Papers by Author: Lutz Krüger

Abstract: The main objective of this work was to obtain information about the hydrogen diffusion behaviour in a cold-worked austenitic stainless steel (X3CrMnNiMoN17-8-4) in which deformation-induced martensite formation occurs during mechanical deformation. Three different states of pre-deformation (31 %, 39 % and 49 %) that showed induced phase transformation from austenite to α’martensite as well as the solution-annealed material were part of this study. All samples were charged with hydrogen in a 0.1 M NaOH solution. This charging took place electrolytic with 10 mA cm^-2 at three different temperatures (50 °C; 65 °C and 80 °C) in the double cell according to Devanathan and Stachurski. Due to the very slow diffusion of hydrogen through austenite, the samples were not charged until the equilibrium state was reached. To find out the necessary diffusion parameters, the data were fitted with numerical optimisation. Using this method, the effective diffusion coefficients of charging could be determined for all material states. The study also contains microscopic analyses to visualize the effect of cold working on the microstructure of the material. The appearance of α’-martensite significantly contributes to the susceptibility to hydrogen uptake leading to increasing diffusion coefficients in relation to higher pre-deformation.

Abstract: In this study, the influence of varying sulphuric acid – sodium chloride electrolyte composition to the electrochemical noise behaviour of a high-alloy cast steel was analysed. The noise analysis was carried out in a bare 0.1 M sulphuric acid solution, in a pure 5 wt.% sodium chloride solution and three solutions with defined ratios of both. The electrochemical current noise signal was recorded with a sampling rate of 100 Hz for 1 hour in each test solution. For the identification of the frequency content of notified characteristic transients, the current-time records were analysed by the continuous wavelet transform (CWT). The characteristic transients were extracted from the noise signal for a further analysis of their frequency and amplitude characteristics. The results show high-frequency transients in the bare sulphuric acid and low-frequency transients in the pure sodium chloride solution. In the combined electrolyte solutions the portion of low-frequency components increases when the NaCl content increases and indicates the enhancing influence of localised damage evolution processes at the steel surface.

Abstract: Metal matrix composites with ceramic reinforcements such as particles or fibers have come into focus during the past decades due to rising requirements on engineering materials. In this work, composite materials out of high-alloy CrMnNi-steel matrices with varying Ni-contents (3 wt.% and 9 wt.%) and 10 vol.% Mg-PSZ were processed by hot-pressing. The variation in Ni-content resulted in a change in stacking fault energy (SFE) which significantly influenced the deformation mechanisms. The mechanical behavior of the developed composites was investigated in a wide strain rate range between 0.0004 s^-1 and 2300 s^-1 under compressive loading. This was done by a servohydraulic testing system, a drop weight tower, and a Split-Hopkinson Pressure Bar for the high strain rates. To study the influence on the deformation mechanisms such as martensitic transformations and/or twinning, interrupted tests were also carried out at 25 % compressive strain. Subsequent microstructural examinations were done by a magnetic balance to measure the quantity of α’-martensite as well as by scanning electron microscopy (SEM). The results show an increase of strength and strain hardening with decreasing SFE of the matrix due to increased α’-martensite formation. The addition of the Mg-PSZ particles resulted in further strengthening over almost the entire deformation range for all investigated composites. At high strain rates quasi-adiabatic heating suppressed the martensite transformation and reduced the strain hardening capacity of the matrix. Nonetheless the particle reinforcement retains its strengthening effect.

Abstract: Composite materials, which consist of a metastable austenitic TRIP-steel matrix (CrMnNi TRIPsteel; TRansformation Induced Plasticity) reinforced by alumina particles (25 vol.% ceramic, designated as AT 25/75) and reinforced by alumina and MgO partially stabilized zirconia particles (Mg-PSZ) (35 vol.% ceramic, designated as AT 25/75 + MgPSZ) were synthesized through spark plasma sintering (SPS). In the AT 25/75 + MgPSZ, the steel particles were mainly surrounded by alumina. Hence, mostly steel/alumina and alumina/MgPSZ interfaces existed. The mechanical behavior of the as-sintered samples was characterized by compression tests at room temperature and 40 °C and in a range of strain rates between 10³ s^-1 and 10³ s¹. The influence of the ceramic content, strain rate and temperature on TRIP-effect of the steel matrix was investigated. Due to the increasing ceramic volume fraction, AT 25/75 + MgPSZ exhibits the highest compressive yield strength under all loading conditions and no strain rate sensitivity. This composite showed no measurable TRIP-effect, due to the low fracture strain. The deformation-induced α’martensite within the steel particles in pure steel and AT 25/75 primary depends on the testing temperature and the strain rate. This is attributed to an increase of stacking fault energy with rising temperature. High strain rates cause adiabatic heating, counteracting the martensitic transformation.

Abstract: Metal-matrix composite materials, based on a metastable austenitic stainless steel reinforced with a magnesia partially stabilised zirconia have been prepared by a ceramics-derived extrusion technology. Using this powder metallurgical method enables the shaping of lightweight cellular structures as well as bulk specimens with a variety of steel/ceramic ratios at room temperature. However, the extrusion of composite structures is limited by the uniform cross section throughout its entire length. Joining of these metal-matrix composite preforms after sintering by conventional welding techniques is a challenging task. The presence of ceramic fractions may lead to several complications and the subsequent heat exposure during joining may initiate phase transformations in both metastable components resulting in a deterioration of the mechanical properties of the composite material. An adapted ceramics-derived joining technology allows the combination of varying TRIP-steel/zirconia composite materials. The main features are the machining and joining of the parts in their dry green state at room temperature before their thermal treatment. Thus, the material’s consolidation and the formation of the joint take place simultaneously. The ability of joining different parts offers the possibility to create structures for complex applications and testing conditions. The key to advanced properties of the joining zone are the base materials, the surface treatment of the parts, and the paste used for joining. The joining process of different base materials, the mechanical properties, and the microstructure of sinter-joint samples are presented.

Abstract: Ceramic particle reinforced metal matrix composites (PRMMCs) combine the strength and brittleness of ceramics with the toughness of a metallic matrix. In order to use these materials in construction and operational design their fracture mechanical behavior must be evaluated. In this study, a 30 vol.-% Al₂O₃ reinforced austenitic TRIP steel processed by powder metallurgical technique was investigated using precracked miniature SENB-specimens in 3-point-bending. An elastic-plastic analysis by means of the J-integral method in combination with optical crack observation showed the materials ability of stable crack growth, i. e. R-curve behavior. In addition to the mechanical tests microstructural studies were performed, whereby particle debonding and fracture as well as martensitic phase transformation and crack bridging within the matrix were identified as fracture energy dissipating mechanisms.

Abstract: Composite materials and micro- and macrostructure designs have been the focus of numerous scientific studies over the past few years according to their crashworthiness [1-3]. Crashworthiness is concerned with the absorption of energy through controlled failure mechanisms and modes that enable a defined load profile during energy absorption [4]. Cellular materials, such as metal foams, are materials which display a unique combination of physical and mechanical properties, e.g. for crash box applications. The defining characteristic of metal foams is a very high porosity, typically in the range of 70 to 90 vol. %. In principle, cellular metals can be manufactured from gas, liquid or solid phases and currently the most advanced methods involve melt-metallurgical processes [5]. Several groups have produced foam structures by using hollow spheres to form the cells of the material [5, 6]. These materials exhibited plateau stresses of 5 MPa and 23 MPa respectively, with volume specific energy absorptions SEA of 2 MJ/m³ and 10 MJ/m³ respectively, up to 50 % strain [6, 7]. By combining ceramics with ductile metals, failure-tolerant metal matrix composites (MMCs) can be created. With regard to application of the MMCs as wear resistant materials in metal forming tools a prolongation of the life time and the resultant reduced equipment downtimes have been achieved by active steel infiltrating of porous zirconia structures with the aid of Ti as activator [8]. A very promising approach concerning zirconia/steel - composite materials with superior mechanical properties has been demonstrated by Guo et al. using a low-alloyed TRIP steel in combination with an Y-PSZ – ceramic [9, 10]. In a previous study honeycomb structures were formed from composites of high-alloyed austenitic stainless TRIP-steel AISI 304 with Mg-PSZ with different mixing proportions due to ceramic extrusion at room temperature and sintering at 1350 °C for 2 h in an 99.9 % Argon atmosphere [11]. One of the most promising manufacturing route to produce open cell composite foams is based on the patent of Schwartzwalder [12] by the replication method using polyurethane sponge as a template. The polymer foam is impregnated in a powder slurry (this first coating contributes as an adhesive porous layer for further coating processes), the ceramic slurry is squeezed out of the functional pores and cold spray coatings are applied in order to eliminate defects out of the squeezing process and reach the critical wall thickness for acceptable mechanical properties. In [13] the authors reported about foams with 90 Vol% high alloyed TRIP-steel and 10 Vol% Mg-PSZ. Up to 50 % compressive strain a remarkable enhancement of the SEA was observed in comparison to comparable structures with TRIP-steel only.

Abstract: At different temperatures ranging from ‑60°C to 200°C a cast CrMnNi-TRIP steel was deformed by uniaxial tension. The resulting microstructure was investigated using XRD, EBSD and LOM. The correlation of the phase transformation with the deformation temperature was examined. Depending on temperature, a transition in the deformation mechanisms was observed. Starting with the generation of deformation bands, accompanied by martensitic phase transformation, followed by twinning, the deformation mechanism turned to conventional dislocation glide with raising temperature. Between -60°C and 20°C the TRIP (TRansformation Induced Plasticity)-effect is the dominating deformation mechanism, whereas between 20°C and 200°C the TWIP (Twinning induced plasticity) effect is observed. The geometrical arrangement of martensite within the microstructure is considered within this study. The amount of α'-martensite is mainly responsible for the hardening rate and the resulting mechanical properties.

Abstract: Three alloys of the magnesium AZ-series (AZ31, AZ61 and AZ91) were processed by multi-temperature equal channel angular pressing (ECAP) with five passes using route B_C. The ECAP temperature was decreased from 275 °C to 250 °C during the process for better grain refinement. The mechanical behaviour was investigated over a wide range of strain rates (10^-3 s^-1 up to 10³ s^-1) under compressive loading at room temperature. The investigations show that significant grain refinement takes place during the ECAP-process. The initial grain size of 12 μm, 9 μm and 5.8 μm for extruded AZ31, AZ61 and AZ91, respectively, could be refined to 2.5 μm. The grain refinement occurs by dynamic recrystallisation. Compared to extruded initial Mg-alloys, the yield stress increases slightly for all selected alloys after ECAP processing, while the amount of strain hardening decreases at the same time, due to reduced grain size and texture effects. Furthermore, the flow stress of extruded and ECAPed material is less affected by strain rates within a range of 10^-3 s^-1 to 10^-1 s^-1.

Abstract: The effect of equal-channel angular extrusion (ECAE) on mechanical properties of an AA2017 produced by powder metallurgy is investigated. Special attention is given to the influence of heat treatment, processing temperature and backpressure on the workability for achieving high strength and moderate ductility. This is of special interest, since it is often reported that Al-Cu alloys have low ductility and therefore are prone to cracking during severe plastic deformation. It is shown that ECAE at high temperatures (>220°C) does not necessitate backpressure to ensure homogeneous deformation but leads to a significant sacrifice in strength due to in-situ precipitation. Thus, most of the extrusions are done at considerably low temperatures. Performing room temperature-extrusion is most effective in achieving high strengths but also requires high backpressures. Due to severe strain hardening during processing, the strength increase is combined with a reduction in ductility. Recently it was reported that a post-ECAE aging of pre-ECAE solution treated material is effective in enhancing the ductility of aluminium alloys. This approach was successfully transferred to the current alloy. A high-temperature, short-time aging after only one extrusion, for example, doubles the failure strain to a value of ~13%. Compared to the naturally aged condition with coarse grains that serves as reference (T4), an increase of 15 % in yield stress (YS) was obtained while retaining the ultimate tensile stress (UTS). Another effective approach is the combination of a pre-ECAE solution treatment with subsequent under-aging prior to ECAE. It is shown that performing ECAE at medium temperatures (160-180°C) enables a better workability and additionally gives higher strengths and better ductility compared to the processing in the water quenched condition. A remarkable YS of 530 MPa and an UTS of 580 MPa combined with a moderate failure strain of 11.6 % were achieved.