The plasma nutriding of tool and bearing steels

There is some evidence to suggest that nitriding of alloy steels, in particular high speed tool steels, under carefully controlled conditions might sharply increase rolling contact fatigue resistance. However, the subsurface shear stresses developed in aerospace bearing applications tend to occur at depths greater than the usual case depths currently produced by nitriding. Additionally, case development must be limited with certain materials due to case spalling and may not always be sufficient to achieve the current theoretical depths necessary to ensure that peak stresses occur within the case. It was the aim of' this work to establish suitable to overcome this problem by plasma nitriding. To assist this development a study has been made of prior hardening treatment, case development, residual stress and case cracking tendency. M2 in the underhardened, undertempered and fully hardened and tempered conditions all responded similarly to plasma nitriding - maximum surface hardening being achieved by plasma nitriding at 450°C. Case development varied linearly with increasing treatment temperature and also with the square root of the treatment time. Maximum surface hardness of M5O and Tl steels was achieved by plasma nitriding in 15% nitrogen/85% hydrogen and varied logarithmically with atmosphere nitrogen content. The case-cracking contact stress varied linearly with nitriding temperature for M2. Tl and M5O supported higher stresses after nitriding in low nitrogen plasma atmospheres. Unidirectional bending fatigue of M2 has been improved up to three times the strength of the fully hardened and tempered condition by plasma nitriding for 16hrs at 400°C. Fatigue strengths of Tl and M5O have been improved by up to 30% by plasma nitriding for 16hrs at 450°C in a 75% hydrogen/25% nitrogen atmosphere.

The influence of non-metallic inclusions upon the properties of linepipe steels

The principal aim of this work was to determine the role of non-metallic inclusions in the process of hydrogen stepwise cracking (SWC). Additionally, the influence of inclusions upon the notch ductility of hydrogen charged (HC) and uncharged (UN) tensile specimens was examined. To obtain a basis for experiment a series of low carbon-manganese steels were prepared by induction melting. In order to produce variations in the composition, morphology, volume fraction, size and distribution of the inclusions the steel chemistry was adjusted prior to casting by additions of deoxidiser and Ca-Si injection. Sections of each ingot were hot rolled. Metallography, image analysis, mechanical tests and hydrogen SWC tests were then carried out. The volume fraction, morphology, and shape of inclusions influenced the tensile ductility of the steels. Marked anisotropy was found in the steels containing type II MnS inclusions at all rolling temperatures, whereas the fully Ca treated steel was isotropic. It was found that several inclusion parameters (projected length PL, mean free distance MFD, nearest-neighbour distance NND) correlated with fracture strain. An increase in inclusion volume fraction and/or the dimension of inclusions on a plane parallel to the plane of fracture led to a decrease in fracture strain. The inclusion parameters did not correlate with the fracture strains for the HC tensile specimens. However, large or clusters of inclusions acted as the principal sites for crack initiation. `Fisheyes' or areas of `flat' fracture were often found on these fracture surfaces. The criteria for SWC initiation was found to be either large inclusions or clusters of inclusions. As the PL of inclusions increased the probability of large SWCs occurring increased. SWC initiation at inclusions was believed to occur at a critical concentration of hydrogen. Factors which assisted the concentration of hydrogen at inclusions were discussed. None of the proposed mechanisms of hydrogen embrittlement could be identified as the single cause of SWC.

Creep crack growth in cast steam turbine casing steels

The creep rupture properties of cast ½Cr½Mo¼V and 1Cr1Mo¼V alloy steel used in the manufacture of power station steam generating plant. have been investigated. The effects of constraint and geometry on the creep rupture properties are also considered. The validity of various criteria controlling macroscopic creep crack growth in cast CrMoV alloys has been examined. It is found that neither the stress intensity factor nor reference stress correlate satisfactorily the creep crack growth rates at the test temperature of 550°C. Certain minimum displacements must be achieved for crack initiation and propagation. It is found that this displacement as measured by crack opening displacement or crack aspect ratio, is the same in both compact tension and centre-cracked panel geometries, is invariant with crack length and decreases with increasing constraint. The effect of constraint on creep crack growth rate in the two geometries is less conclusive. A new model describing creep crack growth in cast CrMoV alloy steels has been developed. The model is based on the results from a numerical finite element creep analysis of the relaxation and redistribution of stress ahead of an incubating creep crack . It is found that macroscopic creep crack growth in a material undergoing either plane stress or plane strain deformation can be described by a fracture stress which is based on the Von Mises equivalent stress. It has been shown that this model is capable of rationalising all of the experimental crack velocity data from the cast CrMoV alloys. The resultant degree of data correlation is far superior to that obtained when using the stress intensity factor or reference stress. A cumulative damage creep fracture model based upon the results from the numerical analysis has been developed. It is found that the model is capable of predicting the behaviour of propagating creep cracks in cast CrMoV alloys from smooth bar creep rupture data.

The fracture toughness of a range of cast steels

A range of plain carbon, carbon-manganese and low alloy cast steels were tested in order to determine their various fracture toughness values under elastic and elastic-plastic conditions. The main fracture toughness parameters which are considered are (1) Linear Elastic Fracture Mechanics (LEFM), (2) the J-Contour Integral, and (3) Crack Opening Displacement (COD). Results are obtained from fracture toughness specimens of various dimensions and the relevance of the validity criteria to cast steels is considered in some detail. In addition, the effect of casting position on specimen toughness values was noted. Valid KIC results according to LEFM, were obtained for three of the eight cast steels tested. Although KIC values from LEFM were not obtained from the remaining five steels, critical COD and J-integral values were determined. It is postulated that these values and particularly the critical J values can be used, with confidence for material selection or in defect tolerance calculations using these steels. Toughness values were found to vary with casting position in several of the steels tested and the possible reasons for such variations are discussed in the Thesis.