schedule in rolling of an airfoil or a similar shape.

Lahoti, G. D.↗

Nucleation and growth of rolling contact failure of 440C bearing steel

A 'two-body' elasto-plastic finite element model of 2-dimensional rolling and rolling-plus-sliding was developed to treat the effect of surface irregularities. The model consists of a smooth cylinder in contact with a semi-infinite half-space that is either smooth or fitted with one of 0.4 microns deep or 7 microns deep groove, or a 0.4 microns high ridge-like asperity. The model incorporates elastic-linear-kinematic hardening-plastic (ELKP) and non-linear-kinematic hardening-plastic (NLKP) material constitutive relations appropriate for hardened bearing steel and the 440C grade. The calculated contact pressure distribution is Hertzian for smooth body contact, and it displays intense, stationary, pressure spikes superposed on the Hertzian pressure for contact with the grooved and ridged surface. The results obtained for the 0.4 microns deep groove compare well with those reported by Elsharkawy and Hamrock for an EHD lubricated contact. The effect of translating the counterface on the half space as opposed to indenting the half space with the counter face with no translation is studied. The stress and strain values near the surface are found to be similar for the two cases, whereas they are significantly different in the subsurface. It is seen that when tiny shoulders are introduced at the edge of the groove in the finite element model, the incremental plasticity and residual stresses are significantly higher in the vicinity of the right shoulder (rolling direction is from left to right) than at the left shoulder. This may explain the experimental observation that the spall nucleation occurs at the exit end of the artificially planted indents. Pure rolling calculations are compared with rolling + sliding calculations. For a coefficient of friction, mu = 0.1, the effect of friction is found to be small. Efforts were made to identify the material constitutive relations which best describe the deformation characteristics of the bearing steels in the initial few cycles. Elastic-linear-kinematic hardening-plastic (ELKP) material constitutive relations produce less net plastic deformation in the initial stages for a given stress, than seen in experiments. A new set of constitutive relations: non-linear-kinematic hardening-plastic (NLKP) was used. This material model produces more plasticity than the ELKP model and shows promise for treating the net distortions in the early stages. Techniques for performing experimental measurements that can be compared with the finite element calculations were devised. The measurements are being performed on 9mm-diameter, 440C steel cylindrical rolling elements in contact with 12.5 mm-diameter, 52100 steel balls in a 3-ball-rod fatigue test machine operating at 3600 RPM. Artificial, 7 microns deep, indents were inserted on the running track of the cylindrical rolling elements and profilometer measurements of these indents made, before and after the rolling. These preliminary measurements show that the indents are substantially deformed plastically in the process of rolling. The deformations of the groove calculated with the finite element model are comparable to those measured experimentally.

Gupta, V.↗

Roll Utilization of an F-100A Airplane During Service Operational Flying

As a means of evaluating the roll utilization of a fighter airplane capable of supersonic speeds, an instrumented North American F-100A fighter airplane was flown by U.S. Air Force pilots at Nellis Air Force Base, NV, during 20 hours of service operational flying. Mach numbers up to 1.22 and altitudes up to 50,000 feet were realized in this investigation. Results of the study showed that except for high g barrel rolls performed as evasive maneuvers and rolls performed in acrobatic flying, rolling was utilized primarily as a means of changing heading. Acrobatic and air combat maneuvering produced the largest bank angles (1,200 deg), roll velocities (3.3 radians/sec), rolling accelerations (8 radians/sq sec) and sideslip angles (10.8 deg). Full aileron deflections were utilized on numerous occasions. Although high rolling velocities and accelerations also were experienced during several air-to-air gunnery missions, generally, air-to-air gunnery and air-to-ground gunnery and bombing required only two-thirds of maximum aileron deflection. The air-to-air gunnery and air combat maneuvers initiated from supersonic speeds utilized up to two-thirds aileron deflection and bank angles of less than 18 deg and resulted in rolling velocities and accelerations of 2 radians per second and 4.6 radians/sq sec, respectively. Rolling maneuvers were often initiated from high levels of normal acceleration, but from levels of negative normal acceleration only once.

Matranga, Gene J.↗

Texture Evolution in an Al-Cu-Mg Alloy During Hot Rolling

The texture evolution in the intermediate (the 1/4 thickness) layer of hot-rolled Al-Cu-Mg alloy sheets was investigated by the x-ray diffraction technique, electron backscattered diffraction analysis and transmission electron microscopy observation. The results showed that a texture transition from the shear texture {001}<110> to the β-fiber textures occurred as the rolling temperature increased to 420 °C. The shear strain caused by friction resulted in this strong shear texture formation at the low rolling temperature. As the rolling temperature increased, the plane strain substituting the shear strain dominated in the intermediate layer, giving rise to a significant increase in the β-fiber textures. Increasing the rolling temperature was found to preferentially activate the non-octahedral {112}<110> slip system, thereby benefiting the development of strong Brass. At the low rolling reduction of 74%, the textures with low intensity tended to converge on the α-fiber, containing Goss, Brass, P and L components. As the rolling reduction increased to 90%, the textures were strengthened and gradually flew toward the β-fiber, containing Brass, Copper and S components. The S and Copper bands were found to be the preferential sites for the development of recrystallizing Cube grains during hot rolling.

36 MATERIALS SCIENCE↗

Effect of cold rolling on the microstructural evolution of new β-typed Ti–6Mo–6V–5Cr–3Sn–2.5Zr alloys

A Ti–6Mo–6V–5Cr–3Sn–2.5Zr (wt.%) alloy was designed as a new metastable β-Ti alloy. The effect that cold rolling had on the microstructural evolution of the material was investigated via optical microscopy (OM), X-ray diffraction (XRD), electron back-scattered diffraction (EBSD) and transmission electron microscopy (TEM) measurements. A single β phase formed in the alloy after solution treatment at 780 °C for 30 min followed by water quenching. The solution-treated alloy was cold rolled with thickness reductions of 10%, 30%, 50% and 70%, and the hardness values increased as the thickness of the specimen decreased. The textures of the cold rolled specimen were characterized according to the 〈110〉 partial parallel to the rolling direction as the rolling reduction increased. The crystallographic orientation showed principal α-fiber textures for (111)〈110〉 and (112)〈110〉. The cold deformation led to the appearance of martensite α″ phases, particularly stress-induced martensite (SIM) α″ phases. - Highlights: • Effect of cold rolling on new β-typed Ti-6Mo-6V-5Cr-3Sn-2.5Zr alloy was studied. • A single β phase was obtained after solution treatment at 780 °C for 30 min. • α-Fiber textures became dominated with the increase in cold rolling reduction. • A stress-induced α″ martensite was caused by cold rolling.

36 MATERIALS SCIENCE↗

Influence of differential speed rolling ratio on the ridging behavior of ultra purified 17%Cr ferritic stainless steel

Highlights: • Differential rolling process improves ridging resistance of ferritic stainless steel. • Texture orientation inhomogeneity were attributed to non-uniform deformation. • Shear bands results in homogeneous deformation and recrystallization nucleation. • Uniform recrystallization grains and random orientation grains were obtained. - Abstract: The effect of the differential speed rolling on the ridging resistance and the crystallographic texture evolution of ultra purified 17%Cr ferritic stainless steel was investigated in order to select the optimal procedure for improving the surface quality. In the present study, the three different cold rolling processes were carried out: a conventional cold rolling and two different speed ratios asymmetric rolling. In the conventional cold rolling, the ridging of ferritic stainless steel was pronounced due to the band-like clusters of grains with similar crystallographic orientations. For differential speed rolling, ridging depth decreased and ridging was less pronounced when a higher different speed ratio was applied. The results show that severe ridging is attributed to the presence of band-like clusters of γ-fiber (<111>//ND) oriented grains. The shear bands introduced by differential speed rolling can enhance the nucleation for recrystallization both in grain interiors and grain boundaries, which can fragment the band-like clusters of similar orientation effectively, promoting the random grain orientation and improving surface quality.

36 MATERIALS SCIENCE↗

Some Effects of Roll Rate on the Longitudinal Stability Characteristics of a Cruciform Missile Configuration as Determined from Flight Test for a Mach Number Range of 1.1 to 1.8

A model of a cruciform missile configuration having a low-aspectratio wing equipped with flap-type controls was flight tested in order to determine stability and control characteristics while rolling at about 5 radians per second. Comparison is made with results from a similar model which rolled at a much lower rate. Results showed that, if the ratio of roll rate to natural circular frequency in pitch is not greater than about 0.3, the motion following a step disturbance in pitch essentially remains in a plane in space. The slope of normal-force coefficient against angle of attack C(sub N(sub A)) was the same as for the slowly rolling model at O deg control deflection but C(sub N(sub A)) was much higher for the faster rolling model at about 5 deg control deflection. The slope of pitching-moment coefficient against angle of attack & same for both models at 0 deg control deflection but was lower for the faster rolling model at about 5 deg control deflection. Damping data for the faster rolling model showed considerably more scatter than for the slowly rolling model.

Barber, H. T., Jr.↗

Rolling maneuver load alleviation using active controls

Rolling Maneuver Load Alleviation (RMLA) was demonstrated on the Active Flexible Wing (AFW) wind tunnel model in the LaRC Transonic Dynamics Tunnel. The design objective was to develop a systematic approach for developing active control laws to alleviate wing incremental loads during roll maneuvers. Using linear load models for the AFW wind-tunnel model which were based on experimental measurements, two RMLA control laws were developed based on a single-degree-of-freedom roll model. The RMLA control laws utilized actuation of outboard control surface pairs to counteract incremental loads generated during rolling maneuvers and roll performance. To evaluate the RMLA control laws, roll maneuvers were performed in the wind tunnel at dynamic pressures of 150, 200, and 250 psf and Mach numbers of .33, .38, and .44, respectively. Loads obtained during these maneuvers were compared to baseline maneuver loads. For both RMLA controllers, the incremental torsion moments were reduced by up to 60 percent at all dynamic pressures and performance times. Results for bending moment load reductions during roll maneuvers varied. In addition, in a multiple function test, RMLA and flutter suppression system control laws were operated simultaneously during roll maneuvers at dynamic pressures 11 percent above the open-loop flutter dynamic pressure.

Woods-Vedeler, Jessica A.↗

Rolling Maneuver Load Alleviation using active controls

Rolling Maneuver Load Alleviation (RMLA) has been demonstrated on the Active Flexible Wing (AFW) wind tunnel model in the NASA Langley Transonic Dynamics Tunnel. The design objective was to develop a systematic approach for developing active control laws to alleviate wing incremental loads during roll maneuvers. Using linear load models for the AFW wind-tunnel model which were based on experimental measurements, two RMLA control laws were developed based on a single-degree-of-freedom roll model. The RMLA control laws utilized actuation of outboard control surface pairs to counteract incremental loads generated during rolling maneuvers and actuation of the trailing edge inboard control surface pairs to maintain roll performance. To evaluate the RMLA control laws, roll maneuvers were performed in the wind tunnel at dynamic pressures of 150, 200, and 250 psf and Mach numbers of 0.33, .38 and .44, respectively. Loads obtained during these maneuvers were compared to baseline maneuver loads. For both RMLA controllers, the incremental torsion moments were reduced by up to 60 percent at all dynamic pressures and performance times. Results for bending moment load reductions during roll maneuvers varied. In addition, in a multiple function test, RMLA and flutter suppression system control laws were operated simultaneously during roll maneuvers at dynamic pressures 11 percent above the open-loop flutter dynamic pressure.

Woods-Vedeler, Jessica A.↗

Mixed convective/dynamic roll vortices and their effects on initial wind and temperature profiles

The onset and development of both dynamically and convectively forced boundary layer rolls are studied with linear and nonlinear analyses of a truncated spectral model of shallow Boussinesq flow. Emphasis is given here on the energetics of the dominant roll modes, on the magnitudes of the roll-induced modifications of the initial basic state wind and temperature profiles, and on the sensitivity of the linear stability results to the use of modified profiles as basic states. It is demonstrated that the roll circulations can produce substantial changes to the cross-roll component of the initial wind profile and that significant changes in orientation angle estimates can result from use of a roll-modified profile in the stability analysis. These results demonstrate that roll contributions must be removed from observed background wind profiles before using them to investigate the mechanisms underlying actual secondary flows in the boundary layer. The model is developed quite generally to accept arbitrary basic state wind profiles as dynamic forcing. An Ekman profile is chosen here merely to provide a means for easy comparison with other theoretical boundary layer studies; the ultimate application of the model is to study observed boundary layer profiles. Results of the analytic stability analysis are validated by comparing them with results from a larger linear model. For an appropriate Ekman depth, a complete set of transition curves is given in forcing parameter space for roll modes driven both thermally and dynamically. Preferred orientation angles, horizontal wavelengths and propagation frequencies, as well as energetics and wind profile modifications, are all shown to agree rather well with results from studies on Ekman layers as well as with studies on near-neutral and convective atmospheric boundary layers.

Haack, Tracy↗