Papers by Author: Saulius Kaciulis

Abstract: W is a promising material to use as protection for thermal shields in future nuclear fusion reactors, however the joining to other metals is really challenging. For realizing such joints plasma spraying (PS) has been used for its simplicity, the possibility to cover complex and extended surfaces and the relatively low cost. An appropriate interlayer must be optimized to increase the adhesion of W on the substrates and to provide a soft interface for better thermo-mechanical compatibility.The present work demonstrates that high-temperature X-ray diffraction (HT-XRD) permits to quickly assess the reliability and quality of the coating-interlayer-substrate system by measuring the strain of coating. This is very useful to orientate the work for optimizing the structure and composition of the interlayer and the parameters of deposition process.

Abstract: Titanium-metal-matrix composites (Ti-MMC) are materials with very large specific resistance and potential operative temperature up to 800° C. At present these composites are produced by Hot Isostatic Pressing (HIP), a reliable but expensive manufacturing method. To cut production costs, Centro Sviluppo Materiali SpA (CSM) has developed and patented an experimental plant for co-rolling at high temperature sheets of titanium alloy and silicon carbide monofilaments fabrics. The experimental Roll Diffusion Bonding (RDB) pilot plant permits a reduction of process costs of about 40% with respect to the HIP process. This work reports the results of microstructural and mechanical examinations carried out on composites realized by RDB and HIP. The comparison shows that the fibre-matrix interface is stable in both the composites while the mechanical properties of RDB composite are better due to its smaller grain size and high dislocation density.

Abstract: The paper reports the results of an extensive characterization of the Ti6Al4V-SiC_f composite produced by hot isostatic pressing (HIP) to assess its capability to withstand the in-service conditions of turbine blades operating at middle temperatures in aeronautical engines. The microstructure of composite, in as-fabricated condition and after long-term heat treatments (up to 1,000 hours) in the temperature range 673-873 K, has been investigated by means of different techniques. Particular attention was paid to the micro-chemical evolution of fibre-matrix interface which is scarcely affected also by the most severe heat treatments examined here. This leads to stable mechanical properties as evidenced by hardness, tensile and FIMEC instrumented indentation tests. Therefore, the composite can operate at the maximum temperature (873 K) foreseen for its aeronautical applications without remarkable modifications of its microstructure and degradation of mechanical properties. The mechanical characterization has been completed by internal friction and dynamic modulus measurements carried out both at constant and increasing temperature, from 80 to 1173 K.

Abstract: The discontinuous precipitation of a high-nitrogen (0.8 wt%) austenitic steel has been investigated after successive steps of heat treatment at two different temperatures (800 and 850 °C). After each step of heating the material has been examined by X-ray diffraction (XRD), optical microscopy (OM), transmission electron microscopy (TEM), Auger electron spectroscopy (AES) and microhardness tests. The precipitation of Cr2N induces the formation of a secondary austenitic phase, leads to the redistribution of N between transformed and untransformed zones and to local variations of mechanical properties.

Abstract: Roll Diffusion Bonding (RDB) is a new process, developed at C.S.M., for producing Ti composites reinforced by long fibres. The prototypal “diffusion bonding” plant permits to co-roll at high temperature in superplastic rolling field (under temperature and strain rate control) foils of titanium alloy and fabrics made of SiC monofilaments. This study evidenced that the Ti6Al4V-SiCf composite produced by roll-bonding exhibits superior mechanical properties with respect the same material prepared by Hot Isostatic Pressing (HIP) owing to the smaller grain size and the higher dislocation density.

Abstract: The composite, consisting of Ti6Al4V matrix reinforced by unidirectional SiC fibres (SCS-6), has been investigated by mechanical spectroscopy at temperatures up to 1,173 K. For comparison, the same experiments have been performed on the corresponding monolithic alloy. The internal friction (IF) spectrum of the composite exhibits a new relaxation peak superimposed to an exponentially increasing background. This peak, which is not present in the monolithic alloy, has an activation energy H = 186 kJ mol-1 and a relaxation time 0 = 2.3 x 10-15 s. The phenomenon has been attributed to a reorientation of interstitial-substitutional pairs in the  phase of Ti6Al4V matrix around the fibres. This explanation is supported by the results of micro-chemical characterization carried out by X-ray photoelectron spectroscopy (XPS) combined with Ar ion sputtering.

Abstract: The microstructure of Ti6Al4V-SiCf composite, in as-fabricated condition and after long-term heat treatments (up to 1,000 hours) in the temperature range 400 - 600 °C, has been investigated by means of high-temperature X-ray diffraction (HT-XRD), energy dispersion spectrometry (EDS), X-ray photoelectron spectroscopy (XPS) and Auger electron spectroscopy (AES). Particular attention was paid to the strains, arising during heating, and to the micro-chemical evolution of fibre-matrix interface. Micro-chemical examinations evidenced that a thin TiC layer has formed between the fibre carbon coating and the matrix during the fabrication process. TiC slows down further diffusion of carbon towards the matrix and guarantees the interface stability also for the most severe treatments examined here.