Chip formation mechanism and machinability of wrought duplex stainless steel alloys

This paper investigates the chip formation mechanism and machinability of two-phase materials, such as, wrought duplex stainless steel alloys SAF 2205 and SAF 2507. SEM and optical microscopic details of the frozen cutting zone and chips revealed that the harder austenite phase dissipates in the advancement of the cutting tool, being effectively squeezed out of the softer ferrite phase. Microhardness profiles reveal correlation in hardness from the workpiece material transitioning to the chip. The tool wear (TiAIN + TiN coated solid carbide twist drill) and machining forces were investigated. Tool wear, was dominantly due to the adhesion process which developed from built-up edge formation, is highly detrimental to the flank face. Flute damage was also observed as a major issue in the drilling of duplex alloys leading to premature tool failure. Duplex 2507 shows higher sensitivity to cutting speed during machining and strain hardening at higher velocity and less machinability due to presence of higher percentage of Ni, Mo and Cr.

Investigation on the behavior of austenite and ferrite phases at stagnation region in the turning of duplex stainless steel alloys

This paper investigates the deformation mechanisms and plastic behavior of austenite and ferrite phases in duplex stainless steel alloys 2205 and 2507 under chip formation from a machine turning operation. SEM images and EBSD phase mapping of frozen chip root samples detected a build-up of ferrite bands in the stagnation region, and between 65 and 85 pct, more ferrite was identified in the stagnation region compared to austenite. SEM images detected micro-cracks developing in the ferrite phase, indicating ferritic build-up in the stagnation region as a potential triggering mechanism to the formation of built-up edge, as transgranular micro-cracks found in the stagnation region are similar to micro-cracks initiating built-up edge formation. Higher plasticity of austenite due to softening under high strain is seen responsible for the ferrite build-up. Flow lines indicate that austenite is plastically deforming at a greater rate into the chip, while ferrite shows to partition most of the strain during deformation. The loss of annealing twins and activation of multiple slip planes triggered at high strain may explain the highly plastic behavior shown by austenite.

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.

Microstructure and mechanical properties of thermomechanically processed TRansformation Induced Plasticity (TRIP) steels

One of the main aims of steel research for the automotive industry is to develop materials with the optimum combination of relevant properties, cost and productivity. The introduction of new TRansformation Induced Plasticity steels has been driven by the requirements to increase the ductility without compromising the strength. The main phenomenon responsible for the unique mechanical properties in these steels has been proposed to be the formation of multiphase structure, which can contribute to an increase in elongation during straining. The thesis studied the effect of the different alloying additions on the structure-property relationship in the TRIP steels.

Formability and forming of advanced steels

The thesis identified how advanced high strength steels perform compared to conventional steels in terms of weight reduction and crash performance for automotive bodies. The novel production method of low pressure tube hydroforming was applied to form these advanced steels to reduce the press tonnage and fluid pressure compared to the conventional high pressure process. In addition analytical models were developed to predict the force and pressure in the low pressure process.

Built-up edge mechanisms in the machining of duplex stainless steels

 The thesis work was aimed at resolving long established issues with difficult-to-machine materials. The main thesis contribution, is the academic community now has a better understanding of how the issue of built-up edge is occurring when machining duplex stainless steel alloys, which will aid in the machining sector.

Method for determining reaction rate of mild steel containers during melting of magnesium-aluminium alloys and effect of aluminium content on directionally solidified microstructures

A magnesium alloy of eutectic composition (33 wt-'%Al) was directionally solidified in mild steel tubes at two growth rates, 32 and 580 mum s(-1,) in a temperature gradient between 10 and 20 K mm(-1). After directional solidification, the composition of each specimen varied dramatically, from 32'%Al in the region that had remained solid to 18%Al (32 mum s(-1) specimen) and 13%Al (580 mum s(-1) specimen) at the plane that had been quenched from the eutectic temperature. As the aluminium content decreased, the microstructure contained an increasing volume fraction of primary magnesium dendrites and the eutectic morphology gradually changed from lamellar to partially divorced. The reduction in aluminium content was caused by the growth of an Al-Fe phase ahead of the Mg-Al growth front. Most of the growth of the Al-Fe phase occurred during the remelting period before directional solidification. The thickness of the Al-Fe phase increased with increased temperature and time of contact with the molten Mg-Al alloy. (C) 2003 Maney Publishing.

Development of the sheared edge in the trimming of steel and light metal sheet, part 1 - experimental observations

Trimming experiments were conducted on sheet metals including two drawing steels, an aluminum alloy and a magnesium alloy, using a specially designed die in a mechanical press. The punch-die clearance was varied and data obtained on the rollover and burr height as a function of the clearance. Samples were also partially trimmed to examine crack initiation, the generation of the fracture surface profile and mechanism of burr formation. The results showed that while the burr height and rollover depth generally increased with increasing clearance for all examined materials, there were differences in the fracture surface profile shape, the burr shape, and the mechanism of burr formation, between the two steels and the two light alloys. The major cause of these differences appeared to be the rate of crack propagation through the sheet material.

Effect of alloying additions on the SFE, Neél temperature and shape memory effect in Fe–Mn–Si-based alloys

A range of Fe–Mn–Si-based shape memory alloys has been investigated to examine the interplay of composition, stacking fault probability (SFP) and Neél temperature on the shape memory effect (SME). It has been found that the SFP (inversely proportional to stacking fault energy) showed little correlation to the SME for the range of alloy compositions examined. Further, the Neél temperature was not found to exhibit a significant effect on the SME. The addition of interstitial elements, however, was found to markedly decrease the SME.

Twinning and the ductility of magnesium alloys Part I: “Tension” twins

Magnesium and its alloys do not in general undergo the same extended range of plasticity as their competitor structural metals. The present work is part I of a study that examines some of the roles deformation twinning might play in the phenomenon. A series of tensile test results are reported for the common wrought alloy AZ31. These data are employed in conjunction with a simple constitutive model to argue that View the MathML source twinning (which gives extension along the c-axis) can increase the uniform elongation in tensile tests. This effect appears to be similar to that seen in Ti, Zr and Cu–Si and in the so called TWIP phenomenon in steel.