Studies on the potential risk of liquid metal assisted cracking (LMAC) in normal‐temperature and high‐temperature hot‐dip galvanizing of high strength bolts of dimensions greater M24

Liquid metal assisted cracking (LMAC) mainly occurs due to an unfavorable interaction of three factors: a susceptible material condition, presence of a liquid metal and sufficient tensile stress. Hot‐dip galvanizing of high‐strength bolts induces high thermal loads in bolts made of tempered steel in the presence of a zinc melt and thus, provides the boundary conditions for the above mentioned critical factors to interact. The focus of this study is on investigating thermally‐induced stresses in large diameter bolts and their impact on the formation of liquid metal assisted cracking (LMAC). In order to calculate the thermal loads in hot‐dip galvanizing, simulations were carried out regarding the thermo‐mechanical behavior of bolts during the hot‐dip galvanizing process. The simulations illustrate that cracks are most likely to occur in the first thread turn. This prediction is confirmed by experimental observations.     

Fatigue assessment of cut edges in high strength steel – Influence of surface quality

The influence of surface roughness on the fatigue strength in high strength steels and different cutting processes are studied. Fatigue testing is conducted on S700 and S960 material for different plate thicknesses cut in dog bone specimens using oxygen, plasma, laser and waterjet cutting. The surface roughness is measured for all specimens and residual stress measurements are carried out. Estimations of the fatigue strength are made based on the measured surface roughness and the ISO 9013:2002 standard for thermal cutting quality tolerances. The testing shows a 15–70 % increase in the fatigue strength compared to the estimation, proving a weak connection between the surface quality levels in ISO 9013:2002 and the fatigue test results. Different codes and design recommendations (IIW, EC3 and EN 13001) for fatigue strength of cut surfaces are compared with the fatigue test results which clearly shows an increased fatigue strength with enhanced quality and steel grades. However, the codes and design recommendations do not allow for any fatigue strength improvement with improved quality and increased yield strength.     

ZnNi – Beschichtung hochfester Bauteile aus Stahl

ZnNi – Plating of high strength steel components Pre‐treatment and electroplating as well as post‐plating treatment of especially low alloyed high tensile strength steel components can be followed by a delayed hydrogen‐induced fracture known as hydrogen embrittlement. The entire coating process has to be controlled to avoid any failure. Most important is, that atomic hydrogen being evolved during the coating process and penetrating into the base metal after all shows an subcritical concentration within the system with respect to the mechanism of hydrogen embrittlement. Generally this will be obtained by a suitable post‐plating heat treatment of the coated components. There is evidence however that under special conditions for ZnNi – plating from alkaline solution this is not necessary. Results are reported concerning the nucleation and crystal growth and the hydrogen diffusion through ZnNi‐deposits. Further on hydrogen depth profiles of coated components and their mechanical properties will be presented and discussed.     

Einfluss der Mikrostruktur auf das Verschleiß‐ verhalten der hartanodisierten Aluminium‐legierungen EN AW‐6082 und EN AW‐7075

Microstructural effect on the wear behaviour of the hard‐anodised aluminium alloys EN AW‐6082 and EN AW‐7075 The suitability of hard‐anodising of high‐strength Al alloys (EN AW‐7075‐T651) for the fabrication of protective coatings which are also applicable on screws was investigated. A medium‐strength AlSi1MgMn alloy (AA60682‐T6), generally rated as applicable for anodising, was used as reference material. After possible setting phenomena of a screw joint, the load‐bearing surface of the screw can be subjected to an oscillating relative movement. The damaging tribological load was simulated in an oscillation wear test. The resulting wear appearances have revealed that the untreated oxide coatings on the EN AW‐6082 substrate are not capable of providing protection against tribological load. Since hot‐water sealing increases the hardness of the coating but also contains the technology‐induced risk of softening the substrate material, other tribological protection methods have been looked for. The analysis of the tribological tests (characterisation of the structure and the resulting properties of the material, measurement of the wear amount and analysis of the wear appearance) have shown that the films sealed with wax emulsion on both substrate materials are the most promising candidates for the application of devices under oscillation wear. The obtained roughness, friction coefficients and hardness values confirm the positive behaviour of the anodically oxidised EN AW‐7075‐T651 alloy under the chosen tribological load.     

Entwicklung eines praxisgeeigneten Prüfverfahrens zur Bewertung des Wasserstoffgefährdungspotenzials von Salzsäurebeizen und zum Vergleich der Wirksamkeit von Inhibitoren

Development of a field-suitable test method to evaluate the danger of hydrogen embrittlement due to hydrochloric acid pickling bathes and comparison of the effectiveness of pickling inhibitors Within the scope of the before hot dip galvanizing necessary treatment in pickling bathes, which are mostly run with hydrochloric acid the possibility of development of atomic hydrogen on the steel surface is given. The subsequent described trials aimed at making the process of hot dip galvanizing of high tensile fasteners, which are possibly susceptible of cracking due to influences of hydrogen because of their high tensile strength, more controllable under aspects of quality assurance and possibly improve the process. The field-suitable test method for process monitoring of inhibited pickling bathes is realized by tension tests. The test method works with locking rings according to DIN 471 in a specially developed tensioning device. The safety of the indication of the test method is proved by the comparison of the results with those achieved with other test methods achieved with the same pickling bathes. The “safety of iteration” of the developed test method is proved by similar results of trials with samples from different charges of production and heat treatment. As a consequence the tension test is qualified as test method for the field. In addition it requires little time and expenses, is easy to handle and has a robust and fault-tolerant construction. With the testing scheme developed during the project it is moreover possible to evaluate capaciously the effectiveness of inhibitors for the pickling of high-tensile fasteners.