Brinell Hardness Research Articles

Effect of Co Addition on the Microstructure and Mechanical Properties of Sn-11Sb-6Cu Babbitt Alloy

A Babbitt alloy SnSb11Cu6 with 0–2.0 wt.% Co was synthesized using the induction melting process. This study examined the effect of cobalt (Co) on the microstructure, tensile properties, compressive properties, Brinell hardness, and wear properties of SnSb11Cu6 using optical microscopy (OM), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD), a universal tensile testing machine, a Brinell hardness tester, and a wear testing machine. The results indicate that the optimal quantity of Co can enhance the microstructure of the Babbitt alloy and promote microstructure uniformity, with presence of Co3Sn2 in the matrix. With the increase in Co content, the tensile and compressive strength of the Babbitt alloy first increased and then decreased, and the Brinell hardness gradually increased with the increase in Co content. The presence of trace Co has a minimal effect on the dry friction coefficient of the Babbitt alloy. When the Co content exceeds 1.5 wt.%, the friction properties of the Babbitt alloy deteriorate significantly. The optimized Babbitt alloy SnSb11Cu6-1.5Co was subsequently fabricated into wires, followed by conducting cold metal transfer (CMT) surfacing experiments. The Co element can promote the growth of interfacial compounds. The microstructure at the interface of the Babbitt alloy/steel is dense, and there is element diffusion between it. The metallurgical bonding is good, and there are serrated compounds relying on the diffusion layer to extend to the direction of the additive layer with serrated compounds extending and growing from the diffusion layer to the additive layer. Overall, Babbitt alloys such as SnSb11Cu6 exhibit improved comprehensive properties when containing 1.5 wt.% Co.

The Influence of Er and Zr on the Microstructure and Durability of the Mechanical Properties of an Al-Mg Alloy Containing 7 wt.% of Mg.

Al-Mg alloys are characterized by permanent solid solution hardening and can additionally be work-hardened. The high mechanical properties of Al-Mg alloys with above-standard Mg content obtained after plastic deformation processes decrease over time. The addition of minor alloying elements like Er or Zr is an alternative method to improve the durability of mechanical properties and increase the strength of Al-Mg alloys due to densely and evenly distributed dispersoids being formed. In this paper, Al-Mg alloys with above-standard Mg content (7 wt.%) and Zr and Er micro-alloying elements and their influence on the microstructure and durability of the mechanical properties were examined. The cast ingots of AlMg7 alloys were characterized by a smooth surface without cracks. The plastic deformation process in a static compression test resulted in an about 60 HBW increase in the Brinell hardness of all the deformed alloys relative to casting. It was revealed that the addition of Er and Zr significantly improved the mechanical properties and durability of the mechanical properties of the Al-Mg after annealing. The addition of Er or Zr slightly restrained the decrease in the Brinell hardness after annealing but did not inhibit it.

Mechanical and micro-structural characterization of biodegradable coir fiber–glass sheet–charcoal reinforced polymer composite: an experimental approach

In the present investigation, the combined influence of coir, glass fibers and charcoal content on the mechanical properties of epoxy-based hybrid composites has been explored, providing insights for the potential development of advanced materials with tailored performance characteristics. Through a systematic analysis of the mechanical properties (tensile strength, Young's modulus, flexural strength, flexural modulus, and Brinell hardness number), various composite formulations were evaluated to discern their performance characteristics. The study reveals significant variations in mechanical properties across different composite configurations, highlighting the critical role of fiber type and charcoal content in determining the materials’ performance. Notably, composites featuring alternating layers of glass and coir fibers exhibit superior tensile and flexural strengths, underscoring the synergistic effects of hybridization. Conversely, the introduction of charcoal as a reinforcement agent leads to deterioration in the mechanical properties, indicating a trade-off between the reinforcement and other desirable attributes. These findings offer valuable insights for the strategic design and engineering of advanced materials tailored to specific applications, paving the way for the development of high-performance epoxy-based hybrid composites with enhanced mechanical properties and durability.

Evolution of Microstructural and Mechanical Properties of Alloy 617B During Service on a Key-Component Test Platform at 700 °C.

The evolution of the microstructural and mechanical properties of alloy 617B during long-term service on a key-component test platform at 700 °C was systematically investigated. The precipitation behavior and size changes of the M23C6 and γ' phases were characterized by scanning electron microscopy (SEM) and transmission electron microscopy (TEM). The results showed that carbide M23C6 precipitated in the form of discontinuous particles, plates, or needles at grain boundaries and within grains, while the γ' phase had a spherical shape and was distributed in a dispersed manner. With prolonged service time, both the M23C6 and γ' phases gradually coarsened. After 24,000 h of service, the yield strength, tensile strength, and Brinell hardness of alloy 617B significantly increased; however, the impact toughness decreased, accompanied by intergranular embrittlement. The increase in precipitate volume fraction and its contribution to the strength of the alloy were evaluated by a precipitation strengthening model. The coarsening of M23C6 was identified as the main cause of embrittlement. The findings of this study provide important experimental data and theoretical support for the stability of 617B alloys under long-term high-temperature service conditions.

Development and characterization of sustainable epoxy resin composites reinforced with palm kernel shell particulate and sisal fiber

This study explores the development and characterization of epoxy resin composites reinforced with palm kernel shell (PKS) particulate and sisal fibers, aiming to create sustainable and high-performance materials. Elemental composition analysis using energy dispersive X-ray revealed significant increases in carbon and oxygen content with higher PKS particulate content, indicating successful reinforcement integration. The mechanical properties were evaluated through Brinell hardness, impact energy, impact strength, tensile stress, and wear resistance tests. The Brinell hardness increased from 31.8 kg/mm2 in the control sample to a peak of 60.6 kg/mm2 in sample SP4, demonstrating enhanced hardness with PKS particulate addition. Impact tests identified an optimal reinforcement level in sample SP3, which achieved the highest impact energy (83 J) and impact strength (47.43 kJ/m2). Tensile stress analysis showed a maximum tensile stress of 28.7991 MPa for SP3, while excessive PKS content in SP4 reduced this to 20.4612 MPa. Wear tests indicated a trade-off between mechanical reinforcement and wear resistance, with the control sample exhibiting the lowest wear rates and SP4 the highest having a 91.9% increase. Based on the obtained results, SP3 with 0.8 g PKS particulate, 0.2 g sisal fiber in epoxy resin matrix seems the optimized composite with enhance mechanical properties without compromising wear resistance.

Study on Mechanical and Microstructural Evolution of P92 Pipes During Long-Time Operation

To investigate the mechanical properties and microstructure evolution of P92 steel during long-term service, the operated P92 main steam pipes from the first ultra-supercritical units in China were sectioned into samples representing various service durations and stresses (0# (as-received state, 1# (82,000 h, 67.3 MPa), 2# (85,000 h, 78.0 MPa), and 3# (100,000 h, 80.3 MPa)). Thereafter, a comprehensive assessment of their mechanical properties, including tensile strength, impact, hardness, and creep resistance, as well as a detailed microstructure analysis, was carried out. The effect of stress on the aging of material properties during operation is discussed. The results show that the circumferential stress caused by the increase in the internal steam pressure can significantly promote the creep life consumption of P92 steel, resulting in the degradation of mechanical properties and the expedited aging of the microstructure. The Rp0.2 and Rm of the P92 main steam pipe at room temperature and 605 °C decreased with the service time increase, reflecting the influence of stress in operation, which is expected to be used for the residual life evaluation of P92 steel. The relationship between the impact absorption energy (FATT50), Brinell hardness, and the operating time of P92 operating pipes is non-monotonic, indicating that these parameters are not sensitive indicators of material aging due to stress. The evaluation of performance degradation in P92 operating pipes due to stress-induced aging is not reliably discernible through optical metallography alone. To achieve a thorough assessment, the use of transmission electron microscopy (TEM) is essential.

Thermal modification of fast-growing Firmiana simplex wood using tin alloy: Evaluation of physical and mechanical properties

Wood is an important structural material, but some undesirable properties limit its application in construction. This study investigated the effect of tin alloy thermal modification (TTM) on selected physical and mechanical properties of Firmiana simplex (Chinese bottletree) wood. Tin alloy thermal modification of F. simplex was performed in a tin alloy bath at two different temperatures (150 oC and 210 oC for 2 h and 8 h). Physical properties such as swelling, water absorption and density and mechanical properties like modulus of elasticity, modulus of rupture, impact bending, compression strength and Brinell hardness of tin alloy thermal modified and control samples were evaluated. The results showed that tin alloy thermal modification decreased the swelling of the wood to 4,85 %, 1,45 % and 6,99 % along the tangential, radial and volumetric coefficient and water absorption and density decreased to 53,10 % and 290 kg/m3 respectively compared to the control. Modulus of elasticity, modulus of rupture, impact bending, compression strength and Brinell hardness of tin alloy thermal modified F. simplex at 210 °C for 8 h decreased to 6366,1 MPa, 54,9 MPa, 2,7 MPa, 29,4 MPa and 1113,5 MPa respectively compared to the control. In conclusion, the tin alloy thermal modified wood at 210 oC significantly affected the physical and mechanical properties of the wood.

Optimization of TIG welding process parameters using Taguchi technique for the joining of dissimilar metals of AA5083 and AA7075

This research paper aims to optimize the TIG welding parameters to join dissimilar metals of AA5083 and AA7075 using the Taguchi technique. The TIG welding current and root gap of butt geometry configuration are considered input parameters, and welding characteristics such as tensile strength, 0.2% of yield strength, hardness, and impact energy are output responses. The base metals are joined according to the Taguchi L-09 design of experiments. The welded samples were inspected using the X-ray radiography method for internal defects. Tensile properties, hardness number, and impact energy of different welding coupons were evaluated by conducting the uni-axial testing, a Brinell hardness test, and an Izod impact test, respectively. A better weld strength of 224 MPa was observed at 210 A welding current, and the root gap of 1.5 mm was maintained. Better hardness and impact energy values were observed when the root gap of 1.5 mm and welding current of 220 A were maintained. The root gap is the primary factor influencing tensile strength enhancement, which accounts for 44.78% of the effect, followed by 40.5% welding current. Root gap is the parameter that affects the tensile properties, hardness number, and impact toughness the most. The findings of this paper suggest the optimal parameters for welding AA5083 and AA7075 dissimilar base metals, which are suitable for complex structures requiring both durability and resistance to harsh environments.

Effects of Solidification Thermal Variables on the Microstructure and Hardness of the Silicon Aluminum Bronze Alloy CuAl6Si2

The properties of the final product obtained by solidification directly result from the thermal variables during solidification. This study aims to analyze the influence of thermal solidification variables on the hardness, microstructure, and phases of the CuAl6Si2 alloy. The material was solidified using unidirectional solidification equipment under non-stationary heat flow conditions, where heat extraction is conducted through a water-cooled graphite base. The thermal solidification variables were extracted using a data acquisition system, and temperature was monitored at six different positions, with cooling rates ranging from 217 to 3 °C/min from the nearest to the farthest position from the heat extraction point. An optical microscope, scanning electron microscope (SEM), and X-ray diffraction (XRD) were used to verify the fusion structure and determine the volumetric fraction of the formed phases. The XRD results showed the presence of β phases, α phases, and possible Fe3Si2 and Fe5Si3 intermetallics with different morphologies and volumetric fractions. Positions with lower cooling rates showed an increased volume fraction of the α phase and possible intermetallics compared to positions with faster cooling. High cooling rates increased the Brinell hardness of the alloy due to the refined and equiaxed β metastable phase, varying from 143 HB to 126 HB for the highest and lowest rates, respectively.

Mechanical Properties and Tribological Study of Bottom Pouring Stir-Cast A356 Alloy Reinforced with Graphite Solid Lubricant Extracted from Corn Stover

The present work epitomises extracting the graphite (Gr) solid lubricant from the corn stover. The extracted Gr was incorporated as reinforcement in the A356 alloy (Al-7Si), and the effect of the Gr particles on the mechanical and tribological properties was investigated. In spite of this, the input process parameters for the dry sliding wear test at room temperature against the EN31 steel disc were optimised through ANOVA analysis. The fabricated A359—X wt% (X = 0, 2.5, 5, 7.5) composite through bottom pouring stir casting techniques was analysed microstructurally by using XRD and FESEM analysis. The micro Brinell hardness and tensile strength were investigated per ASTME10 and ASTME8M standards. A wear test was performed for the composite pins against the EN31 steel disc according to ASTM G99 specifications. The XRD analysis results depict the presence of carbon (C), aluminium (Al), and silicon (Si) in all the wt% of the Gr reinforcement. However, along with the elements, the Al2Mg peak was confirmed for the A356—7.5 wt% Gr composite and the corresponding cluster element was confirmed in FESEM analysis. The maximum micro Brinell hardness of 92 BHN and U.T.S of 123 MPa and % elongation of 7.11 was attained at 5 wt% Gr reinforcement due to uniform Gr dispersion in the A356 alloy. Based on the ANOVA analysis, the optimal process parameters were obtained at 20 N applied load, 1 m/s sliding velocity, and 1000 m sliding distance for the optimal wear rate of 0.0052386 g/km and 0.364 COF.

Development of Automotive and Marine Appliable Aluminium Composite by Utilizing Agro-Waste Material as Performance Enhancement Particles

Aluminium-based materials are lightweight materials used for producing automotive and aircraft components. However, aluminium materials diminish in performance on exposure to degrading environments, which limits their areas of usage and applications. The degrading effect results in poor resistance to wear and corrosion, reduced properties and defective microstructure. In this work, 6063 aluminium alloy was reinforced with particles of agricultural waste (walnut shell) to produce six samples with five samples of reinforced and a control (unreinforced) sample. Each of the samples of the reinforced alloy was moulded into a 25 mm diameter by 130 mm height using the stir casting method using an industrial pit furnace. The samples were thereafter machined to a diameter of 20 mm and cut into a thickness of 10 mm for characterizations. The potentiodynamic polarization method was used to test for the samples’ corrosion resistance properties following the ASTM G102 standard in 3.65% NaCl test medium. The hardness property was investigated using the Brinell hardness machine following the ASTM A-370 standard, while the microstructure and crystallographic phase studies were carried out using SEM/EDS and XRD profiles, respectively. The unreinforced 6063 Al alloy sample exhibited the highest corrosion rate (Cr) of 0.7321 mm/year and the lowest hardness of 104.94 kgf/mm2. The 10% wt. walnut shell particles (WSP) reinforced 6063 Al alloy sample exhibited the lowest corrosion rate (Cr) of 0.1336 mm/year and the highest hardness of 109.24 kgf/mm2. This indicated that the walnut shell particles enhanced the corrosion and indentation resistance of the alloy. In addition, the SEM images indicated that the agricultural waste (walnut shell particles) reinforced samples exhibited more refined microstructure, lower porosity and smoother morphology compared to the unreinforced (control) sample. Also, the XRD profile of samples revealed some high peak intensity crystallites such as Al(ZnS), Al2O3 and (FeMn)SiO2. These high peak intensity crystallites indicated that these reinforced samples possessed chemical and microstructural homogeneity, high stability and good surface texture.

Analysis of Fracture Reason of Transmission Shaft of Screw Drilling Tool in a Certain Well

Abstract During the drilling process of a certain well in an oil field, the transmission shaft of the screw drilling tool broke. According to research, the screw drilling tool is brand new and has been in use for only 63.5 hours, indicating early failure. The fracture of the transmission shaft of the screw drilling tool is flat and severely worn, and the fracture is located at the change in diameter. In order to analyze the causes of the tool’s failure and avoid similar accidents, this article conducted non-destructive testing, macroscopic fracture analysis, chemical composition analysis, tensile performance testing, Charpy impact testing, Brinell hardness testing, metallographic analysis, microscopic analysis, and a comprehensive analysis of the failed transmission shaft of the spiral drilling rig. Through a series of analyses, it is believed that this tool belongs to fatigue fracture. The main reason is the presence of quenching cracks in the matrix structure near the fracture surface, which does not comply with industry standards. At the same time, before the screw drilling tool was put into use in the well, the operator did not conduct a flaw detection on the transmission shaft body according to the standard, so that quenching cracks were not detected in advance. After entering the well, the transmission shaft undergoes rapid propagation of quenching cracks under variable load, ultimately leading to early fatigue failure. This article suggests that manufacturers optimize the heat treatment process of screw drilling tool transmission shafts to improve product quality and prevent quenching cracks from appearing in the body. At the same time, operators should strictly follow the standards for non-destructive testing to avoid drilling tools with quality issues from entering the well for use.

Preparation, Mechanical Properties, and Degradation Behavior of Zn-1Fe-xSr Alloys for Biomedical Applications.

As biodegradable materials, zinc (Zn) and zinc-based alloys have attracted wide attention owing to their great potential in biomedical applications. However, the poor strength of pure Zn and binary Zn alloys limits their wide application. In this work, a stir casting method was used to prepare the Zn-1Fe-xSr (x = 0.5, 1, 1.5, 2 wt.%) ternary alloys, and the phase composition, microstructure, tensile properties, hardness, and degradation behavior were studied. The results indicated that the SrZn13 phase was generated in the Zn matrix when the Sr element was added, and the grain size of Zn-1Fe-xSr alloy decreased with the increase in Sr content. The ultimate tensile strength (UTS) and Brinell hardness increased with the increase in Sr content. The UTS and hardness of Zn-1Fe-2Sr alloy were 141.65 MPa and 87.69 HBW, which were 55.7% and 58.4% higher than those of Zn-1Fe alloy, respectively. As the Sr content increased, the corrosion current density of Zn-1Fe-xSr alloy increased, and the charge transfer resistance decreased significantly. Zn-1Fe-2Sr alloy had a degradation rate of 0.157 mg·cm-2·d-1, which was 118.1% higher than the degradation rate of Zn-1Fe alloy. Moreover, the degradation rate of Zn-1Fe-xSr alloy decreased significantly with the increase in immersion time.

Determination of Dynamic Stresses and Displacements under the Action of an Impact Load on a Two-Layer Structure during the Indentation Process

Introduction. Numerous researchers of the reliability of building structures pay attention to hardness, an important characteristic of the structural material. It is determined by indentation — pressing the tip of the tool into the surface. The advantages of dynamic indentation methods and the distribution of stress intensity on the surface and inside the sample are investigated. However, the condition of layered materials on impact has been poorly studied. The objective of the presented work is to consider indentation for a two-layer sample and determine the sensitivity of the top layer to the strength of the substrate. This will allow us to identify significant characteristics of the strength properties of homogeneous and heterogeneous structures.Materials and Methods. An elastoplastic model of material behavior and a shock indentation scheme were used, which took into account the masses of the indenter and the striker coupled by linear springs. The surface of the indenter was conical, the opening angle was 120°. The impact was simulated in the MATLAB system. Finite element model in Ansys APDL was used to verify the data and analyze the results of the experiment. Traditional models of elasticity theory were used for calculations. The behavior of the material in the zone of plastic deformation was described using the options of multilinear isotropic hardening and the von Mises plasticity criterion.Results. The results of comparing three versions of varying the level of yield strength in the bottom layer are presented: when the yield strength in the bottom layer is half as high as the top one, equal to it, and twice as high. Displacements at different observation points for samples with a top layer of 2 mm and 1 mm were analyzed. In the first case, under horizontal shear, the displacement indices inside the sample did not change if the yield strength level was twice lower or higher than in the top one. If these indicators were equal, the difference became noticeable. In the second case (layer 1 mm), the difference in displacement was visible at all observation points. Thus, it can be reasonably concluded that a structure with a smaller top layer is more sensitive to impact. In the course of the research, it became known that vibrations associated with the transition to the plasticity zone occurred in the 2 mm zone, and elastic damping vibrations occurred below this zone. We solved the classification problem for the top layer of the material with changing characteristics of the base. The indicator for comparison was the Brinell hardness (HB) in the range of 200–600. The results were processed using a neural network and visualized in the form of graphs. The accuracy of its calculations was 98%.Discussion and Conclusion. To determine the strength properties of homogeneous structures, it is sufficient to characterize the speed of displacement inside the sample. For an inhomogeneous structure, additional parameters should be introduced — displacements on the surface and inside the sample at fixed observation points. An integrated approach to determining the strength properties of an inhomogeneous structure improves the accuracy of calculations, and the use of neural networks increases their speed.

Dependence of wear of friction pairs of the mechanism for loading solid household waste into a garbage truck on the characteristics of antifriction materials

The article is dedicated to the establishment a regression dependence of wear of friction units of the mechanism of loading a garbage truck on the properties of antifriction materials. By using a first-order planning of experiment with first-order interaction effects using the Box-Wilson method, an appropriate regularity of wear of friction units of the garbage truck loading mechanism on the properties of antifriction materials has been determined. It is established that, according to the Student's criterion, among the studied factors of influence, the wear of friction units of the garbage truck loading mechanism is most influenced by the pressure in the friction zone, and the least – by the Brinell hardness of the antifriction material. The response surfaces of the objective function – wear of friction units of the garbage truck loading mechanism and their two-dimensional cross-sections in the planes of the influence parameters are shown, which allow to clearly illustrate the specified dependence of this objective function on individual influence parameters. It has been established that an increase in the pressure in the friction zone and sliding speed by 60% leads to an increase in the wear of friction units of the garbage truck loading mechanism during reverse motion by 6.3...34%, depending on the properties of antifriction materials. The expediency of conducting further research to determine ways to further improve the wear resistance of friction units of the mechanism for loading solid household waste into a garbage truck has been shown.

Effect of Low-Temperature Tempering Temperature on the Mechanical Properties of NM500 Wear-Resistant Steel

Abstract In order to explore the effect of low temperature tempering heat treatment temperatures on Brinell hardness (HB), impact absorption energy (KV2) and tensile mechanical properties of NM500 wear-resistant steel, isothermal tempering heat treatment of NM500 wear-resistant steel sheets after quenching were carried out at 200~260 °C. The microstructures, Brinell hardness, -20 °C impact energies and tensile mechanical properties of NM500 wear-resistant steel after tempered were analyzed by optical microscope, Brinell hardness tester, pendulum impact testing machine and tensile testing machine respectively. The results show that when the tempering temperature increases from 200 °C to 260 °C, the Brinell hardness of NM500 wear-resistant steel decreases from 490 HBW to 460 HBW, the offset yield strength (Rp0.2) decreases from 1396.3MPa to 1351.0MPa, and the tensile strength (Rm) decreases from 1708.5 MPa to 1615.0 MPa. However, the low temperature tempering temperature has no significant effect on the microstructure and elongation after fracture. According to GB/T 24186-2022, 200~220 °C is the suitable low temperature tempering temperature range for NM500 wear-resistant steel.

Characterization of the hydrostatic core and plastic zone that form during Brinell and Vickers hardness tests

Abstract During a hardness test, a hydrostatic core and a plastic zone are formed under the impression due to the load. The size and shape of the hydrostatic core and the plastic zone are greatly influenced by the tested material, the loading force and the shape of the indenter. In this study, we examine in detail the characteristics of the hydrostatic core and plastic zone formed during a Brinell and Vickers hardness test with the same (bilinear) hardening material model and with the same load using the finite element method in the ANSYS environment. The results of our resarch is concluded that the characteristics under the indenter can be determined well with finite element modeling and in the case of the Vickers procedure, the ratio of the hydrostatic core to the plastic zone is greater for all loads as in the case Brinell method.

Arc erosion behaviour of Cu–diamond composites at different load voltages in air atmosphere

ABSTRACT To investigate the arc erosion performance of Cu–diamond composites, Cu–5vol.-% diamond composites were fabricated using the hot-pressing sintering method. Compared to pure copper, Cu–5vol.-% diamond composites exhibited improvements in Brinell hardness of 60.1 HB. The relative density and electrical conductivity of Cu–5vol.-% diamond composites were 97.54% and 83.29% IACS (International Annealing Copper Standard), respectively, with no significant decrease compared to pure copper. The thermal conductivity was 423.48 W·(m·K)−1, showing a slight enhancement. The effect of different load voltages on the arc erosion behaviour of Cu–5vol.-% diamond composites was investigated. Experimental results indicated that as the voltage rose from 3 to 7 kV, the breakdown strength decreased from 7.164 × 106 V m–1 to 2.535 × 106 V m–1, while the arc duration increased from 21.752 × 10−3 s to 28.864 × 10−3 s, and the breakdown current rose from 10.8 to 27.2 A. Additionally, the presence of diamond particles enhanced the viscosity of the molten pool, thus the splashing phenomenon of copper liquid during arc discharge was not obvious, indicating that the material loss was small. Few cracks and holes were detected. The Cu–5 vol.-% diamond composites possess good resistance to arc erosion.

Influence of submerged arc welding process parameters and metallurgical behaviour in a thick carbon steel section for boiler application

AbstractThe aim of the research is to investigate the weldability of thick sections of carbon steel using submerged arc welding with varying process parameters. The experimental design for joining thick carbon steel involves manipulating input weld process parameters such as current (A), voltage (V), weld speed (mm/h), and weld electrode diameter (mm). The quality of the weld material is assessed based on transformations in microstructure, weld hardness measured by Brinell hardness number, and tensile strength (MPa). It is crucial to note that the grain structure and metallurgical behavior of other hard materials may differ significantly. The presence of carbon in the ferrite phase has led to the formation of bainite, martensite, and composites of martensite and austenite within the weld zone, as confirmed by high‐resolution microscopy. The weldment‘s hardness has increased from 242.5 HV 30 in the base metal to 316.4 HV 30 in the weldment due to metallurgical alterations in the microstructure. Weld energy input emerges as the primary factor influencing weld quality. With increasing weld current and voltage, there is a corresponding increase in the joined metal, resulting in improved characteristics in the weld structure, particularly at maximal energy input and welding speed. In the context of boiler applications, understanding the weldability of thick carbon steel sections is paramount for ensuring structural integrity and longevity under high‐temperature and high‐pressure conditions. The optimized welding parameters identified in this study can contribute to enhancing the reliability and performance of boilers, thereby promoting safety and efficiency in industrial settings.

Current-carrying tribological properties and wear mechanisms of Mo-containing Cu alloy coatings produced by laser cladding

Copper alloy-molybdenum coatings were prepared on the surface of Cu-Cr-Zr alloys by laser cladding. The phase and microstructure were observed, and the hardness, conductivity, friction and wear properties under current-carrying conditions were tested. The results indicate that the prepared coatings exhibit good metallurgical bonding with the substrate. The Brinell hardness of the coatings ranges from 60 to 105 HB, and the electrical conductivity ranges from 17 % to 27 % IACS. The primary wear mechanism is abrasive wear and adhesive wear without current, resulting in the detachment of the Mo phase and transfer of the Cu phase during the sliding process. And it shifts to severe adhesive wear under current-carrying conditions, leading to the formation of aluminum deposit on the coatings.