Papers by Author: Abhay Kumar Jha

Abstract: Titanium alloys play a major role in launch vehicle due to its high specific strength, good weldability, excellent corrosion resistance and retain toughness at cryogenic temperatures. In the present paper we discuss on the electron beam welding studies carried on alpha-beta titanium alloys for cryogenic applications in launch vehicle programme. The Ti6Al4V having extra low interstitial elements and Ti5.4Al3Mo1V alloys were joint individually through electron beam welding on 6.8mm thickness coupon. Carried microstructural observations of the weld by optical microscope and are reported. Further tensile properties evaluated in welded condition at ambient and cryogenic (20K) temperatures are compared with parent metal properties. Micro hardness plot was generated across the weld in the transverse direction for both the alloys. Showing highest hardness in the weld region and drops towards the parent metal, due to formation of very fine martensitic alpha with high dislocation densities within coarse beta grains of the weld and HAZ region. The failure location of all the weld specimens is in parent metal far away from the weld region.Keywords: Ti6Al4V-ELI, Ti5.4Al3Mo1V, electron beam welding, cryogenic, microstructure, micro hardness and tensile properties.

Abstract: The beta titanium alloys are highly cold workable in annealed condition, due to presence of single phase bcc structure (beta) at ambient temperature. The Ti15V3Al3Sn3Cr alloy is a metastable beta alloy retains single beta phase at ambient temperature by beta annealing. The beta alloys are most hardenable among titanium alloys, due to the formation of hard alpha (hcp) precipitates in beta (bcc) grains in solution treated and aged (STA) conditions. The present paper brings out the hot forging and rolling studies carried above beta transus temperature and correlating microstructure with mechanical properties in heat treated conditions (a. 800°C for 30 minutes and b. 800°C for 45 minutes, subsequent water quenched from single phase beta region plus aged at 482°C/538°C). The results conclude that solution treatment carried for 45 minutes and aged at 482°C/538°C achieved high tensile strength with improvement in ductility. This is due to less nucleation sites of alpha precipitates along the grain boundaries for the 45 minutes solution treated specimens. The Young’s modulus evaluated for solution treated (78GPa), aged at 482°C (105GPa) and 538°C (103GPa), the increase in aged conditions is due to the formation of alpha precipitates throughout the matrix and makes the alloy two phase alpha-beta system.Keywords: Metastable beta, alpha precipitates, solution treatment, tensile strength, Young’s modulus.

Abstract: Al-Cu-Mg (Russian grade V65) alloys are used for riveting applications in aerospace industries due to relatively high shear strength of the order of 25 kg/mm² combined with a high plasticity. The main advantage of using V65 aluminum alloy for rivet application comes from its significantly slower natural aging response, which gives flexibility to carryout riveting operation even after 4 days after solution heat treatment and natural aging at room temperature. This very valuable feature is not found in its counterpart alloy AA2024 where due to rapid aging kinetics of this alloy, the riveting operation must be completed within 30 min of the solution treatment, which is many times impractical. This paper presents the processing of V65 aluminium alloy by Direct Chill (DC) casting followed by subsequent secondary processing through extrusion and forging to realize feedstock for caliber rolling. These ingots were caliber rolled to 12 mm diameter rods at different temperatures and mechanical properties were evaluated in T6 and T4 tempers. Detailed microstructural examination using optical microscopy and fractography of the tensile tested samples using scanning electron microscopy were carriedout to correlate microstructure and mechanical properties.

Abstract: Missile and rocket motor cases are often fabricated by welding process. The replacement of welded hardware with the flow formed construction eliminates many problems associated with welded joints. Data on the cold workability of the material in different heat treatment conditions is essential for the flow forming of the material. The cold workability of a 0.3C-CrMoV grain refined steel processed by air melting and electroslag refining was studied in annealed and Q&T conditions through cold rolling process. The effect of heat treatment on the strength properties of the rolled materials was also studied. The observed behaviour is explained in the light of the results of the microstructural characterization.

Abstract: High yield strength and good wear resistance of hypereutectic steels in hardened and tempered condition made them attractive to manufacture rotating parts of mechanical systems. However, they suffered with poor corrosion, owing to high carbon content. The need for a material with improved strength, wear resistance and corrosion resistance for bearing application resulted in the design of a new steel having 17 wt.% Cr, up to 0.75 wt.% Mo and 1 wt.% C, which was christened as 440C. This martensitic grade of stainless steel was surface hardened by laser transformation hardening (LTH) technique using Pulsed Nd: YAG laser. Optimised process parameter could result in 300 µm thick hardened layer consisted of martensite, retained austenite and fine carbide with an average hardness of 540 VHN, while it was about 220 VHN in the core. Laser process parameter like energy/power density, pulse width, scanning speed and overlap ratio were responsible in influencing the microstructural constituents, hardness achievable and in turn dictates the wear resistance capability of the material. Experimental results such as temperature distribution, depth of hardening have been verified analytically. A reasonable agreement between the theoretical and experimental measurements was obtained. This paper highlights the details of experimental work.

Abstract: Metallography technique is used as an important tool in designing and development of materials. The technique is destructive and hence has its own limitations. Non destructive metallography emerged as a solution for its limitations. The microstructure of the component in the field/service can be replicated and observed under microscope. In the recent past, this technique has drawn the attention of quality control personals due to its non destructive nature. This paper explains the use of nondestructive metallography technique for Ti-6Al-4V alloy domes and low carbon steel static test bed exposed to high temperature.

Abstract: Advancement in material science has reached great heights both in terms of development and properties but still failures continue to happen. Failure is often accompanied by economic and human loss. Failures generally occur due to error of knowledge, error of performance and error of intent which comprises improper design and/or material selection, deficiency in processing and assembly. Failure analyst plays an important role in evaluating the causes of failure by using various analytical tools to arrive at the conclusion and suggests remedies to avoid its reoccurrence. This paper highlights the important steps in failure analysis with a few case studies demonstrated. Case studies include the failure of plumbing tube used in engine gimbal control system of liquid propulsion system, where failure was initiated due to process deficiency and its propagation was facilitated under fatigue loading. In the other case study discussed, failure of steel fasteners was due to hydrogen induced stress corrosion cracking (HISCC).

Abstract: Aluminium alloy AA 2219 has been selected for fabrication of both earth storable and cryogenic propellant tanks of launch vehicles due to its high specific strength, compatibility with liquid propellants, good resistance to stress corrosion cracking (SCC), excellent properties at cryogenic temperatures and good fabricability including weldability. Propellant tanks are fabricated by welding sheets in T87 and rings in T851 temper conditions. Microstructural characterization was carried out on the weldments with sheet-sheet and sheet-forge configuration using optical microscopy and electron microscopy with energy dispersive spectroscopy. Microstructure of weld pool had dendritic pattern, typical of weld cast structure. Fine recrystallised grains were observed near fusion line. Heat affected zone on either side of the weld revealed thickened grain boundaries. EDS on these thickened grain boundaries indicated composition of eutectic. Microhardness and tensile strength for both the configurations was evaluated. Fractures surface of tensile tested specimens were examined for fracture morphology and to understand the role of eutectic film in fracture. Presence of the eutectic film along the grain boundaries was explained with the help of liquation mechanism and Al-Cu phase diagram. This paper brings out details of the investigation carried out.

Abstract: Copper to stainless steel brazed components are used in the thrust chamber of cryogenic propulsion system of Indian Space Programme. Temperature and time play a major role in the optimization of brazing cycle. An effort has been made to study the influence of the above parameters and correlate with the microstructure and shear strength achieved. In the present work, brazing was performed using Cu based filler metal. Temperature selected was within the range of 1010-1045 °C for two different time durations (20 minutes and 30 minutes) under high vacuum (10^-5 Torr). Extensive scanning electron microscopy with energy dispersive spectrometry was carried out to understand the kinetics of elemental diffusion and phase formation at and near the brazed joint. Microhardness was evaluated across the joints to facilitate further understanding of the joint chemistry. The optimized shear strength of the joints was as high as 155 MPa for the joint brazed at 1030 °C for 30 minutes against the required strength of 150 MPa. The joint could retain strength at cryo temperature and meet the minimum expected value of 320 MPa. At the same time, it exhibited good mechanical properties at elevated temperatures. This paper brings out details of the investigation carried out.