Defect and Diffusion Forum Vol. 405

Abstract: Two thirds of all examined defect cases present on rolled steel strips appeared to be chemical in nature. They are characterized by a modification in surface chemistry. Chemistry-based defects on the steel strips can vary in composition and generally consist of reaction products with the steel substrate. First big category of widely occurring chemistry-based defects is corrosion or oxidation, second contamination with alien matter and third defect category is related to carbon sediments. A number of different surface chemistry-based defects are related to annealing process. Common problem, that occurs in communication is, that identical defects are often indicated by different names and identical names are given for different defects. In the present study an overview including possible causes of three types of the continuous chemistry-based defects situated on the steel strip edges, that appeared to be the same at first glance, is presented: carbon edge deposit, low reflectivity band and annealed border.

Abstract: This paper focus on evaluation of behavior, damage and failure processes occurring during the loading cycles in the carbon fiber reinforced composite by acoustic emission method. Since acoustic emission is physical phenomenon that detects the released energy in form of waves spreading through the material due to stimulation of material by external or internal stress, it is possible to evaluate complex damage and failure processes. For that purpose, the standard and open holes tensile testing specimens with different number of plies were manufactured. Selected acoustic emission parameters were correlated with data obtained from mechanical test. Linear localization method together with signal analysis using Fast Fourier transform algorithm were used as another tool for detection and evaluation of spreading damage processes inside the composite during the load. Basic damage types inside the composite material were identified by metallographic analysis using light microscopy. More complex damage processes were observed on the fracture surface using stereomicroscopy and scanning electron microscopy.

Abstract: Depending on the composition and structure of metallic glasses cells with the dimensions in the range from tenths nanometers to tenths micrometers were observed on the ductile fracture surface. The variation in dimple size was compared with the serrations presented on the loading curve at the nanoindentation of the metallic glasses with different compositions. Higher instantaneous deformation can be connected with simultaneous shearing at more suitable shear band configurations. The cell morphology with the various cell sizes is observed at the failure of the metallic glasses. At the failure of high strength metallic glasses, the cells are formed in short time due to the release of high amount of stored elastic energy. In this case the uniform cell morphology with the cell size of about 20 nm is observed.

Abstract: In the manufacture of wires designed for the welding of low-alloy fine-grain steels, multiple internal discontinuities appear during some periods that are the cause of major failures (cracking) of the wires. To establish the causes of this phenomenon, a complex analysis was performed making use of light and electron microscopy, metallography, microfractography, computerized tomography and hardness measurement. The analysis revealed that wire cracking in course of wire drawing was due to the superposition of the effects of an inappropriate structure of the initial intermediate product (the presence of polyhedral grains of hard bainitic phase) and unsuitable conditions of the forming process.

Abstract: The paper focuses on the metallographic analysis of the damaged inner shaft of a centrifugal pump with a magnetic clutch. This pump was used for the pumping of viscous suspensions. The damaged part of the centrifugal pump was made of stainless steel and transmitted power from the magnetic clutch to the impeller of the pump. The pump was overhauled by the Manufacturer after ten years of routine work. Slightly worn parts of the pump, including the inner stainless steel shaft, were replaced by the Manufacturer according to the preserved documentation. The overhauled pump failed after two days of running in the original conditions. The problematic is solved by an analysis of three used inner shafts with the aid of a metallographic analysis of the microstructure of the material, using light microscopy and scanning electron microscopy, and an EDS microanalysis of the chemical composition and hardness measurements.

Abstract: Material used for screw production was investigated due to its inconvenient properties which caused the screw breaking on threads or in the head during the installation. Chemical composition of analyzed material corresponded with standard STN 17153 according to technological drawing for specific product. The metallographic analysis showed that failure of screws happened due to improper microstructure resulting from unsuitable thermal treatment of material. Fine inclusions based on aluminum nitride (AlN) and chromium carbonitride (Cr(C,N)) were segregated along the ferritic grain boundaries. Coarse aluminum nitride inclusions (AlN) in ferritic matrix affected the character of present fracture surface characterized by cleavage facettes. The fracture was propagated step by step following the planes with the increased concentration of inclusions across the whole cross-section of the screw.

Abstract: This paper deals with rarely occurring defect on the surface of the tinplates produced in the conditions of U. S. Steel Košice, s.r.o. at the cleaning section of the continuous annealing line (CAL), which was caused by burnt. Random occurrence of such surface imperfections was observed within the short period of time (two months) for various continuous annealed tinplate grades, i.e. TH415, TH435 or TH550 with the thickness of the materials in the interval of 0.172 – 0.240 mm. Surface defects caused by burnt (thermal attack) manifested in different ways. Their appearance on the sheet surface was spot with regular or irregular circle shape, as well as line with the length of up to 2 mm oriented not directly in the rolling direction. By observing of the imperfections in scanning electron microscope (SEM) it was found that the surface of the steel substrate was always compact in the defective areas with clearly visible rolling lines. Foreign material, EDS analysis of which revealed that its chemical composition was on the basis of Fe and Cr, was deposited on the surface of the base material. The appearance of the foreign material shape indicated that it was in the liquid state at the time of incidence on the steel substrate surface. Metallographic analysis from the longitudinal metallographic sections through the defective areas revealed that the substrate under the spot defect with regular circle shape had thermally influenced microstructure. Similar manifestations of the microstructure influence were observed for the line defects. In the case of the spot defect with irregular shape, the microstructure of the material was not influenced, what indicated that the particle of liquid metal was solidified at the time of incidence on the plate surface. After revising technical conditions of the cleaning section of CAL, this type of imperfection was suppressed.

Abstract: Introduction of new technologies demands a new access to quality evaluation of products. Joining of steel sheets with laser butt welding requires increased demand on precision of welded sheet ends alignment as well as condition of cutting edge. Moreover, increased requirements are placed on purity of environment, flatness of strips, gases, etc. The paper deals with evaluation of quality of laser butt welds of steel sheets and description of defects which could occur on welds from the metallographic point of view. The influence of relative displacement of welded strips ends alignment, different relative sheet thickness alignment, welding gap size and quality of sheet shear edge on quality of weld will be described. The most significant effect on quality of weld joints and their final mechanical properties has relative position of strip ends and geometry of cutting edge.

Abstract: For the corrosion resistance analysis of the heat exchanger plates (made of AISI 316L steel) the samples with visible damage was delivered. The major part of the surface damages was located at the place of "close proximity" (or surface contact) of individual plates. Some of delivered samples showed an unequal layers of sediments, which indicating a different flow velocities of operating fluid through the plates. At locations of the upper part of the plates with no sedimentation (high velocity flow), the most surface damage was detected in "near contact" areas as well as outside. On the other hand, the area of the lower part of the plates, where the sediment deposition was massive (lowest velocity flow), was observed the smallest surface damage. The results of the chemical composition analyses showed a lower amount of molybdenum and a higher amount of phosphorus in case of all samples. The contents of the key elements necessary for the corrosion resistance (chromium and nickel) were only just above the lower limit of the prescribed chemical composition interval. For detailed study of surface damage, selected defects were observed and documented using scanning electron microscopy. Localized damage showed intercrystalline failure of material with typical surface morphology degraded as a result of cavitation damage under hydrodynamic stress.

Abstract: The paper deals with the microstructural and chemical analysis of military steel from World War II (WWII). The sample of steel which was found in the form of totally destroyed military armoured transporter from WWII close to Hornad River near Košice city, Slovakia by well-known Slovakian artist Juraj Bartusz in the early 60-ties and nowadays analysed by advanced techniques. Juraj Bartusz created from these pieces of steel cycle of Works under name Forest (1965 – 67) which was exhibited in Paris in Museum Rodin (1968). Steel was non-standardly heat treated by melting during fire of bombs without detonators, pure ecrasite. Thus pieces of steel were exposed to extremely high temperature and change structure. Achieved structure was analysed by optical microscopy (OM) and scanning electron microscopy (SEM) supported by EDX chemical analysis. The layer of corrosion products of this sculpture exposed to rural atmosphere for 58 years in Kosice region was also analysed by both techniques.