Magnetic superelasticity and inverse magnetocaloric effect in Ni-Mn-In

Applying a magnetic field to a ferromagnetic Ni50Mn34In16 alloy in the martensitic state induces a structural phase transition to the austenitic state. This is accompanied by a strain which recovers on removing the magnetic field, giving the system a magnetically superelastic character. A further property of this alloy is that it also shows the inverse magnetocaloric effect. The magnetic superelasticity and the inverse magnetocaloric effect in Ni-Mn-In and their association with the first-order structural transition are studied by magnetization, strain, and neutron-diffraction studies under magnetic field.

Zur Verbesserung des Ermüdungsverhaltens des austenitischen Stahls X5CrNi18-10 im Temperaturbereich 25-600°C durch mechanische Randschichtverfestigungsverfahren

Die technischen Oberflächen werden oft als Bauteilversagungsorte definiert. Deswegen ist eine optimale Ausnutzung der Werkstoffeigenschaften ohne mechanische Oberflächenbehandlungsverfahren nicht mehr wegzudenken. Mechanische Randschichtoptimierungsverfahren sind vergleichsweise einfach, Kosten sparend und hocheffektiv. Gerade das Festwalzen wird wegen seiner günstigen Auswirkungen wie die exzellente Oberflächengüte, die hohen Druckeigenspannungen sowie die hohe Oberflächenverfestigung zunehmend an Bedeutung gewinnen. Außerdem wird durch das Festwalzen in einigen Legierungen eine nanokristalline Oberflächenschicht gebildet. Diese brillanten Eigenschaften führen nach einer mechanischen Oberflächenbehandlung zur Erhöhung des Werkstoffwiderstandes unter anderem gegen Verschleiß, Spannungsrisskorrosion und insbesondere zur Steigerung der Schwingfestigkeit. Ein etabliertes Beispiel zur Steigerung der Schwingfestigkeit ist das Festwalzen von Achsen und Kurbelwellen. Auch solche komplexen Komponenten wie Turbinenschaufeln werden zur Schwingfestigkeitssteigerung laserschockverfestigt oder festgewalzt. Die Laserschockverfestigung ist ein relativ neues Verfahren auf dem Gebiet der mechanischen Oberflächenbehandlungen, das z.B. bereits in der Flugturbinenindustrie Anwendung fand und zur Schwingfestigkeitsverbesserung beiträgt. Das Verfahrensprinzip besteht darin, dass ein kurzer Laserimpuls auf die zu verfestigende, mit einer Opferschicht versehene Materialoberfläche fokussiert wird. Das Auftreffen des Laserimpulses auf der verwendeten Opferschicht erzeugt ein expandierendes Plasma, welches eine Schockwelle in randnahen Werkstoffbereichen erzeugt, die elastisch-plastische Verformungen bewirkt. Eine konsekutive Wärmebehandlung, Auslagerung nach dem Festwalzen, nutzt den statischen Reckalterungseffekt. Hierdurch werden die Mikrostrukturen stabilisiert. Die Änderung der Mikrostrukturen kann jedoch zu einer beträchtlichen Abnahme der mittels Festwalzen entstandenen Druckeigenspannungen und der Kaltverfestigungsrate führen. Das Festwalzen bei erhöhter Temperatur bietet eine weitere Möglichkeit die Schwingfestigkeit von metallischen Werkstoffen zu verbessern. Die Mikrostruktur wird durch den Effekt der dynamischen Reckalterung stabilisiert. Die Effekte beim Festwalzen bei erhöhten Temperaturen sind ähnlich dem Warmstrahlen. Das Festwalzen erzeugt Oberflächenschichten mit sehr stabilen Kaltverfestigungen und Druckeigenspannungen. Diese Strukturen haben viele Vorteile im Vergleich zu den durch rein mechanische Verfahren erzeugten Strukturen in Bezug auf die Schwingfestigkeit und die Stabilität der Eigenspannungen. Die Aufgabe der vorliegenden Dissertation war es, Verfahren zur Verbesserung der Schwingfestigkeit im Temperaturbereich zwischen Raumtemperatur und 600 °C zu erforschen. Begleitende mikrostrukturelle sowie röntgenographische Untersuchungen sollen zum Verständnis der Ursachen der Verbesserung beitragen. Für diese Arbeit wurde der in der Praxis häufig verwendete Modellwerkstoff X5CrNi18-10 ausgewählt. Als Randschichtverfestigungsverfahren wurden das Festwalzen, eine Kombination der mechanischen und thermischen, thermomechanischen Verfahren auf der Basis des Festwalzens und eine Laserschockverfestigung verwendet.

The influence of albumin on the anodic dissolution of chromium present in UNSS31254 stainless steel in chloride environment

The influence of bovine serum albumin (BSA) on the anodic dissolution of chromium present in UNS S31254 stainless steel (SS) in 0.15 mol L-1 NaCl at 37.0 +/- 0.5 degrees C has been studied, using anodic potentiostatic polarization curves and optical emission spectroscopy. Electrochemical results have shown that BSA has little effect on the transpassivation potential (E-T) and on the passivation current density values. However on the passivation range, BSA diminishes the intensity of the anodic wave seen at about E=750mV versus SCE attributed to Cr(III)/Cr(VI) oxidation. Optical emission spectroscopy results have shown that BSA prevents the anodic dissolution of chromium to occur and minimizes iron dissolution above the transpassivation potential (E=1160 mV versus SCE). (C) 2007 Elsevier B.V. All rights reserved.

Evolution of artificial defects during shape rolling

Very often defects are present in rolled products. For wire rods, defects are very deleterious since the wire rods are generally used directly in various applications. For this reason, the market nowadays requires wire rods to be completely defect-free. Any wire with defects must be rejected as scrap which is very costly for the production mill. Thus, it is very important to study the formation and evolution of defects during wire rod rolling in order to better understand and minimize the problem, at the same time improving quality of the wire rods and reducing production costs. The present work is focused on the evolution of artificial defects during rolling. Longitudinal surface defects are studied during shape rolling of an AISI M2 high speed steel and a longitudinal central inner defect is studied in an AISI 304L austenitic stainless steel during ultra-high-speed wire rod rolling. Experimental studies are carried out by rolling short rods prepared with arteficial defects. The evolution of the defects is characterised and compared to numerical analyses. The comparison shows that surface defects generally reduce quicker in the experiments than predicted by the simulations whereas a good agreement is generally obtained for the central defect.

Experimental and computational investigation of the roll forming process

One of the first questions to consider when designing a new roll forming line is the number of forming steps required to produce a profile. The number depends on material properties, the cross-section geometry and tolerance requirements, but the tool designer also wants to minimize the number of forming steps in order to reduce the investment costs for the customer. There are several computer aided engineering systems on the market that can assist the tool designing process. These include more or less simple formulas to predict deformation during forming as well as the number of forming steps. In recent years it has also become possible to use finite element analysis for the design of roll forming processes. The objective of the work presented in this thesis was to answer the following question: How should the roll forming process be designed for complex geometries and/or high strength steels? The work approach included both literature studies as well as experimental and modelling work. The experimental part gave direct insight into the process and was also used to develop and validate models of the process. Starting with simple geometries and standard steels the work progressed to more complex profiles of variable depth and width, made of high strength steels. The results obtained are published in seven papers appended to this thesis. In the first study (see paper 1) a finite element model for investigating the roll forming of a U-profile was built. It was used to investigate the effect on longitudinal peak membrane strain and deformation length when yield strength increases, see paper 2 and 3. The simulations showed that the peak strain decreases whereas the deformation length increases when the yield strength increases. The studies described in paper 4 and 5 measured roll load, roll torque, springback and strain history during the U-profile forming process. The measurement results were used to validate the finite element model in paper 1. The results presented in paper 6 shows that the formability of stainless steel (e.g. AISI 301), that in the cold rolled condition has a large martensite fraction, can be substantially increased by heating the bending zone. The heated area will then become austenitic and ductile before the roll forming. Thanks to the phenomenon of strain induced martensite formation, the steel will regain the martensite content and its strength during the subsequent plastic straining. Finally, a new tooling concept for profiles with variable cross-sections is presented in paper 7. The overall conclusions of the present work are that today, it is possible to successfully develop profiles of complex geometries (3D roll forming) in high strength steels and that finite element simulation can be a useful tool in the design of the roll forming process.

Prediction of stress-strain behaviors in steels using an integrated constitutive, FEM and ANN model

Austenitic steels with a carbon content of 0.0037 to 0.79 wt% C are torsion tested and modeled using a physically based constitutive model and an Integrated Phenomenological and Artificial neural Network (IPANN) model. The prediction of both the constitutive and IPANN models on steel 0.017 wt% C is then evaluated using a finite element (FEM) code ABAQUS with different reduction in the thickness after rolling through one roll stand. It is found that during the rolling process, the prediction accuracy of the reaction force from FEM simulation for both constitutive and IPANN models depends on the strain achieved (average reduction in thickness). By integrating FEM into IPANN model and introducing the product of strain and stress as an input of the ANN model, the accuracy of this integrated FEM and IPANN model is higher than either the constitutive or IPANN model.

Ammonia dissociation in the fluidised bed furnace

Ammonia dissociation is the controlling reaction for several important thermochemical heat treatment processes; nitriding, nitrocarburising (ferritic and austenitic) and carbonitriding. The fluidised bed furnace is a convenient and widely used medium for all of these treatments, yet understanding of the reaction in a fluidised bed context is minimal. This paper deals with the influence of process parameters on nitrogen activity aN; temperature, fluidising flowrate, ammonia inlet level, carbonaceous gas. Two basic behaviours were observed; inlet NH3-dependant and inlet NHr insensitive, with a transition region at intermediate temperatures. The nitrocarburising response of steel specimens was measured by optical microscopy of the layer thicknesses and glow discharge optical emission spectroscopy (GD-OES) determination of nitrogen depth-penetration profiles. aN was found by gas analysis of the exit stream ammonia with the aid of a dissociation burette.

Mapping the hot deformation microstructure of Ni-30Fe alloy

The evolution of structure during the hot working of an austenitic Ni-30%Fe alloy is studied using EBSD analysis of samples tested in torsion. A microstructural map in temperature-strain space that plots grain size, cell size, fracture and dynamic recrystallization is presented.

Nucleation sites for ultrafine ferrite produced by deformation of austenite during single-pass strip rolling

An austenitic Ni-30 wt pct Fe alloy, with a stacking-fault energy and deformation characteristics similar to those of austenitic low-carbon steel at elevated temperatures, has been used to examine the defect substructure within austenite deformed by single-pass strip rolling and to identify those features most likely to provide sites for intragranular nucleation of ultrafine ferrite in steels. Samples of this alloy and a 0.095 wt pct C-1.58Mn-0.22Si-0.27Mo steel have been hot rolled and cooled under similar conditions, and the resulting microstructures were compared using transmission electron microscopy (TEM), electron diffraction, and X-ray diffraction. Following a single rolling pass of ∼40 pct reduction of a 2mm strip at 800 °C, three microstructural zones were identified throughout its thickness. The surface zone (of 0.1 to 0.4 mm in depth) within the steel comprised a uniform microstructure of ultrafine ferrite, while the equivalent zone of a Ni-30Fe alloy contained a network of dislocation cells, with an average diameter of 0.5 to 1.0 µm. The scale and distribution and, thus, nucleation density of the ferrite grains formed in the steel were consistent with the formation of individual ferrite nuclei on cell boundaries within the austenite. In the transition zone, 0.3 to 0.5 mm below the surface of the steel strip, discrete polygonal ferrite grains were observed to form in parallel, and closely spaced “rafts” traversing individual grains of austenite. Based on observations of the equivalent zone of the rolled Ni-30Fe alloy, the ferrite distribution could be correlated with planar defects in the form of intragranular microshear bands formed within the deformed austenite during rolling. Within the central zone of the steel strip, a bainitic microstructure, typical of that observed after conventional hot rolling of this steel, was observed following air cooling. In this region of the rolled Ni-30Fe alloy, a network of microbands was observed, typical of material deformed under plane-strain conditions.

The effect of multiple deformations on the formation of ultrafine grained steels

A C-Mn-Nb-Ti steel was deformed by hot torsion to study ultrafine ferrite formation through dynamic strain-induced transformation (DSIT) in conjunction with air cooling. A systematic study was carried out first to evaluate the effect of deformation temperature and prior austenite grain size on the critical strain for ultrafine ferrite formation (ε C,UFF) through single-pass deformation. Then, multiple deformations in the nonrecrystallization region were used to study the effect of thermomechanical parameters (i.e., strain, deformation temperature, etc.) on ε C,UFF. The multiple deformations in the nonrecrystallization region significantly reduced ε C,UFF, although the total equivalent strain for a given thermomechanical condition was higher than that required in single-pass deformation. The current study on a Ni-30Fe austenitic model alloy revealed that laminar microband structures were the key intragranular defects in the austenite for nucleation of ferrite during the hot torsion test. The microbands were refined and overall misorientation angle distribution increased with a decrease in the deformation temperature for a given thermomechanical processing condition. For nonisothermal multipass deformation, there was some contribution to the formation of high-angle microband boundaries from strains at higher temperature, although the strains were not completely additive.

The formation of ultrafine ferrite through static transformation in low carbon steels

A novel approach was used to produce an ultrafine grain structure in low carbon steels with a wide range of hardenability. This included warm deformation of supercooled austenite followed by reheating in the austenite region and cooling (RHA). The ultrafine ferrite structure was independent of steel composition. However, the mechanism of ferrite refinement hanged with the steel quench hardenability. In a relatively low hardenable steel, the ultrafine structure was produced through dynamic strain-induced transformation, whereas the ferrite refinement was formed by static transformation in steels with high quench hardenability. The use of a model Ni–30Fe austenitic alloy revealed that the deformation temperature has a strong effect on the nature of the intragranular defects. There was a transition temperature below which the cell dislocation structure changed to laminar microbands. It appears that the extreme refinement of ferrite is due to the formation of extensive high angle intragranular defects at these low deformation temperatures that then act as sites for static transformation.

Modeling the flow behavior, recrystallization, and crystallographic texture in hot-deformed Fe-30 Wt Pct Ni Austenite

The present work describes a hybrid modeling approach developed for predicting the flow behavior, recrystallization characteristics, and crystallographic texture evolution in a Fe-30 wt pct Ni austenitic model alloy subjected to hot plane strain compression. A series of compression tests were performed at temperatures between 850 °C and 1050 °C and strain rates between 0.1 and 10 s⁻¹. The evolution of grain structure, crystallographic texture, and dislocation substructure was characterized in detail for a deformation temperature of 950 °C and strain rates of 0.1 and 10 s⁻¹, using electron backscatter diffraction and transmission electron microscopy. The hybrid modeling method utilizes a combination of empirical, physically-based, and neuro-fuzzy models. The flow stress is described as a function of the applied variables of strain rate and temperature using an empirical model. The recrystallization behavior is predicted from the measured microstructural state variables of internal dislocation density, subgrain size, and misorientation between subgrains using a physically-based model. The texture evolution is modeled using artificial neural networks.

The production of ultrafine ferrite during hot torsion testing of a 0.11 Wt Pct C steel

Ultrafine ferrite grain sizes were produced in a 0.11C-1.6Mn-0.2Si steel by torsion testing isothermally at 675 °C after air cooling from 1250 °C. The ferrite was observed to form intragranularly beyond a von Mises equivalent tensile strain of approximately 0.7 to 0.8 and the number fraction of intragranular ferrite grains continued to increase as the strain level increased. Ferrite nucleated to form parallel and closely spaced linear arrays or “rafts” of many discrete ultrafine ferrite grains. It is shown that ferrite nucleates during deformation on defects developed within the austenite parallel to the macroscopic shear direction (i.e., dynamic strain-induced transformation). A model austenitic Ni-30Fe alloy was used to study the substructure developed in the austenite under similar test conditions as that used to induce intragranular ferrite in the steel. It is shown that the most prevalent features developed during testing are microbands. It is proposed that high-energy jogged regions surrounding intersecting microbands provide potential sites for ferrite nucleation at lower strains, while at higher strains, the walls of the microbands may also act as nucleation sites.

Conversion of the hot torsion test results into flow curve with multiple regimes of hardening

The method of Fields and Backofen has been commonly used to reduce the data obtained by hot torsion test into flow curves. The method, however, is most suitable for materials with monotonic strain hardening behaviour. Other methods such as Stüwe’s method, tubular specimens, differential testing and the inverse method, each suffer from similar drawbacks. It is shown in the current work that for materials with multiple regimes of hardening any method based on an assumption of constant hardening indices introduces some errors into the flow curve obtained from the hot torsion test. Therefore such methods do not enable accurate prediction of onset of recrystallisation where slow softening occurs. A new method to convert results from the hot torsion test into flow curves by taking into account the variation of constitutive parameters during deformation is presented. The method represents the torque twist data by a parametric linear least square model in which Euler and hyperbolic coefficients are used as the parameters. A closed form relationship obtained from the mathematical representation of the data is employed next for flow stress determination. Two different solution strategies, the method of normal equations and singular value decomposition, were used for parametric modelling of the data with hyperbolic basis functions. The performance of both methods is compared. Experimental data obtained by FHTTM, a flexible hot torsion test machine developed at IROST, for a C–Mn austenitic steel was used to demonstrate the method. The results were compared with those obtained using constant strain and strain rate hardening characteristics.

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.