Papers by Keyword: Microstructure Development

Abstract: The contribution of crystallography-dependent metallurgical factors, such as supersaturation of liquid aluminum and minimum dendrite tip undercooling, to solidification behavior and microstructure development is numerically analyzed during Ni-Cr-Al ternary single-crystal superalloy molten pool solidification to better understand thermodynamic and kinetic driving forces behind solidification cracking resistance. The variation of supersaturation of liquid aluminum and minimum dendrite tip undercooling with location of solid/liquid interface is symmetrically consistent in (001)/[100] welding configuration. By comparison, the variation is asymmetrically consistent in (001)/[110] welding configuration. The different distribution is attributed to growth crystallography and dendrite selection. Significant increase of supersaturation of liquid aluminum and dendrite tip undercooling from [010] dendrite growth region to [100] dendrite growth region preferentially aggravates microstructure development as result of nucleation and growth of stray grain formation with the same heat input on each half of the weld pool in (001)/[110] welding configuration. High heat input (both increasing laser power and decreasing welding speed) exacerbates supersaturation of liquid aluminum and dendrite tip undercooling by faster diffusion to incur stray grain formation with severity of contributing thermometallurgical factors for susceptibility to solidification cracking, while low heat input (both decreasing laser power and increasing welding speed) ameliorates microstructure development and increases resistance to solidification cracking. Weld microstructure of optimum welding conditions, such as combination of low heat input and (001)/[100] welding configuration, is less susceptible to solidification cracking to suppress asymmetrical microstructure development and improve weld integrity potential rather than insidious welding conditions, such as combination of high heat input and (001)/[110] welding configuration. Severer supersaturation of liquid aluminum and wider dendrite tip undercooling occur in the [100] dendrite region as consequence of alloying enrichment, while smaller supersaturation of liquid aluminum and narrower dendrite tip undercooling occur in the [001] dendrite region as consequence of alloying depletion to spontaneously facilitate epitaxial growth of single-crystal essential. Symmetrical (001)/[100] welding configuration decreases growth kinetics of dendrite tip with smaller overall supersaturation of liquid aluminum and dendrite tip undercooling than that of asymmetrical (001)/[110] welding configuration regardless of combination of laser power and welding speed. Mitigation of supersaturation of liquid aluminum and dendrite tip undercooling simultaneously alleviate crack-susceptible microstructure development and solidification cracking. Additionally, the appropriate mechanism of solidification cracking resistance improvement through modification of crystallography-dependent supersaturation and undercooling of dendrite tip is proposed. Calculation analyses are sufficiently explained by experiment results in a reasonable way. The additional purpose of this theoretical analysis is to evaluate solidification cracking susceptibility of similar nickel-based or iron-based single-crystal superalloys.

Abstract: Due to the exploration of gas and oil sources in remote regions with harsh environment, the pipe line designers are faced with the challenging conditions. Especially in the cases where displacement-controlled loads are the predominant design condition, such as ground movement, strain-based design is applied instead of stress-based design to build safer pipelines and to assure the integrity of the lines along their lifetimes. It requires steels to have a large strain hardening capacity, long uniform elongation, and good toughness to achieve a well-defined and sufficient plastic deformation. In order to fulfil the requirements, all the processing steps are supposed to be well designed, for example, the chemical composition, microstructural design, thermo-mechanical controlled process (TMCP) and heat treatment, etc. In general pipe line steel has a low carbon, high manganese content combined with a certain amount of micro-alloying elements as Nb, Ti and sometimes B. Using Thermo-mechanical rolling and cooling schedules excellent combinations of strength and toughness can be established. To successfully produce steel plates for strain based design pipe lines the actual heating rolling and cooling technologies must be developed further as well as the equipment to produce such steel. The paper gives an overview about modern plate mill equipment and new setup strategies for the production of heavy plates X70 to X100 as well as thethermo-dynamic simulations used during the development.

Abstract: Response to isochronal annealing up to 440°C was investigated in squeeze cast Mg2Y1Zn alloy and in the same alloy prepared by powder metallurgy and extrusion at 280°C (PM). Electrical resistivity measurements at 77 K and at room temperature after each annealing step and differential scanning calorimetry performed at various heating rates characterized phase changes proceeding during the heat treatments. Transmission and scanning electron microscopy and optical microscopy revealed ribbons of a long-period ordered structure and a relatively high density of stacking faults in grain interiors of the cast alloy having the grain size of ~50 μm. Well pronounced subgrains were observed in the PM prepared alloy. Secondary phase particles decorate grain boundaries in this alloy. Electrical resistivity response of the cast alloy to isochronal annealing up to 440°C shows three precipitation processes, whereas one significant process was revealed in the PM alloy. Activation energies of precipitation processes were determined. Microhardness exhibits good thermal stability in the whole temperature range in the cast alloy and up to 360°C in the PM alloy.

Abstract: True stress-strain data is obtained for 6061Al/ 10% SiC composites by hot compression test. Mathematical models for % volume of recrystallization and diameter of the recrystallized grains are developed with process parameters such as strain, strain rate and temperature. These models are applied for optimization of the grain size and % volume of recrystallization. An attempt has been made to control microstructure evolution during hot deformation using fuzzy logic controller through simulation in MATLAB software. The fuzzy logic controller parameters are tuned using genetic algorithm.

Abstract: A new approach to dynamic recrystallization (DRX) is introduced. It is based on the assumption that the critical conditions for DRX and the arrest of DRX grain boundaries are related to the development of mobile subboundaries. The theoretical predictions are compared to experimental results during incipient and steady-state DRX. The grain size sensitivity of the DRX grains establishes the desired link between deformation and DRX microstructure.

Abstract: Technical purity Cu (99.95 wt%) polycrystals have been processed at room temperature by equal channel angular pressing. The results of mechanical tests and the microstructure characterization by various experimental techniques are presented. The yield stress as well as the strength were shown to increase with increasing strain and exceed the respective values of a coarsegrained material. The microstructure development and its fragmentation after ECAP was investigated by the TEM and EBSD. The proportion of high angle grain boundaries was found to increase with increasing strain reaching the value of 90% after 8 ECAP passes. Two kinds of defects were identified in ECAP specimens by positron annihilation spectrometry (PAS): (a) dislocations which represent the dominant kind of defects, and (b) small vacancy clusters (so called microvoids). The main increase of defect density was found to occur during the first ECAP pass. PAS analysis indicated that in the specimens subjected to one ECAP pass the mean dislocation density ρD and the concentration of microvoids cν exceeded the values of 1014 m-2 and 10-4 at.-1, respectively. After 4 passes, the number of defects becomes saturated and practically does not change with increasing strain.

Abstract: In the present investigation, serial sectioning and 3D reconstructions are made on samples quenched at selected temperatures during unconstrained solidification in order to observe the evolution in morphology of coarse dendrites in 3D. The 3D microstructure reconstruction during the solidification of an Al−7 wt.% Cu alloy allowed the identification of a complex coarse morphology of dendrites. High-ordered branches present different morphologies at different temperatures and locations in the microstructure due to coarsening and coalescence. 3D visualization of complex dendritic structures is discussed in the present investigation.

Abstract: Work hardening behavior and microstructure development during deformation by cold rolling were investigated in iron with different grain size. Grain refinement makes the introduction of dislocation easier. For instance, under the same deformation condition (5% reduction in thickness), dislocation density is the order of 1014m-2 in a coarse grained material (mean grain size; 20μm), while it reaches 7×1015m-2 in an ultrafine grained material (0.25μm). It is well known that the yield stress of metals is enlarged with an increase in dislocation density on the basis of the Bailey-Hirsch relationship. However, it should be noted that the ultrafine grained material never undergoes usual work hardening although the dislocation density is surely enhanced to around the order of 1016m-2: 0.2% proof stress is almost constant at 1.4 ~ 1.5GPa regardless of the amount of deformation. The dislocation density of 1016m-2 is thought to be the limit value which can be achieved by cold working of iron and the yield stress of iron with this dislocation density (ρ) is estimated at 1.1GPa from the Bailey-Hirsch relationship; σd [Pa] = 0.1×109 + 10 ρ1/2. On the other hand, yield stress of iron is enhanced by grain refinement on the basis of the Hall-Petch relationship; σgb [Pa] = 0.1×109 + 0.6×109 d-1/2 as to the grain size d [μm]. This equation indicates that the grain size of 0.35 μm gives the same yield stress as that estimated for the limit of dislocation strengthening (1.1GPa). As a result, it was concluded that work hardening can not take place in ultrafine grained iron with the grain size less than 0.35 μm because dislocation strengthening can not exceed the initial yield stress obtained by grain refinement strengthening.