Evaluation of galling resistance for some selected combinations of tool steels/stainless steel sheet materials/lubricants using pin-on-disc testing

Stainless steels are well known to be prone to cold welding and material transfer in sliding contacts and therefore difficult to cold form unless certain precautions as discussed in this paper are taken. In the present study different combinations of tool steels/stainless steels/lubricants has been evaluated with respect to their galling resistance using pin-on-disc testing. The results show that a high galling resistance is favored by a high stainless steel sheet hardness and a blasted stainless steel sheet surface topography. The effect of type of lubricant was found to be more complex. For example, the chlorinated lubricants failed to prevent metal-to-metal contact on a brushed sheet surface but succeeded on a blasted sheet surface of the same stainless steel material. This is believed to be due to a protective tribofilm which is able to form on the blasted surface, but not on the brushed surface.

Energy Efficient Buildings with Functional Steel Cladding

The aim of the study is to develop a model for the energy balance of buildings that includes the effect from the radiation properties of interior and exterior surfaces of the building envelope. As a first step we have used ice arenas as case study objects to investigate the importance of interior low emissivity surfaces. Measurements have been done in two ice arenas in the north part of Sweden, one with lower and one with higher ceiling emissivity. The results show that the low emissivity ceiling gives a much lower radiation temperature interacting with the ice under similar conditions. The dynamic modelling of the roof in ice arenas shows a similar dependence of the roof-to-ice heat flux and the ceiling emissivity.A second part of the study focus on how to realise paints with very low thermal emissivity to be used on interior building surfaces.

Tribological Testing of Some Potential PVD and CVD Coatings for Steel Wire Drawing Dies

Cemented carbide is today the most frequently used drawing die material in steel wire drawing applications. This is mainly due to the possibility to obtain a broad combination of hardness and toughness thus meeting the requirements concerning strength, crack resistance and wear resistance set by the wire drawing process. However, the increasing cost of cemented carbide in combination with the possibility to increase the wear resistance of steel through the deposition of wear resistant CVD and PVD coatings have enhanced the interest to replace cemented carbide drawing dies with CVD and PVD coated steel wire drawing dies. In the present study, the possibility to replace cemented carbide wire drawing dies with CVD and PVD coated steel drawing dies have been investigated by tribological characterisation, i.e. pin-on-disc and scratch testing, in combination with post-test observations of the tribo surfaces using scanning electron microscopy, energy dispersive X-ray spectroscopy and 3D surface profilometry. Based on the results obtained, CVD and PVD coatings aimed to provide improved tribological performance of steel wire drawing dies should display a smooth surface topography, a high wear resistance, a high fracture toughness (i.e. a high cracking and chipping resistance) and intrinsic low friction properties in contact with the wire material. Also, the steel substrate used must display a sufficient load carrying capacity and resistance to thermal softening. Of the CVD and PVD coatings evaluated in the tribological tests, a CVD TiC and a PVD CrC/C coating displayed the most promising results.

An investigation of worn work roll materials used in the finishing stands of the hot strip mill for steel rolling

The surface failure characteristics of different work roll materials, i.e. High Speed Steel, High Chromium Iron and Indefinite Chill Iron, used in the finishing stands of a hot strip mill have been investigated using stereo microscopy, 3D optical profilometry, scanning electron microscopy and energy dispersive X-ray spectroscopy. The results show that the surface failure mechanisms of work rolls for hot rolling are very complex, involving plastic deformation, abrasive wear, adhesive wear, mechanical and thermal induced cracking, material transfer and oxidation. Despite the differences in chemical composition and microstructure, the tribological response of the different work roll materials was found to be strongly dependent on the material microstructure and especially the presence and distribution of microstructural constituents, such as the different carbide phases and graphite (in the case of Indefinite Chill Iron). Cracking and chipping of the work roll surfaces, both having a negative impact on work roll wear, are strongly influenced by the presence of carbides, carbide networks and graphite in the work roll surface. Consequently, the amount of carbide forming elements as well as the manufacturing process must be controlled in order to obtain an optimised microstructure and a predictable wear rate.

A study of slag corrosion of oxides and oxide-carbon refractories during steel refining

The use of ceramic material as refractories in the manufacturing industry is a common practice worldwide. During usage, for example in the production of steel, these materials do experience severe working conditions including high temperatures, low pressures and corrosive environments. This results in lowered service lives and high consumptions of these materials. This, in turn, affects the productivity of the whole steel plant and thereby the cost. In order to investigate how the service life can be improved, studies have been carried out for refractories used in the inner lining of the steel ladles. More specifically, from the slag zone, where the corrosion is most severe. By combining thermodynamic simulations, plant trails and post-mortem studies of the refractories after service, vital information about the behaviour of the slagline refractories during steel refining and the causes of the accelerated wear in this ladle area has been achieved. The results from these studies show that the wear of the slagline refractories of the ladle is initiated at the preheating station, through reduction-oxidation reactions. The degree of the decarburization process is mostly dependent on the preheating fuel or the environment. For refractories without antioxidants, refractory decarburization is slower when coal gas is used in ladle preheating than when a mixture of oil and air is used. In addition, ladle preheating of the refractories without antioxidants leads to direct wear of the slagline refractories. This is due to the total loss of the matrix strength, which results in a sand-like product. Thermal chemical changes that take place in the slagline refractories are due to the MgO-C reaction as well as the formation of liquid phases from impurity oxides. In addition, the decrease in the system pressure during steel refining makes the MgO-C reaction take place at the steel refining temperatures. This reduces the refractory’s resistance to corrosion. This is a serious problem for both the magnesia-carbon and dolomite-carbon refractories. The studies of the reactions between the slagline refractories and the different slag compositions showed that slags rich in iron oxide lead mostly to the oxidation of carbon/graphite in the carbon-containing refractories. This leads to an increased porosity and wettability and therefore an enhanced penetration of slag into the refractory structure. If the slag contains high contents of alumina and or silica (such as the steel refining slag), reactions between the slag components and the dolomite-carbon refractory are promoted. This leads to the formation of low-temperature melting phases such as calcium-aluminates and silicates. The state of these reaction products during steel refining leads to an accelerated wear of the dolomite-carbon refractory. The main products of the reactions between the magnesia-carbon refractory and the steel refining slag are MgAl2O4 spinels, and calcium-aluminates, and silicates. Due to the good refractory properties of MgAl2O4 spinels, the slag corrosion resistance of the magnesiacarbon refractory is promoted.

Replacing Finned Copper withCorrugated Stainless Steel, forthe Heat Exchangers of a SolarCombisystem Store : Performance and EconomicEvaluation

The importance of investigating cost reduction in materials and components for solar thermal systems is crucial at the present time. This work focuses on the influence of two different heat exchangers on the performance of a solar thermal system. Both heat exchangers studied are immersed helically coiled, one made with corrugated stainless steel tube, and the other made with finned copper tube with smooth inner surface.A test apparatus has been designed and a simple test procedure applied in order to study heat transfer characteristics and pressure drop of both coils. Thereafter, the resulting experimental data was used to perform a parameter identification of the heat exchangers, in order to obtain a TRNSYS model with its corresponding numerical expression. Also a representative small-scale combisystem model was designed in TRNSYS, in order to study the influence of both heat exchangers on the solar fraction of the system, when working at different flow rates.It has been found that the highest solar fraction is given by the corrugated stainless steel coil, when it works at the lowest flow rate (100 l/hr). For any higher flow rate, the studied copper coil presents a higher solar fraction. The advantageous low flow performance of stainless steel heat exchanger turns out to be beneficial for the particular case of solar thermal systems, where it is well known that low flow collector loops lead to enhanced store stratification, and consequently higher solar fractions.Finally, an optimization of the stainless steel heat exchanger length is carried out, according to economic figures. For the given combisystem model and boundary conditions, the optimum length value is found between 10 and 12 m.

Radiation properties of coil-coated steel in building envelope surfaces and the influence on building thermal performance

Recent studies have shown that the optical properties of building exterior surfaces are important in terms of energy use and thermal comfort. While the majority of the studies are related to exterior surfaces, the radiation properties of interior surfaces are less thoroughly investigated. Development in the coil-coating industries has now made it possible to allocate different optical properties for both exterior and interior surfaces of steel-clad buildings. The aim of this thesis is to investigate the influence of surface radiation properties with the focus on the thermal emittance of the interior surfaces, the modeling approaches and their consequences in the context of the building energy performance and indoor thermal environment. The study consists of both numerical and experimental investigations. The experimental investigations include parallel field measurements on three similar test cabins with different interior and exterior surface radiation properties in Borlänge, Sweden, and two ice rink arenas with normal and low emissive ceiling in Luleå, Sweden. The numerical methods include comparative simulations by the use of dynamic heat flux models, Building Energy Simulation (BES), Computational Fluid Dynamics (CFD) and a coupled model for BES and CFD. Several parametric studies and thermal performance analyses were carried out in combination with the different numerical methods. The parallel field measurements on the test cabins include the air, surface and radiation temperatures and energy use during passive and active (heating and cooling) measurements. Both measurement and comparative simulation results indicate an improvement in the indoor thermal environment when the interior surfaces have low emittance. In the ice rink arenas, surface and radiation temperature measurements indicate a considerable reduction in the ceiling-to-ice radiation by the use of low emittance surfaces, in agreement with a ceiling-toice radiation model using schematic dynamic heat flux calculations. The measurements in the test cabins indicate that the use of low emittance surfaces can increase the vertical indoor air temperature gradients depending on the time of day and outdoor conditions. This is in agreement with the transient CFD simulations having the boundary condition assigned on the exterior surfaces. The sensitivity analyses have been performed under different outdoor conditions and surface thermal radiation properties. The spatially resolved simulations indicate an increase in the air and surface temperature gradients by the use of low emittance coatings. This can allow for lower air temperature at the occupied zone during the summer. The combined effect of interior and exterior reflective coatings in terms of energy use has been investigated by the use of building energy simulation for different climates and internal heat loads. The results indicate possible energy savings by the smart choice of optical properties on interior and exterior surfaces of the building. Overall, it is concluded that the interior reflective coatings can contribute to building energy savings and improvement of the indoor thermal environment. This can be numerically investigated by the choice of appropriate models with respect to the level of detail and computational load. This thesis includes comparative simulations at different levels of detail.

Steel Sheet Applications and Integrated Heat Management

Increasing energy use has caused many environmental problems including global warming. Energy use is growing rapidly in developing countries and surprisingly a remarkable portion of it is associated with consumed energy to keep the temperature comfortable inside the buildings. Therefore, identifying renewable technologies for cooling and heating is essential. This study introduced applications of steel sheets integrated into the buildings to save energy based on existing technologies. In addition, the proposed application was found to have a considerable chance of market success. Also, satisfying energy needs for space heating and cooling in a single room by using one of the selected applications in different Köppen climate classes was investigated to estimate which climates have a proper potential for benefiting from the application. This study included three independent parts and the results related to each part have been used in the next part. The first part recognizes six different technologies through literature review including Cool Roof, Solar Chimney, Steel Cladding of Building, Night Radiative Cooling, Elastomer Metal Absorber, and Solar Distillation. The second part evaluated the application of different technologies by gathering the experts’ ideas via performing a Delphi method. The results showed that the Solar Chimney has a proper chance for the market. The third part simulated both a solar chimney and a solar chimney with evaporation which were connected to a single well insulated room with a considerable thermal mass. The combination was simulated as a system to estimate the possibility of satisfying cooling needs and heating needs in different climate classes. A Trombe-wall was selected as a sample design for the Solar Chimney and was simulated in different climates. The results implied that the solar chimney had the capability of reducing the cooling needs more than 25% in all of the studied locations and 100% in some locations with dry or temperate climate such as Mashhad, Madrid, and Istanbul. It was also observed that the heating needs were satisfied more than 50% in all of the studied locations, even for the continental climate such as Stockholm and 100% in most locations with a dry climate. Therefore, the Solar Chimney reduces energy use, saves environment resources, and it is a cost effective application. Furthermore, it saves the equipment costs in many locations. All the results mentioned above make the solar chimney a very practical and attractive tool for a wide range of climates.

Ultrafine grained ferrite formed by interrupted hot torsion deformation of plain carbon steel

A plain carbon steel was deformed using a hot torsion deformation simulator. A schedule known to produce strain-induced ferrite was used with the strain interrupted for increasing intervals of time to determine the effect of an isothermal hold on the final microstructure. Microscopy and electron back-scattered diffraction (EBSD) were used to analyse the changes that occurred in the partially transformed microstructure during the hold and the subsequent applied strain. The strain-induced ferrite coarsened during the hold and this coarsened ferrite was refined during the second deformation. These results were compared to those obtained for a different plain carbon steel deformed in single pass rolling close to the Ar3 temperature.

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.

Grain size effect on behaviour and microstructure of a warm deformed Ti-IF steel

The effect of grain size on the deformation behaviour in the fenite region of a Titanium stabilized Interstitial Free steel was investigated by hot torsion. The initial work hardening regime is followed by a softening regime where a broad peak stress develops. The peak stress and the stress at final strain were relatively insensitive to grain size. However, at low values of the Zener-Hollomon parameter, the strain to the peak stress was strongly dependent on the grain size. A series of microstructural parameters were examined to explain these observations.

Effect of deformation schedule on the microstructure and mechanical properties of a thermomechanically processed C-Mn-Si transformation-induced plasticity steel

Thermomechanical processing simulations were performed using a hot-torsion machine, in order to develop a comprehensive understanding of the effect of severe deformation in the recrystallized and nonrecrystallized austenite regions on the microstructural evolution and mechanical properties of the 0.2 wt pct C-1.55 wt pct Mn-1.5 wt pct Si transformation-induced plasticity (TRIP) steel. The deformation schedule affected all constituents (polygonal ferrite, bainite in different morphologies, retained austenite, and martensite) of the multiphased TRIP steel microstructure. The complex relationships between the volume fraction of the retained austenite, the morphology and distribution of all phases present in the microstructure, and the mechanical properties of TRIP steel were revealed. The bainite morphology had a more pronounced effect on the mechanical behavior than the refinement of the microstructure. The improvement of the mechanical properties of TRIP steel was achieved by variation of the volume fraction of the retained austenite rather than the overall refinement of the microstructure.

Fragmentation of orientation within grains of a cold-rolled interstitial-free steel

The formation of a favourable recrystallization texture in interstitial-free (IF) steels depends on the availability and activation of particular nucleation sites in the deformed microstructure. This paper presents a description of the deformed microstructure of a commercially cold-rolled IF steel, with particular emphasis on the microstructural inhomogeneities and short-range orientational variation that provide suitable nucleation sites during recrystallization. RD-fibre regions deform relatively homogeneously and exhibit little short-range orientational variation. ND-fibre regions are heavily banded and exhibit considerable short-range orientational variation associated with the bands. While the overall orientational spread of ND-fibre grains frequently is about the ND-axis, the short-range orientational variation often involves rotation about axes in the TD-ND plane that are nearer to the TD than the ND.

Frictional behaviour and wear performance of a nitrocarburised coating sliding against AISI 1019 steel

This work employed a commercial nitrocaburising process to diffuse a coating onto M2 grade high speed tool steel. Properties of the nitrocaburised coating (CN) such as thickness, roughness and hardness were characterised using a variety of techniques including Glow-Discharge Optical Emission Spectrometry (GD-OES) and Scanning Electron Microscopy (SEM). A tribological test has been developed in which two nominally identical crossed cylinders slide over each other under selected test conditions. The test has been employed to investigate the wear performance of both CN coated and uncoated M2 specimens and frictional behaviour of the sliding interface between the tool and a AISI 1019 steel workpiece under unlubricated (dry) and lubricated conditions. Fourier Transform Infrared Spectroscopy (FTIR) was used to monitor the formation of chemical species from the oxidation of lubricant during tribological testing.