The Metallurgy and Foundry Engineering (ISSN: 1230-2325, e-ISSN: 2300-8377) journal will disseminate knowledge relating to the metallurgical and foundry engineering in general.
THE INFLUENCE OF STRAIN RATE ON MICROSTRUCTURE AND MECHANICAL BEHAVIOR OF P/M FEAL
As part of a broader study of the thermomechanical processing of P/M FeAl alloys, this research is focused on the influence of processing strain rate on the microstructural evolution and mechanical behavior of the processed materials. For the purposes of this study, water atomized FeAl powder was consolidated by hot pressing resulting in fully dense products. The consolidated P/M samples were thermomechanically processed in compression at 800 and 900oC at strain rates of 0.1 s-1 and 10 s-1, to a true strain of 1. The influence of thermomechanical processing parameters on the material flow and microstructural development of investigated alloy was analyzed. Considerable strain rate sensitivity of investigated alloy was observed, specially with reference to microstructural development.
THE HIGH-TEMPERATURE TRIBOLOGY OF IRON MATRIX HYPOEUTECTIC ALLOY AFTER UNDER-ANNEALING NORMALIZING
This work includes the results of high-temperature tribology test of cast alloy with iron matrix. The paper presents the discussion on the results of the studies of wear mechanisms and friction factor of G200CrNiMo4-3-3 adamite cast steel after three variants of under - annealing normalization. During the heat treatment of cast steel four annealing temperatures were applied: 850, 900, 950 and 1050°C. Annealing was conducted for 10 h, and then the samples were cooled at a rate of 48°C/h to room temperature. Four different annealing temperatures resulted in adequate differences in microstructure of test cast steel what determinated tribological properties of the material. Results obtained allow for determination of optimal, from wear resistance point of view, microstructure of test cast steel used for mill rolls.
THE EFFECT OF NON-METALLIC INCLUSIONS ON THE CRAK PROPAGATION IMPACT ENERGY OF TOUGHENED 35B2+Cr STEEL
35B2+Cr steel was designed as a material for screws. The investigations were carried out on toughened samples, taken from three ingots of 35B2+Cr steel (delivered from three various steel suppliers), and of different content of non-metallic inclusions. In each case, the fraction of non-metallic inclusions was in agreement with the corresponding standard. This study presents the results of the research focused on the influence of non-metallic inclusions on the impact energy of crack development in 35B2+Cr steel. The role of non-metallic inclusions was considered both in relation to their total fraction and in relation to the fraction of oxides, sulfides, nitrides and exogenous inclusions separately. Assuming linear dependence between notch-root radius and the impact energy of crack nucleation, basing on the impact toughness tests, the impact energy of the crack development was evaluated. It was proved, that in spite of the level of fraction of non-metallic inclusions compatible with the corresponding standards, they directly or indirectly influence the impact energy of 35B2+Cr steel. This influence depends on the character of the inclusions.
FORGING PROCESS IN THREE TOOL FOLDING DIE
The aim of the paper was presentation control lubrication influence on forging process and apply possibilities. Numerical modeling of the forging process in three tool folding die has been presented. Five different variants of lubrication method have been analysed in order to define lubrication influence on the filling process of the die impression. The results indicate full usefulness of presented lubrication method in planning forging technologies.
FOAMING OF EAF STAINLESS STEEL SLAGS WITH Cr2O3 USING STEELCALTM
Foaming of EAF stainless steel slags with Cr2O3 using Steelcal has been examined in a 10 kg laboratory furnace at the AGH University of Science & Technology in Kraków, Poland. Steelcal (a modified grade of calcium nitrate) has been injected through a lance into the molten slag in a crucible electric arc furnace with one electrode. 22 tests have been performed changing such parameters as the slag composition, injection gas, pure Steelcal or mixed with C or FeSi. The slag height has been measured. Steel and slag analyses have been carried out. The results of the tests have been evaluated.
MICROSTRUCTURE AND TEXTURE WELDS OF 15-7Mo STEEL AFTER HEAT TREATMENT
This paper presents the results of determining the effect of heat treatment after welding X8CrNiMoAl15-7-2 steel (commercial name: PH 15-7Mo steel) on the microstructure and texture of the welds. XRD studies showed the presence of the two phases in the welds of 15-7Mo steel; i.e., δ ferrite and austenite. Annealing at a temperature of 400°C/1 h and 550°C/1 h results in changes of the intensities for individual peaks derived from austenite and ferrite. Microstructure investigations carried out by LM and TEM indicated that the austenite and δ ferrite coexist in themicrostructure of 15-7Mo steel in as-welded condition. Annealing at a temperature range of between 400–620°C after welding causes small changes in the microstructure. The hardness of the welds after annealing in that temperature range increases.
Copyright (c) 2019 Metallurgy and Foundry Engineering
CHARACTERIZATION OF MICROSTRUCTURE AND MECHANICAL PROPERTIES OF LASER-WELDED STAINLESS STEELS
This work presents the laser welding of dissimilar X12CrCoWVNbN12-2-2 and X10CrNi18-10 steels. This system is of interest, as laser welding offers new flexibility in the joining of metals and laser welds (LWs) and are usually of high quality; they are obtained only after the optimization of process parameters. The aim of the work was to investigate the microstructure, chemical composition, and hardness changes of laser-welded steels. After laser welding, two zones were generated in the processed materials: a fusion zone and a heat-affected zone. Due to solidification, a refinement of the microstructure occurred in the fusion zone. Examinations of the chemical composition of particular melted areas showed the occurrence of Nb-rich precipitations. The laser welding of steels led to increased hardness in the fusion zone (about 240–530 HV0.3).
DETECTION OF NITRATES(V) AND SULFATES(VI) BY UV-VIS SPECTROPHOTOMETRY METHOD IN USED GREEN SAND BONDED BY BENTONITE WITH MODIFIED STARCH ADDITION
The research results (SEM, UV-Vis) that contain a part of the work connected with determining the influence of a modified starch addition on the physical and chemical property changes of green sands (including the emission levels of harmful substances from the used molding sands formed as a result of the liquid metal pouring of molds) are presented in this paper. A surface analysis (SEM) was performed for the fresh molding sands and used molding sands with and without modified starch samples. On the bases of the received microscopic images, the impact of the temperature factor on the morphology of the molding sand samples after the liquid metal pouring process are assessed. In the second part of the performed work on the UV-Vis research, eluates from two used molding sands (green sand [sand number 1] and green sand with the addition of a modified starch [sand number 2]) were tested for nitrate and sulfate content. In order to determine whether the level of nitrate and sulfate elusion from the used molding sands is permissible, the received results were compared with the Minister of Environment’s regulations concerning the requirements of surface waters used for supplying the population with potable water.
CHARACTERISTICS OF Al-Fe SINTERS MADE BY THE POWDER METALLURGY ROUTE
The Al/Fe material was prepared by the powder metallurgy route with an additional intermediate stage which was a centrifuge of powder mixture. The application of the centrifuge stage was applied to obtain circular phase distribution of Al-rich phases in a sintered material. Iron powder with a particle size under 100 μm and aluminum powder with a particle size of about 25 μm, were used as starting materials. To determine the effect of centrifuging time on the distribution of Fe-Al particles, scanning electron microscopy (SEM, EDS) and XRD techniques were used. Microstructure observations show the influence of the centrifuging time on the distribution of Fe particles. It was observed that a longer centrifuging time caused changes in the ratio concentration of elements and allowed the growth of the intermetallic phase at the interface between solid Al and Fe particles.
THE EFFECT OF HEAT TREATMENT ON THE MICROSTRUCTURE AND PROPERTIES OF THE CORROSION RESISTANCE OF THE PROSTHETIC ALLOY WIRONIT EXTRAHART (Co-Cr-Mo)
The presented study performs an analysis of the effect of thermal treatment on the microstructure and corrosion resistance of the commercial prosthetic alloy Wironit ExtraHart (Co-Cr-Mo). Experiments of thermal treatment, homogenization, oversaturation as well as oversaturation with ageing of the alloys were carried out. Metallographic tests, hardness measurements, EDS analyses and electrochemical investigations were performed. For the examined samples, the corrosion potential (OCP) and polarization curve (LSV) were determined, based on which the corrosion properties in the simulated solution of artificial saliva were established. The results of the obtained tests made it possible to evaluate the effect of the performed thermal treatment on the changes in the properties (hardness) as well as the microstructure and corrosion resistance of the examined alloy Co-Cr-Mo.
MAGNETIC PROPERTIES OF Fe NANOWIRES ELECTRODEPOSITED IN SELF-ORDERED ALUMINA MEMBRANE
The iron nanowire arrays (NWs) were fabricated by DC electrodeposition into hexagonally ordered alumina pores. With the use of X-ray diffraction analysis, the structure of iron wires was determined. The iron wires have the Body Centered Cubic structure. The influence of cathodic deposition potential and parameters of membrane on the magnetic properties of nanowire arrays was investigated. Magnetic properties analyzed by VSM measurements suggest that the easy axis of magnetization follows the nanowire axis, with coercivity increasing with a decrease of nanowire diameter and length. The dependence of the height of Fe wires on the electrodeposition potential was determined. The low cathodic potential and smaller pore diameter are the synthesis parameters most beneficial for large coercivity with easy axis along nanowires.
INFLUENCE OF DEFORMATION CONDITIONS ON THE RHEOLOGICAL PROPERTIES OF 6xxx SERIES Al ALLOY
Knowledge of the characteristics describing the technological properties of the material is the basis for correct numerical simulation and the design of new technological processes or the modernization of existing ones. For each technological process of plastic forming, a set of features should be defined that correctly describe the susceptibility of the material to its shaping in a given process. The paper presents the results of rheological tests of 6xxx series Al alloy, obtained for deformation parameters corresponding to the process of the extrusion of large-size profiles. The effect of deformation conditions on changes in yield stress was determined. Next, the true values of the mathematical model coefficients describing the rheological properties of the tested material were determined using the inverse method, which is the basis for conducting numerical tests.
NON-INVASIVE ANALYSIS AND VISUALIZATION OF OBJECTS FROM FSW AlSi9Mg/2017A ALUMINUM ALLOY JOINTS
Friction stir welding (FSW) technology allows for the welding of materials that differ in their chemical compositions, microstructures, and properties. When selecting the parameters, it is necessary to analyze the structure of a weld and eliminate the defects. The use of X-ray microtomography creates the possibility of precise imaging of a joint structure – especially when it contains defects (voids). The tests were carried out on an FSW joint made with both 2017A and AlSi9Mg aluminum alloys. The macrostructure was cross-sectional, and a defect was found in the middle part of the joint and on the advancing side. We used a conventional method of observation light microscopy. Then, an analysis was performed using X-ray microtomography, which revealed the shape of the defect in 3D. Individual cross-sections were extracted, which enabled us to measure the geometric quantities. A dependence was found for the shape of the defect on the welding parameters and the variability of its construction. The usefulness of this advanced material imaging technology for the analysis of FSW welds has been confirmed.
ANALYSIS OF INFLUENCE OF PROCESS PARAMETERS ON TEMPERATURE DISTRIBUTION IN PROFILES EXTRUDED FROM 6xxx-SERIES ALUMINUM ALLOYS
Changing market preferences regarding expectations in terms of the functionality, properties, and appearance of a finished product place excessive demands on manufacturers. The 6xxx-series alloys are the most commonly used in extrusion, and they have broad applications (e.g., the construction, electronics, automotive, and shipbuilding industries). The development of deformation technology at the design stage reaps unquestionable benefits when planning the production process. Under real conditions, the extrusion of hollow profiles requires the use of pocket dies, whose proper design is a complex process. This paper presents the results of preliminary numerical investigations of the extrusion process of structural panels from the 6005A aluminum alloy intended for the construction of transport car bodies. The influence of selected parameters of the extrusion process on the temperature distribution was analyzed in the material. The calculations were made using FEM for a three-dimensional deformation state, taking into account the thermal phenomena occurring during the applied deformation scheme in the extrusion process carried out in a flat die.
RESEARCH ON COPPER RECOVERY FROM SLEDGE FROM SUSPENDED COPPER CONCENTRATE REDUCTION PROCESS
The research on the dispersal of slag from the slurry process was carried out in a laboratory resistance furnace. Before declaring, the slag contained 13.62% copper. In the processes of reduction of slag samples with calcium carbide in the form of carbide with activating additives Na2CO3 and CaF2, the content of copper in the slag was reduced to a level of 0.28–0.63% Cu. The polymetallic melt formed after the decoupling of the slag contained 78.55–84.9% Cu, 10.8–16.48% Pb, and 0.08–0.39% Fe.
INFLUENCE OF Ho3+ IONS FOR THE QUANTITATION OF IRON (Fe) IN 0.1 M HCl SOLUTION USING MICROWAVE PLASMA-ATOMIC EMISSION SPECTROMETRY (MP-AES)
During research work on Non-Ferrous Metals Faculty concerning on the new corrosion inhibitors of iron alloy in magnetic field, Ho3+ ions were proposed as one of the new inhibitors. One of the methods to determine the rate of corrosion process is determination of concentration of Fe ions in solution. Due to required high precision of the determination of the concentration Fe ions in solution contains Ho3+ ions in a wide range of concentrations, the influence of matrix effect and interferences of Ho3+ ions must be known. The present work investigates the impact of Ho ions in rang 0 to 100 mg/L for the quantitation of Fe ions in 0.1 M HCl solution using MP-AES method. Obtained results were analyzed using single-factor ANOVA method. In range up to 40 mg/L Ho3+ ions is not significant factor to determination of Fe concentration by MP-AES.
EFFECT OF TEXTURE ON DEFORMATION MODE IN MAGNESIUM AND AZ61 ALLOY
The effect of the initial texture on the deformation mode and mechanical properties was studied in magnesium and its AZ61 alloy. Both materials had a very similar initial texture. Two cases were investigated: samples with a texture where the basal slip system was blocked, and samples having a texture where the basal slip system was allowed to activate. The samples were deformed by compression at room temperature at a strain rate of 10-3 s-1. It was found that the initial texture had a very strong impact on the deformation mode in magnesium; however, there was no effect of the initial texture on the deformation mode in the case of AZ61. The investigations were compared to simulations of texture evolution using the Taylor model. From the simulations, the Taylor factor and slip system activity were obtained. It was found that, in the case of magnesium, twinning or slip (both basal and non-basal) are the two main deformation modes, while in the case of AZ61, slip is the only main deformation mechanism despite the initial texture. The impact of the initial texture is discussed in more detail in the present study.
ELECTRODEPOSITION OF SILVER FROM NITRATE-TARTRATE SOLUTIONS
The electrodeposition of silver from AgNO3 solutions with the addition of L-tartaric acid was investigated. The cathodic reaction was accompanied by low electrode polarization and run under activation control for AgNO3 concentrations of above 70 mM. Tartaric acid only slightly shifted the polarization curves towards more electronegative potentials (by approx. 50 mV), but it did not change the rate-determining step. The activation control of the process resulted in the formation of rough and coherent deposits, while the mixed or diffusion control of the process promoted the formation of dendritic-like structures and spongy deposits.
Microstructure evaluation of laser-welded 600 nickel alloy
This paper presents the results of a microstructure analysis of a laser butt-welded 600 nickel alloy. A microstructure evaluation of the joint is carried out with the use of light microscopy and scanning electron microscopy. The results indicate a phase γ with some particles in the grain boundaries in the base metal. In the weld, a cellular-dendritic structure was observed.
ANNEALING EFFECT ON MICROSTRUCTURE AND CHEMICAL COMPOSITION OF INCONEL 625 ALLOY
Our research focused on Inconel 625 weld overlays on 16Mo3 steel boiler pipes. The investigation focused on the characterization of changes in the microstructure and chemical composition after annealing. The annealing was performed for ten hours at temperatures from 600 to 1000°C. Changes in the microstructure were observed with a scanning and transmission electron microscope (SEM and TEM). The investigation was supplemented by hardness measurements.
THERMOPHYSICAL PROPERTIES OF 904L AUSTENITIC STEEL
This paper presents the results of the structural investigations and thermophysical properties of 904L steel parent material. Experimental studies on the structure of 904L steel proved a pure austenitic structure. Both the experimental research and analysis of the thermophysical properties of 904L steel were complemented with the results of the thermal conductivity calculations for the tested material. The paper presents a brief description of the measurements, the procedures for evaluating the data, and a set of the obtained results.
EXPERIMENTAL STUDY ON DP600 CLINCHED JOINTS
Clinching is an effective joining technique for lightweight sheet materials that are difficult or impossible to weld. Clinching is a relatively new technology in which two to three sheet metal parts are joined together by a process of local plastic deformation without the use of any additional components with the application of a special tool. In this study, an experimental investigation of clinch joints was performed. A non-standardized technique was used to determine the optimal joint geometry for further experiments. The used material type was DP600 (dual-phase, advanced high strength steel).
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INFLUENCE OF CONTINUOUS STEEL CASTING CONDITIONS ON BEHAVIOR AND STABILITY OF LIQUID MOLD SLAG DURING SLAB CASTING – PHYSICAL MODELING
This article presents the results of the physical modeling of the continuous casting of steel slabs in a mold. The experiments focused on the assessment of the shape and stability of the liquid mold slag layer, which was reproduced in studies using silicone oil. The experimental tests were carried out for two different geometries of the submerged entry nozzle, two extreme submergence depths of the submerged entry nozzle (0.215 and 0.295 m), and two extreme casting speeds (1.0 and 1.6 m/min) used in industry. For each variant of the experiment, photographic documentation of the oil layer’s behavior was presented and discussed. The research was supplemented with a visualization of the flow structure using a marker for the selected variant of the experiment.
EFFECT OF ORGANIC ADDITIVES ON ELECTRODEPOSITION OF TIN FROM ACID SULFATE SOLUTION
Basic electrochemical experiments on the kinetics of tin deposition from an acid sulfate solution containing organic additives were performed. The measurements showed that tin deposits with activation polarization in a narrow potential range. Organic additives like gelatin and β-naphtol inhibit the charge transfer stage of the cathodic reaction due to the formation of adsorption layers. In turn, the gluconate ions increase the rate of tin deposition due to the bonding of hydrogen ions and inhibiting hydrogen coevolution. This results in serious changes in the morphology of tin deposits from isolated polyhedron crystals (no additive) via rectangular plates (β-naphtol) and thin plates (sodium gluconate) to rounded grains (gelatin).
INFLUENCE OF LADLE SHROUD AND CHANGE IN ITS POSITION ON LIQUID STEEL FLOW HYDRODYNAMIC STRUCTURE IN SIX-STRAND TUNDISH
This paper presents the numerical simulation results of the liquid steel flow in a six-strand tundish used for casting billets. The influence of using a ladle shroud, changing its immersion depth in liquid steel on the transition zone, and shaping the liquid steel volume flow were tested. Three positions of the ladle shroud immersion depth in liquid steel were checked. The computer calculation results have shown that the use and position change of the ladle shroud locally influences the shape of the liquid steel hydrodynamic structure in the tundish. The numerical simulations were carried out using the Ansys-Fluent computer program.
INFLUENCE OF WELDING TECHNIQUES ON MICROSTRUCTURE AND HARDNESS OF STEEL JOINTS USED IN AUTOMOTIVE AIR CONDITIONERS
Austenitic steels belong to a group of special-purpose steels that are widely used in highly aggressive environments due to their enhanced anticorrosive behavior and high mechanical properties. The good formability and weldability of these materials has made them very popular in automotive AC systems. This study presents the results of hardness tests and microstructure observations on plasma- and laser-welded joints. The examined joints consisted of two different stainless steel components; i.e., a nipple made from corrosion-resistant AISI 304 steel and a corrugated hose made from 316L steel. Microplasma welding was carried out on a workstation equipped with an MSP-51 plasma supply system and a BY-100T positioner. The laser-welded joint was made on a numerically controlled workstation equipped with an Nd:YAG laser (without filler material) with 1 kW of maximum power; the rotational speed of the welded component was n = 4 rpm. Microstructural observations were performed using a scanning electron microscope and an optical microscope. Vickers hardness was measured with a hardness tester. The obtained results proved that both the microplasma- and laser-welded joints were free from any visible welding imperfections. In the micro areas of the austenitic steel weld, crystals of intercellular ferrite appeared against a background of austenite. The crystallization front (depending on the welding technology) was running from the fusion line towards the weld axis. The grain size depended on the distance from the fusion line.
OPTIMIZATION OF ISOTHERMAL TRANSFORMATION PERIOD FOR AUSTEMPERED DUCTILE IRON
The present paper examines and compares the influence of austempering parameters such as temperature and time on the isothermal transformation and microstructural changes of ductile iron. To identify the compositional and structural changes during an isothermal transformation, a very wide austempering period is chosen at a transformation temperature for the precise determination of the process window. XRD, optical, and scanning electron microscopic techniques are exploited to identify and analyze the changes in the austempered structure, at austempering temperatures of 250°C and 400°C. The various structural parameters like austenite volume fraction (Vg, its carbon content (Cg), lattice parameter, and the average cell size of the ferrite are ascertained. Electron backscattered diffraction (EBSD) analysis is used to identify the carbide precipitation obtained due to the austempering Stage-II reaction. It is noticed that, at the end of the austempering Stage-II reaction, there is a significant reduction in the volume fraction of stabilized austenite and it’s carbon content, as the microstructure at this stage not only contains ausferrite but also additional precipitated iron carbides. With an increase in austempering time, the austenite and ferrite volume fraction increase until the austenite becomes stabilized with sufficient carbon. The increase in the lattice parameter of the austenite during austempering corresponds to the rise in carbon content within the austenite. A rise in the austempering temperature leads to a reduction in the volume fraction of the ferrite and an increase in the stabilized austenite volume fraction. The optimum isothermal transformation period for austempered ductile iron is established, based on the period during which the maximum content of the austenite volume fraction, its carbon, the lattice parameter, and the average cell size of the ferrite are maintained.
IMPACT OF SELECTED PARAMETERS ON EXTRACTION OF INDIUM FROM LCD SCREENS
Due to the minute availability of indium and its crucial importance to the world economy, it is necessary to find alternative sources of this metal. As a large proportion of indium production is consumed for the purpose of LCD screen manufacturing, it seems reasonable to investigate their recycling leading to the recovery of this metal. The present work investigates the impact of time, temperature, and the concentration of sulfuric acid on the effectiveness of indium extraction from milled LCD panel glass scrap originating from portable computers manufactured between 2005 and 2012. The conclusion of our research defines the optimal conditions for extraction.
INFLUENCE OF CORROSION ON MECHANICAL PROPERTIES AND MICROSTRUCTURE OF 3XXX, 5XXX, AND 6XXX SERIES ALUMINUM ALLOYS
Growing demands imposed on passenger car producers concerning the reduction of exhaust emission to the environment are forcing a search for new materials and design solutions. One of the most-important factors that can reduce this emission is the low mass of a vehicle, leading to a decrease in its average fuel consumption. A reduction in weight can be obtained by the use of aluminum elements instead of steel; e.g., in air conditioning pipes, decreasing the specific weight of the construction by nearly three times. In the present study, the influence of the SWAAT corrosion test on A/C piping made from 3xxx, 5xxx, and 6xxx series aluminum alloys was investigated. The study focused on changes in the mechanical properties of samples before and after a SWAAT test determined by a tensile test and Vickers hardness measurements. Additionally, microstructure examinations were performed with the use of optical and scanning microscopy. Corrosion products on the surface of pipes were identified by Energy Dispersive X-ray Spectroscopy. Pipes made from the EN AW 6063 alloy revealed an almost 50% decrease in its strength properties after the tests. The largest decline in plastic properties was observed in pipes made from the EN AW 6060 alloy.
EFFECT OF TEST CONDITIONS ON WEAR PROPERTIES OF STEEL-MATRIX COMPOSITES
The friction coefficient and wear behavior of 316L austenitic stainless steel and 316L steel + 8vol% TiB2 + 1vol% B composites were investigated within a temperature range of 20°C to 800°C. The materials were prepared by the powder metallurgy method. The wear behavior was studied by using a ball-on-disc wear tester at room temperature. The surface before and after wear tests was analyzed using scanning electron microscopy (SEM). The results indicated that the friction coefficient and wear resistance of stel-8TiB2-1B composites depend on the wear test conditions.