Rapid solidification and microstructure development during plasma spray deposition

Plasma spray processing is a well-established method for forming protective coatings and free-standing shapes from a wide range of alloys and ceramics. The process is complex, involving rapid melting and high-velocity impact deposition of powder particles. Due to the rapid solidification nature of the process, deposit evolution also is complex, commonly leading to ultrafine-grained and metastable microstruc-tures. The properties of a plasma-sprayed deposit are directly related to this complex microstructure. This paper examines the solidification dynamics and the resultant microstructures in an effort to estab-lish a processing/microstructure relationship. Existing models in the literature developed for splat coo-ling have been extended and applied for examining the rapid solidification process during plasma spraying. Microstructural features of the splats that are produced by individual impinging droplets are examined through scanning and transmission electron microscopy. The relation of dimensions and mor-phologies of these individual splats to the consolidated deposit microstructure is considered. In addition, the distinguishing features in the solidification and microstructural development between air plasma spraying and vacuum plasma spraying are explored, and a unified model is proposed for splat solidifica-tion and evolution of the microstructure.     

不同热输入的低合金钢HAZ中组织、夹杂对韧性的影响

低合金钢经高热输入的焊接之后,可能产生热影响区(HAZ)粗晶区韧性的严重下降。这与HAZ 的组织转变有密切关系。本文采用光学金相、扫描电子显微镜和金属膜透射电子显微镜等方法,对正火状态14MnCuNiV 钢的HAZ 的显微组织和夹杂与韧性之间的关系进行了研究,主要结论如下:正火态的低合金钢经焊接热循环后,HAZ 粗晶区韧性均有不同程度的下降,热输入增高,HAZ 的脆性转变温度上升,韧性显著下降。当HAZ 组织在具有足够冲击韧性的转变温度时,带状硫化物对冲击值起了显著的破坏作用。但在材料本身具有较大脆性而出现准解理形貌时,带状夹杂不再具有主导作用。金属薄膜透射电镜分析表明,高热输入HAZ 的粒状贝氏体中存在挛晶马氏体的M-A 组织。这类组织是高热输入脆化的主要原因.低热输入HAZ 为板条马氏体 细粒状贝氏体组织,具有较好的低温韧性.本文利用HAZ 的非平衡态冷却条WF粒状贝氏体形成过程的机理,来解释不同焊接热输入对HAZ 粒贝小岛内M-A 组织产生条件的影响.这一解释在薄膜透射电镜分析中得到了证实.     

2250mm热粗轧支承辊剥落的原因分析

通过对支承辊剥落断面及外露裂纹通道的形貌勘察,结合超声检测、组织及夹杂物检测,判定该支承辊由于无法及时发现并清除表面裂纹,导致表面裂纹发展为严重的条带状疲劳裂纹,最终导致支承辊强度不够产生大面积剥落。     

柴油机铸铝活塞碎裂失效分析

通过对失效件整体形貌、断口、内部质量及显微组织的全面检验和试验分析 ,确定工件内部存在严重的质量问题 ,铸造冷裂纹、大型疏松孔洞和未经变质处理的缺陷组织 ,是导致构件在服役时早期失效碎裂的主要原因。     

Unique microstructure and excellent mechanical properties of ADI

I t has been a mission for cast iron metallurgists to improve the properties of cast irons. For many years the strength of cast iron was very low, with a tensile strength of only 60-100 MPa in 1860. During World War I, the tensile strength was increased to 120-140 MPa, by adding scrap steel during melting. In 1922, inoculated iron was invented and the tensile strength of cast iron increased further to 300 MPa. Later, alloyed, inoculated grey iron reached strength of 400 MPa. Although Whi…     

Creep effects on crack growth in a Mo–Si–B alloy

Crack growth behavior during monotonic and cyclic loading at elevated temperature is affected by creep and/or by environment and, therefore, high-temperature toughness and fatigue response can be temperature and loading-rate dependent. This paper reports on the effect of loading rate on fracture toughness at high temperatures for a two-phase Mo–Si–B alloy; the observed response is understood by examining the interaction of the advancing crack with the microstructure, and the evolution of microstructure ahead of the crack tip as a consequence of the crack-tip field. Parallel studies were also performed under cyclic loading conditions by subjecting compact tension specimens to sinusoidal and trapezoidal loading waveforms. In certain cases, the microstructure ahead of the crack tip revealed several instabilities (recrystallization, grain growth and creep cavitation). Finite element analysis revealed strain localization ‘pockets’ ahead of the crack tip, which are thought to provide the driving force for the observed microstructural instabilities.     

A three-phase simulation of the effect of microstructural features on semi-solid tensile deformation

A direct finite-element microstructure model for prediction of the deformation behavior of semi-solid metallic alloys is presented. The 2D model geometry is based on a modified Voronoi tessellation, and includes rounded corners to approximate an equiaxed-globular grain structure, liquid surrounding the grains, and micro-porosity. An elasto-plastic empirical constitutive equation is derived for the solid grains, while the liquid is approximated as a perfectly plastic material with a very low yield stress. The resulting three-phase model was used to investigate the effects of fraction solid, porosity, and grain size on the constitutive behavior of a semi-solid aluminum alloy, AA5182. The model predictions were validated against experimental data at high fraction solid. These simulations reveal a strong correlation between semi-solid grain size and yield stress, and between porosity and strain localization. The application of direct finite-element simulations is shown to be an effective technique for examining the effects of microstructure phenomena on the macro constitutive behavior of semi-solid materials.     

AZ31B 镁合金板材中晶界滑移的晶体塑性仿真

建立一种耦合滑移、动态再结晶以及晶界滑移的晶体塑性模型以仿真镁合金的高温变形行为及织构演化。首先,通过实验测量单轴拉伸、压缩后的织构以及显微组织演化,研究AZ31B镁合金在300°C的变形机制。结果发现,动态再结晶在应变小于0.2时起到细化晶粒的作用,之后晶界滑移在变形过程中起显著作用。此外,建立晶界滑移模型来评估由晶界滑移产生的应变以及晶粒转动,并与多晶体塑性模型VPSC相耦合。所建立的VPSC-DRX-GBS模型可以很好地计算应力?应变曲线、晶粒尺寸、织构演化以及实验中所发现的拉伸与压缩织构演化显著差异。计算的晶界滑移贡献率在拉伸条件下显著高于压缩条件的,这是由于在拉伸时晶界上更易产生孔洞形核。     

超音速等离子喷涂WC/Co纳米结构涂层性能研究

采用超音速等离子喷涂设备分别制备了含纳米结构和普通结构的WC／Co涂层。研究了2种涂层的结合强度、显微硬度和摩擦磨损性能，并用扫描电镜(SEM)和透射电镜(TEM)对涂层喂料(纳米WC／Co粉体)、涂层表面形貌和晶粒结构进行了分析。结果表明：含纳米结构涂层的性能优于普通的WC／Co喷涂涂层，纳米晶粒细晶强化是涂层性能提高的主要原因。     

Resistance and friction stir spot welding of DP600: a comparative study

Abstract

Efforts to reduce vehicle weight and improve crash performance have resulted in increased application of advanced high strength steels (AHSS) and a recent focus on the weldability of these alloys. Resistance spot welding (RSW) is the primary sheet metal welding process in the manufacture of automotive assemblies. Friction stir spot welding (FSSW) was invented as a novel method to spot welding sheet metal and has proven to be a potential candidate for spot welding AHSS. A comparative study of RSW and FSSW on spot welding AHSS has been completed. The objective of this work is to compare the microstructure and mechanical properties of Zn coated DP600 AHSS (1·2 mm thick) spot welds conducted using both processes. This was accomplished by examining the metallurgical cross-sections and local hardnesses of various spot weld regions. High speed data acquisition was also used to monitor process parameters and attain energy outputs for each process. Results show a correlation found among microstructure, failure loads, energy requirements and bonded area for both spot welding processes.