Current trends in machinability research

The manufacturing index of a country relies on the quality of manufacturing research outputs. Theemergence of new materials such as composites and multi component alloy has replaced traditionalmaterials in certain design application. Materials with properties like high strength to weight ratio,fatigue strength, wear resistance, thermal stability and damping capacity are a popular choice for adesign engineer. Contrary, the manufacturing engineer is novice to the science of machining thesematerials. This paper is an attempt to focus on the current trends in machinability research and anaddition to the existing information on machining. The paper consist of information on machiningAustempered Ductile Iron (ADI), Duplex Stainless Steel and Nano-Structured Bainitic Steel. Thevarious techniques used to judge the machinability of these materials is described in this paper.Studying the chip formation process in duplex steel using a quick stop device, metallographic analysisusing heat tinting of ADI and cutting force analysis of Nano-structured bainitic steel is discussed.

Effect of isothermal dissolution and re-precipitation of austenite on the mechanical properties of duplex structures

The hot deformation behaviour of a duplex ferritic/austenitic stainless steel was studied after different deformation conditions. The results showed a strange and interesting behaviour in the strength of the material during post-deformation studies. For most deformation conditions, the flow stress of the material was un-expectedly increased after annealing of deformed structures. This phenomenon implied that microstructural hardening occurred in the material during the interpass annealing rather than the expected softening. Also, an interesting change was observed where the morphology of the austenite phase changed from stringers or layers of austenite to a widmanstätten structure. The microstructural studies suggest that the austenite was dissolved and re-precipitated during the annealing process and the hardening was mostly associated with the change in the morphology of austenite.

Solidification behaviour and microstructural development of ironbased alloys under conditions pertinent to strip casting - 200 series stainless steels

The castability and microstructures produced from strip casting simulations of three compositions in the 200 series stainless steels have been examined. The nucleation density was similar for all three compositions.The as-cast microstructure showed very fine austenite grains of 10–20 μm in width. Retained delta ferrite was observed in the inter-dendritic regions, and was likely to be stabilised by the segregation of Cr into these regions. An analysis of the crystallography expected of different solidification sequences is presented, but a strict adherence to the Kurdjumov-Sachs orientation relationship was not found in these samples.

Microstructure and electrical conductivity of aluminium/steel bimetallic rods processed by severe plastic deformation

Equal-channel angular pressing (ECAP) was used to fabricate Al/steel bimetallic rod for potential application in overhead transmission conductors. Bimetallic rods consisted of an austenitic stainless steel 316L core and an Al alloy 6201 cladding layer. By means of ECAP processing at 175°C, increase of mechanical strength without loss of electrical conductivity was achieved for one particular rod geometry out of three geometries tested. X-ray diffraction and transmission electron microscopy were employed to analyse how the microstructure was influenced by the number of processing passes and the bimetallic rod geometry. The co-deformation mechanism of the bimetallic rod under ECAP and accelerated dynamic ageing of Al alloy 6201 were discussed based on the microstructure characterisation results.

Theoretical investigation of wear-resistance mechanism of superelastic shape memory alloy NiTi

Recent experimental research indicates that superelastic shape memory alloy nickel–titanium (NiTi) is superior to stainless steel against wear and could be applied in tribological engineering. It is believed that the super wear resistance of shape memory alloys is mainly due to the recovery of the superelastic deformation. Our recent wear study indicates that wear rate is very sensitive to the maximum contact pressure. In the present investigation, which involves applying Hertz contact theory and the finite element method, the wear behaviour of shape memory alloys is examined against that of stainless steels through analyzing the maximum contact pressure and the plastic deformation. Our investigation indicates that the contribution of superelasticity to the high wear resistance of NiTi is directly linked to the low transformation stress and the large recoverable transformation strain. Furthermore, the low Young's modulus of this alloy also plays an important role to reduce the maximum contact pressure and therefore reduce the wear rate. Additionally, the high plastic yield strength of transformed martensite NiTi enhances its wear resistance further.

Controlled growth of zinc nanowires

Zinc nanowires have been synthesized by heating a mixture of boron and zinc oxide (ZnO) powders at 1050 °C under a nitrogen atmosphere. The influences of the gas flow rate and the substrate character on the nanowire formation were investigated. It was found that higher-flow rate of gas led to the formation of thinner nanowires; while lower-flow rate of gas produced thicker nanowires and even particles due to the higher partial pressure of Zn vapor in this case. Zn nanowires can be produced on alumina and quartz substrates, but not on a stainless-steel substrate under the same or different synthetic conditions. Photoluminescence measurements were conducted on Zn nanowires and particles and weak emission bands at 482 and 493 nm were observed, which may be contributed by the thin ZnO film on the nanowire surface.

A morphology-related study on photodegradation of protein fibres

The wool fibre has a complex morphology, consisting of an outer layer of cuticle scales surrounding an inner cortex. These two components are hard to separate effectively except by using harsh chemical treatments, making it difficult to determine the susceptibility of the different components of the fibre to photoyellowing. An approach to this problem based on mechanical fibre modification is described. To expose the inner cortex of wool to different degrees, clean wool fibres were converted into ‘powders’ of various fineness via mechanical chopping, air-jet milling, ball milling or their combination. Four types of powdered wool (samples A, B, C and D) were produced with reducing particle size distributions and an increasing level of surface damage as observed using SEM. Sample A contained essentially intact short fibre snippets and sample D contained a large amount of exposed cortical materials. Samples B and C contained a mixture of short fibre snippets and cortical materials. Solid wool discs were then compressed from the corresponding powder samples in a polished stainless steel die to enable colour measurement and UV irradiation studies. ATR-FTIR studies on powder discs demonstrated a small shift in the amide I band from 1644 cm−1 for disc A to 1654 cm−1 for disc D due to the different structures of the wool cuticle and cortex, in agreement with previous studies. Similarly an increase in the intensity ratio of the amide I to amide II band (1540 cm−1) was observed for disc D, which contains a higher fraction of cortical material at the surface of the disc.

Discs prepared from sample D appeared the lightest in colour before exposure and had the slowest photoyellowing rate, whereas discs made from powders A–C with a higher level of cuticle coverage were more yellow before exposure and experienced a faster rate of photoyellowing. This suggests that the yellow chromophores of wool may be more prevalent in cuticle scales, and that wool photoyellowing occurs to a greater extent in the cuticle than in the cortex. Photo-induced chemiluminescence measurements showed that sample D had a higher chemiluminescence intensity after exposure to UVA radiation and a faster decay rate than samples A and B. Thus one of the roles of the wool cuticle may be to protect the cortex by quenching of free radical oxidation during exposure to the UV wavelengths present in sunlight.

Correlation between the deformation and post-deformation softening behaviours in hot worked Austenite

The relation between the deformation and post-deformation softening behaviours of austenite is examined in a 304 stainless steel. This correlation has been exploited in the modelling of hot rolling and it is argued here that the key to this understanding lies in the deformation structure. The latter is characterized in the present work by the fraction of dynamic recrystallization. The value of this fraction at the peak in the flow stress curve is found to decrease with increasing stress (i.e. with decreasing temperature and increasing strain rate). By contrast, the fraction of dynamic  recrystallization at the strain corresponding to the point where  post-deformation softening becomes strain independent is found to be constant. These observations are used to explain the nature of the important difference between the flow curve peak and the onset of strain independent post-deformation softening.

Dependency of recrystallization mechanism to the initial grain size

The effect of initial grain size on the recrystallization behavior of a type 304 austenitic stainless steel during and following hot deformation was investigated using hot torsion. The refinement of the initial grain size to 8 μm, compared with an initial grain size of 35 μm, had considerable effects on the dynamic recrystallization (DRX) and post-DRX phenomena. For both DRX and post-DRX, microstructural investigations using electron backscattered diffraction confirmed an interesting transition from conventional (discontinuous) to continuous DRX with a decrease in the initial grain size. Also, there were unexpected effects of initial grain size on DRX and post-DRX grain sizes.

In vitro cytotoxicity of binary TI alloys for bone implants

Interest in using titanium (Ti) alloys as load-bearing implant materials has increased due to their high strength to weight ratio, lower elastic modulus, and superior biocompatibility and enhanced corrosion resistance compared to conventional metals such as stainless steel and Co-Cr alloys. In the present study, the in vitro cytotoxicity of five binary titanium alloys, Ti15Ta, Ti15Nb, Ti15Zr, Ti15Sn and Ti15Mo, was assessed using human osteosarcoma cell line, SaOS-2 cells. The Cell proliferation and viability were determined, and cell adhesion and morphology on the surfaces of the binary Ti alloys after cell culture were observed by SEM. Results indicated that the Ti binary alloys of Ti15Ta, Ti15Nb and Ti15Zr exhibited the same level of excellent biocompatibility; Ti15Sn alloy exhibited a moderate biocompatibility while Ti15Mo alloy exhibited a moderate cytotoxicity. The SaOS-2 osteoblast-like cells had flattened and spread across the surfaces of the Ti15Ta, Ti15Nb, Ti15Zr and Ti15Sn groups; however, the cell shapes on the Ti15Mo alloy was shrinking and unhealthy. These results indicated that the Mo contents should be limited to a certain level in the design and development of new Ti alloys for implant material applications.

Fine structure of shear bands formed during hot deformation of two austenitic steels

Shear bands formed during both cold and hot plastic deformation have been linked with several proposed mechanisms for the formation of ultrafine grains. The aim of the present work was to undertake a detailed investigation of the microstructural and crystallographic characteristics of the shear bands formed during hot deformation of a 22Cr-19Ni-3Mo (mass%) austenitic stainless steel and a Fe-30 mass%Ni based austenitic model alloy. These alloys were subjected to deformation in torsion and plane strain compression (PSC), respectively, at temperatures of 900°C and 950°C and strain rates of 0.7s_-1 and 10s_-1, respectively. Transmission electron microscopy and electron backscatter diffraction in conjunction with scanning electron microscopy were employed in the investigation. It has been observed that shear bands already started to form at moderate strains in a matrix of pre-existing microbands and were composed of fine, slightly elongated subgrains (fragments). These bands propagated along a similar macroscopic path and the subgrains, present within their substructure, were rotated relative to the surrounding matrix about axes approximately parallel to the sample radial and transverse directions for deformation in torsion and PSC, respectively. The subgrain boundaries were largely observed to be non-crystallographic, suggesting that the subgrains generally formed via multiple slip processes. Shear bands appeared to form through a co-operative nucleation of originally isolated subgrains that gradually interconnected with the others to form long, thin bands that subsequently thickened via the formation of new subgrains. The observed small dimensions of the subgrains present within shear bands and their large misorientations clearly indicate that these subgrains can serve as potent nucleation sites for the formation of ultrafine grain structures during both subsequent recrystallisation, as observed during the present PSC experiments, and phase transformation.

Hexavalent chromium in welding fume

Evaluates the current Australian Standard method (AS3853.1) for the determination of total hexavalent chromium (Cr(VI)) in stainless steel welding fume. Investigates the extraction kinetics of this Cr(VI) into a range of media. Develops an analytical method for the determination of Cr(VI) in acidic extract solutions and investigates the extraction of Cr(VI) under simulated in vivo conditions.

Study of the deformation behaviour of austenite via model alloys

This study compared two potential model alloys, 304 stainless steel and Ni-30wt.%Fe, to study the behaviour of austenite during the thermo-mechanical processing of steel. The deformation behaviour as well as the textural and microstructural evolution was characterised in detail over a wide range of deformation conditions.

The effect of skin passing on the material behavior of metal strip in pure bending and tension

The metal strip used in roll forming has often been preprocessed by (tension or roller) leveling or by skin-pass rolling, and as a consequence, may contain residual stresses. These stresses are not well observed by the tensile test, but could have a significant effect on the bending and springback behavior. With the advent of improved process design techniques for roll forming, including advanced finite element techniques, the need for precise material property data has become important. The major deformation mode of roll forming is that of bending combined with unloading and reverse bending, and hence property data derived from bend tests could be more relevant than that from tensile testing.

This work presents a numerical study on the effect of skin passing on the material behavior of stainless steel strip in pure bending and tension. A two dimensional (2-D) numerical model was developed using Abaqus Explicit to analyze the affect of skin passing on the residual stress profile across a section for various working conditions. The deformed meshes and their final stress fields were then imported as pre-defined fields into Abaqus Standard, and the post-skin passing material behavior in pure bending was determined. The results show that a residual stress profile is introduced into the steel strip during skin passing, and that its shape and stress level depend on the overall thickness reduction as well as the number of rolling passes used in the skin passing process. The material behavior in bending and the amount of springback changed significantly depending on the skin pass condition.

Surface alloying of metals using fluid bed reactor

The use of fluidised bed reactors for surface alloying is reviewed. Research at Deakin has includes the use of chemical vapour deposition to form chromium rich layers on ferrous substrates, including stainless and tool steel grades. These layers can be modified to carbide or nitride if required by the end application. The deposition of aluminium and silicon has also been successfully achieved.