Papers by Keyword: Processing Map

Abstract: Laser Powder Bed Fusion (LPBF) represents a significant advancement in metal additive manufacturing, facilitating the near-net-shape fabrication of intricate, high-performance tool-steel components. This process is accomplished through a layer-by-layer selective melting technique and extremely rapid solidification (ranging from 10³ to 10⁶ K/s). The establishment of process maps — both empirical and predictive frameworks that correlate variables such as laser power, scan speed, and defect thresholds — is crucial for defining processing windows and optimising parameter selection. In tool steels, the influence of alloying elements is significant as they affect solidification behaviour, phase stability, and susceptibility to cracking. Carbide-forming additions can constrict the defect-free range, while stabilising elements can enhance toughness and dimensional accuracy. This study aims to develop a process map for S6 tool steel by varying laser scan speed and laser power. Small cubes are printed using various combinations of these parameters, followed by microstructural characterisation of the as-built material. This characterisation includes optical microscopy (OM) and porosity assessment. After establishing the process map for S6, the resulting microstructures are compared with those previously characterised for LPBF-processed S2 tool steel. This comparison provides valuable insight into the differences in the as-built microstructures of LPBF S2 and LPBF S6, particularly in relation to how the presence and relative amounts of alloying elements influence processability and microstructural development.

Abstract: The hot deformation behavior of Ti-Al-Nb-Zr-Mo-Cr titanium alloy has been investigated using a Gleeble-1500D thermal simulation test machine in the temperature range of 855°C~1015°C,at constant strain rate from 0.01 s^-1 to 10s^-1 and with height reduction of 45%. The flow curves characteristic under different deformation parameters show significant difference. According to the stress-strain curves of the alloy and its stress characteristics, the Arrhenius constitutive equation was obtained. The average activation energy is about 541 kJ/mol in the α+β field, and about 243 kJ/mol in the β field, respectively. Based on the dynamic materials model, the processing map is generated, which shows that the peak efficiency domain appears at the temperature of 874°C~900°C and the strain rate of 0.001 s^-1~0.06s^-1 with a peak efficiency of 0.58 at about 887°C/0.001s^-1.

Abstract: Deformation behavior of an as-cast Mg-6.8Y-2.5Zn-0.4Zr alloy during plane strain compression was characterized in present work by high-temperature testing. Based on the experimental data, the values of strain rate sensitivity, efficiency of power dissipation and the instability parameter under the condition of various hot working parameters were investigated. Processing maps were established by superimposing the instability map over the power dissipation map, this being connected with microstructural evolution analysis in the hot deformation processes. Accompanied microstructure characterization of the binary α-Mg/ Long Period Stacking Ordered (LPSO) microstructure reveals that the flow behavior is related to the deformation mechanisms. At lower temperatures (350 – 400 °C) formation of kink bands is observed, which normally occur when deformation twinning is inhibited and other slip systems are strongly hindered by the complex LPSO structures. Dynamic recrystallization (DRX) was initiated at higher temperatures above 400 °C, influencing the softening behavior of the material significantly. DRX was the main softening mechanism when deformation takes place at 500 °C and the kink band deformation decreased.

Abstract: The effect of the applied state-of-stress on the processing maps depicting the mechanisms for hot working of hot extruded Mg-3Al-1Zn alloy has been evaluated. Flow stresses at various temperatures in the range 300 – 500 °C and strain rates in the range 0.0003 – 1 s^-1 have been measured by deforming in compression and in tension. Processing maps have been developed from the respective flow stress data at a strain of 0.1. The maps are essentially similar irrespective of the mode of deformation – compression or tension, and exhibited two domains in the temperature and strain rate ranges: (1) 375 – 500 °C and 0.0003 – 0.01 s^-1, and (2) 450 – 500 °C and 0.1 – 1 s^-1. On the basis of slower strain rates, high tensile ductility, and the apparent activation energy (152 kJ/mole closer to that for self-diffusion), Domain #1 is interpreted in terms of the occurrence of climb controlled dynamic recrystallization. In Domain #2, which occurs at higher strain rates and has an apparent activation energy near to 165 kJ/mole, dynamic recrystallization occurs that involves second order pyramidal slip {11-22} <11-2-3> and recovery by cross-slip of screw dislocations. The state-of-stress imposed on the specimen (compression or tension) does not have any significant effect on the processing maps or the kinetics of hot deformation.

Abstract: The deformation behavior in isothermal compression of Ti-5Al-4Mo-2Cr-4Zr-2Sn-1Fe alloy was investigated at the deformation temperature of 800°C, 850°C, 900°C, 950°C and 1000°C, the strain rate of 0.01s^-1, 0.1s^-1, 1.0s^-1 and 10.0s^-1, and the height reduction of 70%. The flow stress increases rapidly with the increasing of strain at the beginning of deformation. When the strain exceeds a certain value, the flow stress begins to decline and becomes steady. With the increasing of deformation temperature and decreasing of strain rate, the steady stress and peak stress decrease significantly. The effect of strain on the processing maps of Ti-5Al-4Mo-2Cr-4Zr-2Sn-1Fe alloy is obvious. As the strain increases, the instable region moves towards high temperature and high strain rate area. Meanwhile, the contour of efficiency of power dissipation becomes more and more intensive, and the region with high efficiency of power dissipation reduces. Strain rate of 0.01s^-1 and deformation temperature of 900°C are the optimum processing parameters for Ti-5Al-4Mo-2Cr-4Zr-2Sn-1Fe alloy forging under strain of 0.3.

Abstract: A new modified low-cost titanium alloy, Ti-Al-X, was designed for petroleum drilling applications. The alloy ingots were prepared by combination of vacuum consumable electrode arc melting, forging/hot rolling, homogenization, and solid-solution/aging treatments. The hot deformation behavior of Ti-Al-X alloy was investigated by a thermal simulation machine Gleeble 1500 at temperature range of 850~1000°C with the strain rate range of 0.001 s^-1~1s^-1. The deformation resistance significantly decreases with the increase of deformation temperature and the strain rate. The alloy exhibits flow instability under the deformation conditions of strain rates about 0.001 s^-1 and temperature above 1000°C, which should be avoided during hot working. In addition, the instability area enlarged in processing map with the increasing of true strain.

Abstract: In this paper, the flow stresses, the constitutive equation, processing map and the critical conditions of dynamic recrystallization (DRX) of the hot forged QCr0.8 alloy are studied by hot compressive test in the 750-900°C temperature and 0.01-10s^-1 strain rate ranges using Gleeble-1500D thermo-mechanical simulator. The compression reduction of thermal compression deformation is 50%. The results show that the thermal deformation temperatures and strain rates have a significant effect on the high temperature deformation behavior of the alloy. The higher the temperature, the smaller the strain rate and the easier the DRX of the alloy is found.The peak stresses of the alloy decreases with the increase of temperature and increases with the increase of the strain rates.The flow stresses during hot deformation can be described by a hyperbolic sine function. The activation energy Q of the thermal compression deformation is determined to be 370.8KJ/mol. The constitutive equation and processing map of the alloy are established. Critical strains of DRX ε_c are studied by the inflection point characteristic of the lnθ-ε curve of the alloy and the corresponding minimum value of the ∂θ (∂θ)/∂ε-ε curve.

Abstract: The hot workability and hot pack-rolling process of B₄C_P/AA6061 composite were studied. The results showed that the addition of B₄C particles could effectively promote the dynamic recrystallization (DRX) process of the composite. DRX and DRX grains growth were dominant deformation mechanism during hot deformation of B₄C_P/AA6061composite. Typical instability defects included micro voids and particle aggregation. The optimum processing parameters for good workability were obtained in the temperature range of 450°C-500°C and strain rate range of 0.01s^-1-0.1s^-1. According to the flow stress curves and processing maps, a temperature of 500°C and a rolling velocity of 40 mm/s were chosen for pack-rolling experiments. The pack-rolled composite sheets in the RD and TD showed more homogeneous DRX grains than as-HIPed microstructures, which might indicate that hot pack-rolling could lead to more homogeneous microstructures without any edge cracking and surface cracking.

Abstract: To study the hot deformation behavior of Al-Mg-Er alloy, hot compression tests were conducted on a Gleeble-1500D thermal simulator at the temperature range of 200-500°C with the strain rates from 0.001 to 10s^-1. With the increase in the deformation temperature and the decrease in strain rates, the flow stress of the Al-Mg-Er alloy decreased. Processing maps were constructed to study on hot workability characteristics. The results showed that the flow stress curves exhibited the typical dynamic recrystallization characteristics and the stress decreased with the increase of deformation temperature and the decrease of strain rate. Moreover, the processing maps were established on the basis of dynamic material model and Prasad’s instability criterion.

Abstract: Hot compression tests of as-homogenized Al-7.5Zn-1.5Mg-0.2Cu-0.2Zr alloy were carried out on Gleeble-3500 thermal simulation machine at the temperature ranging from 350°C to 550°C and strain rate ranging from 0.001s^-1 to 10s^-1. Processing maps were established on the basis of dynamic material model, and the microstructure was studied using electron back scattered diffraction (EBSD) technique. The results showed that the peak stress and steady flow stress decrease with decreasing strain rate or increasing deformation temperature. There are one peak efficiency domain and one flow instability domain in the processing maps. The flow instability domain which exists in high-strain-rate region becomes larger with increasing strain. Shear bands occur at 45° toward the compression axis at grain interiors and meanwhile flow localization occurs. The optimum deformation temperature and strain rate ranges from 450°C to 500°C and 0.003s^-1 to 0.1s^-1, respectively, with high power dissipation efficiency of 34-39%.