Integrated fluid-thermal-structural numerical analysis for the quenching of metallic components

The quenching of a metal component with a channel section in a water tank is numerically simulated. Computational fluid dynamics (CFD) is used to model the multiphase flow and the heat transfer in film boiling, nucleate boiling and convective cooling processes to calculate the difference in heat transfer rate around the component and then combining with the thermal simulation and structure analysis of the component to study the effect of heat transfer rate on the distortion of the U-channel component. A model is also established to calculate the residual stress produced by quenching. The coupling fluid-thermal-structural simulation provides an insight into the deformation of the component and can be used to perform parameter analysis to reduce the distortion of the component. © 2011 Shanghai Jiaotong University and Springer-Verlag Berlin Heidelberg.

Morphology evolution during annealing and electrical conductivity of titania nanotube films

Titania nanotube films were produced by anodization of titanium foil. The titania nanotube films were annealed at different temperatures. Morphology evolution, phase transformation and electrical conductivity of the titania nanotubes were studied. Results showed that the nanotube walls became rough, porous and even collapsed after annealed at 400, 500 and 600°C respectively. Titania anatase phase formed after annealed at 400°C; the amount of anatase phase increased as the annealing temperature increased. The conductivity of the nanotube film annealed at 400°C was improved greatly compared with the conductivity of the as-anodized nanotube film. However, the conductivity of the nanotube films annealed at higher temperatures decreased. The effect of the morphology on the electronic conductivity of the titania nanotube films was discussed.

Thermodynamic and kinetic modelling hydrogenation of titanium particles and sheets

Use of hydrogen as a temporary alloying element in Ti alloys is an attractive approach to improve the mechanical properties of the materials, enhance processability and thereby reduce manufacturing costs. In this paper, the hydrogen diffusion process and the phase transformation both between Ti particles and in Ti sheets were simulated to analyze the mechanism of hydrogen diffusion in different phases (α-Ti, β-Ti and TiHx). With the simulation based on the kinetics and thermodynamics, quantitative behaviors of the hydrogen diffusion and the phase transformation were analyzed. The simulation results provide an insight into the diffusion process and improve the fundamental understanding of the mechanism of diffusion and phase transformation.

Wear characteristics of ultra-hard cutting tools when machining austempered ductile iron

Nodularised Ductile Cast Iron, when subjected to heat treatment processes - austenitising and austempering produces Austempered Ductile Iron (ADI). The microstructure of ADI also known as "ausferrite" consists of ferrite, austenite and graphite nodules. Machining ADI using conventional techniques is often a problematic issue due to the microstructural phase transformation from austenite to martensite during machining. This paper evaluates the wear characteristics of ultra hard cutting tools when machining ADI and its effect on machinability. Machining trials consist of turning ADI (ASTMGrade3) using two sets of PCBN tools with 90% and 50% CBN content and two sets of ceramics tools; Aluminium Oxide Titanium Carbide and Silicon Carbide - whisker reinforced Ceramic. The cutting parameters chosen are categorized as roughing and finishing conditions; the roughing condition comprises of constant cutting speed (425 m/min) and depth of cut (2mm) combined with variable feed rates of 0.1, 0.2, 0.3 and 0.4mm/rev. The finishing condition comprises of constant cutting speed (700 m/min) and depth of cut (0.5mm) combined with variable feed rates of 0.1, 0.2, 0.3 and 0.4mm/rev. The benchmark condition to evaluate the performance of the cutting tools was tool wear evaluation, surface texture analysis and cutting force analysis. The paper analyses thermal softening of the workpiece by the tool and its effect on the shearing mechanism under rough and finish machining conditions in term of lower cutting forces and enhanced surface texture of the machined part.

Orientation relationship, texture and microstructure in electromagnetic processed materials (EPM)

In this work, some of our recent results in microstructure, texture and orientation relationship resulting from the application of an external high magnetic field during diffusional and non-diffusional phase transformation in both steel and functional metallic materials have been summarized. A 12-T magnetic field was applied to the diffusional decomposition of austenite in 0.81C-Fe alloy and martensitic transformation of a Ni-Mn-Ga magnetic shape memory alloy. For the 0.81C-Fe alloy, it was found that the magnetic field induces the formation of proeutectoid ferrite and slightly enhances the <001> fiber component in ferrite in the transverse field direction. The magnetic dipolar interaction between Fe atoms in the transverse field direction accounts for this phenomenon. The magnetic field favors the formation of pearlite with Pitsch-Petch 2 (P-P 2) and Isaichev (IS) orientation relationships (OR) between the lamellar ferrite and cementite. For the Ni-Mn-Ga magnetic shape memory alloy, the magnetic field makes the martensite lamellas to grow in some specific directions with their c-axes [001] orientated to the field direction and transverse field direction.

On anomalous depth-dependency of the hardness of NiTi shape memory alloys in spherical nanoindentation

An experimental study on the indentation hardness of NiTi shape memory alloys (SMAs) by using a spherical indenter tip and a finite element investigation to understand the experimental results are presented in this paper. It is shown that the spherical indentation hardness of NiTi SMAs increases with the indentation depth. The finding is contrary to the recent study on the hardness of NiTi SMAs using a sharp Berkovich indenter tip, where the interfacial energy plays a dominant role at small indentation depths. Our numerical investigation indicates that the influence of the interfacial energy is not significant on the spherical indentation hardness of SMAs. Furthermore, the depth dependency of SMA hardness under a spherical indenter is explained by the elastic spherical contact theory incorporating the deformation effect of phase transformation of SMAs. Hertz theory for purely elastic contact shows that the spherical hardness increases with the square root of the indentation depth. The phase transformation beneath the spherical tip weakens the depth effect of a purely elastic spherical hardness. This study enriches our knowledge on the basic concept of hardness for SMAs under spherical indentation at micro- and nanoscales.

Back calculation of parent austenite orientation using a clustering approach

A new approach is presented for calculating the parent orientation from sets of variants of orientations produced by phase transformation. The parent austenite orientation is determined using the orientations of bainite variants that transformed from a single parent austenite grain. In this approach, the five known orientation relationships are used to back transform each observed bainite variant to all their potential face-centered-cubic (f.c.c.) parent orientations. A set of potential f.c.c. orientations has one representative from each bainite variant, and each set is assembled on the basis of minimum mutual misorientation. The set of back-transformed orientations with the minimum summation of mutual misorientation angle (SMMA) is selected as the most probable parent (austenite) orientation. The availability of multiple sets permits a confidence index to be calculated from the best and next best fits to a parent orientation. The results show good agreement between the measured parent austenite orientation and the calculated parent orientation having minimum SMMA.

Multiscale microstructure engineering of steels

The development of modern steels is based on the tailoring of the microstructure to achieve the required properties. While historically this was performed at the micrometre scale length, there is now the scope to undertake this at the nanoscale or atom scale. The present paper reviews recent work related to the development of ultrafine and nanoscale microstructures in steel as well as changes at shorter scale lengths, such as cluster formation and solute effects. This includes the development of ultrafine ferrite through phase transformation, nanoscale and ultrafine bainite, precipitation and cluster strengthening and bake hardening of steels. A key element of the present work has been the use of atom probe tomography to unlock the nature of these structures.

A case study on effect of feed rate on machinability of austempered ductile iron

Austempered Ductile Iron (ADI) is a type of nodular, ductile cast iron subjected to heat treatments - austenitising and austempering. Whilst machining is conducted prior to heat treatment and offers no significant difficulty, machining post heat treatment is demanding and often avoided. Phase transformation of retained austenite to martensite leading to poor machinability characteristics is a common problem experienced during machining. This case study explains the effect of feed rate on machinability of ADI using cutting force analysis and tool failure analysis. The experimental design consists of conducting drilling trials on grade 1200 and 1400 at constant depth of cut, 25mm; constant speed, 45m/min; no coolant and variable feed rates from 0.2 to 0.35 mm/rev (increment of 0.025mm/rev). Metallography and X-ray diffraction technique was carried out in order to identify and quantify the microstructural phases before and after drilling. The results from the trial infer that the best way to machine ADI efficiently without tool failure is using low feeds and high speeds and without coolant.

A preliminary study on machinability assessment of nanobainite steel

The demand for high strength materials and improvements in heat treatment techniques has given rise to this new form of high strength steel known as nanobainite steel. The production of nanobainite steel involves slow isothermal holding of austenitic steel around 200oC for 10 days, in order to obtain a carbon enriched austenite and cooling to room temperature using austempering. The microstructure of nanobainite steel is dual phase consisting of alternate layers of bainitic ferrite and austenite. The experimental design consists of face milling under 12 combination of Depth of Cut (DoC)-1, 2 and 3mm; cutting speed-100 and 150m/min; constant feed- 0.15mm/rev and coolant on/off. The machinability of the material is assessed by means of analysis such as metallography and cutting force analysis. The results obtained are used to assess the most favorable condition to machine this new variety of steel. Future work involves study on phase transformation by quantifying the microstructural phase before and after milling using XRD.

Variant selection and intervariant crystallographic planes distribution in martensite in a Ti-6Al-4V alloy

The transformation texture was studied in a Ti-6Al-4V alloy for two microstructures produced through different phase transformation mechanisms (i.e. diffusional vs. displacive). Both microstructures revealed qualitatively similar crystallographic texture characteristics, having two main texture components with Euler angles of (90°, 90°, 0°) and (90°, 30°, 0°). However, the overall α texture strength was considerably weaker in the martensitic structure (i.e. displacive mechanism) compared with the α + β microstructure produced through slow cooling (i.e. diffusional mechanism). The intervariant boundary distribution in martensite mostly revealed five misorientations associated with the Burgers orientation relationship. The five-parameter boundary analysis also showed a very strong interface plane orientation texture, with interfaces terminated mostly on the prismatic planes {hki0}, when misorientation was ignored. The highest intervariant boundary populations belonged to the 63.26°/[10 553 ] and 60°/[112 0] misorientations, with length fractions of 0.38 and 0.3, respectively. The former was terminated on (41 3 0), and the latter was a symmetric tilt boundary, terminated on (1 011). The intervariant plane distribution in martensite was determined more by the constraints of the phase transformation than by the relative interface energies.

Observations on the nonlinear unloading behavior of advanced high strength steels

The unloading behavior was compared for three different steel grades: a dual-phase steel, a transformation-induced plasticity steel, and a twinning-induced plasticity steel. Steels that harden by phase transformation or deformation twinning exhibited a smaller component of microplastic strain during unloading and a smaller reduction in the chord modulus compared to the conventional hardening steel. As a result, unloading is closer to pure elastic unloading when the TRIP effect or TWIP effect is active.

Thermomechanical properties of Ni-Ti shape memory wires containing nanoscale precipitates induced by stress-assisted ageing.

This paper systematically examines the thermomechanical properties and phase transformation behaviour of slightly Ni-rich Ni-Ti biomedical shape memory wires containing homogeneously distributed nanoscale precipitates induced by stress-assisted ageing. In contrast to previous studies, particular attention is paid to the role of precipitates in impeding twin boundary movement (TBM) and its underlying mechanisms. The size and volume fraction of precipitates are altered by changing the ageing time. The martensitic transformation temperatures increase with prolonged ageing time, whereas the R-phase transformation temperature remains relatively unchanged. The stress-strain behaviour in different phase regions during both cooling and heating is comprehensively examined, and the underlying mechanisms for the temperature- and thermal-history-dependent behaviour are elucidated with the help of the established stress-temperature phase diagram. The effect of precipitates on TBM is explored by mechanical testing at 133K. It is revealed that the critical stress for TBM (σcr) increases with increasing ageing time. There is a considerable increase of 104MPa in σcr in the sample aged at 773K for 120min under 70MPa compared with the solution-treated sample, owing to the presence of precipitates. The Orowan strengthening model of twinning dislocations is insufficient to account for this increase in σcr. The back stress generation is the predominant mechanism for the interactions between precipitates and twin boundaries during TBM that give rise to the increase in σcr. Such results provide new insights into the thermomechanical properties of precipitate containing Ni-Ti biomedical shape memory wires, which are instructive for developing high-performance biomedical shape memory alloys.

Heat affected zone microstructures and their influence on toughness in two microalloyed HSLA steels

Microstructures and Charpy impact properties have been examined in two microalloyed steels following heat treatments to simulate weld heat affected zone (HAZ) structures over a range of heat input conditions, characterised by the cooling time from 800 to 500°C (Δt8/5). The base materials were low carbon structural steel plates microalloyed with vanadium and nitrogen (V-N) and niobium (Nb), respectively. The toughnesses of the HAZs displayed remarkably different behaviours as shown by their impact transition temperatures. For the V-N steel, the toughness improved with increasingly rapid cooling (low heat input conditions) whereas the Nb steel showed an opposite trend. Some of this behaviour could be explained by the presence of coarse ferrite grains in the slowly cooled V-N steel. However, other conditions where all the structures were bainitic and rather similar in optical micrographs gave widely different toughness values. The recently developed method of five dimensional boundary analysis based on electron backscattering diffraction has been applied to these cases for the first time. This showed that the lath boundaries in the bainite were predominantly on {1 1 0} planes of the ferrite and that the average spacing of these boundaries varied depending on steel composition and cooling rate. Since {1 1 0} is also the slip plane in ferrite, it is considered that close spacing between the lath boundaries inhibits general plasticity at stress concentrations and favours initiation of fracture. The differences between the two steels are believed to be due to their transformation behaviours on cooling where precipitation of vanadium nitride in austenite accelerates ferrite formation and raises the temperature of the phase transformation in V-N steels.