Heat Treatment Cycles Research Articles

Very-High-Cycle Fatigue Behaviors for Bearing Steel Microstructural Transformation

It has been reported that the multiphase structure with martensite and a mixed structure obtained by the quenching and tempering of bearing steel shows high strength and ductility. However, there appears to be no study on the effects of very-high-cycle fatigue (VHCF) and ultrasonic nanocrystal surface modification (UNSM) of a new bearing steel required for the durability design of next-generation bearing steel. This study analyzed the characteristics of microstructure transformation associated with heat treatment cycles and studied and evaluated the fatigue strength characteristics by the UNSM. Fisheye cracks occur from small inclusions inside the specimen only in martensitic microstructure materials in the long-life range. And the characteristic of a double S-N curve in which the fatigue limit decreased in two stages appeared. However, fisheye cracks and double S-N curves did not appear in pearlite and mixed-structure materials.

Unravelling the dominant influence of microsegregation on creep rupture behaviour of additively manufactured inconel 718

This investigation focuses on unravelling the dominant influence of microsegregation and microstructure altered due to heat treatment cycle variation on creep rupture behaviour of additively manufactured Inconel 718 (AM-IN718). Two microstructural variants differing in the fraction of recrystallized grains while δ-phase being absent, were produced. A typical heat treatment (HT) cycle includes the stress-relieving of the as-built specimens at 980 °C, followed by solution treatment at 1080 °C (STA1080, a partially recrystallized microstructural variant) or 1150 °C (STA1150, a fully recrystallized microstructural variant), and double ageing (soaking at 720 °C for 8h and subsequent furnace cooling, followed by 8h at 620 °C and air cooling).Detailed microstructural characterization of two microstructural variants through correlative microscopy revealed a prevalent existence of Nb-rich precipitate-free zones (PFZ) in STA1080 than in STA1150. Creep characterization of the two microstructural variants in the temperature range of 625–675 °C and at 500–750 MPa demonstrated superior creep resistance in STA1150. The correlation of kinetic analysis and comprehensive post-deformation microstructural characterization suggests grain boundary cavitation as the main damage/softening mechanism and the reason for the difference in creep rupture behaviour between the two microstructural variants. The long-term exposure heat treatment methodology demonstrates that PFZs are the major influencing factor responsible for microsegregation-dependent creep rupture behaviour. Interestingly, the presence of the δ phase within PFZs appeared to retard cavity coalescence and failure during creep, despite its usual detrimental role in creep resistance.

Comparative study of microstructural evolution and mechanical properties in friction stir processed, reinforced friction stir processed, and heat-treated reinforced friction stir processed Al composites

The development of friction stir welding (FSW) created the basic foundation for friction stir processing (FSP). This process entails refining the local microstructure and achieving the localised plastic deformation due to the stirring effect of the tool, which may involve adding additional filler material as required. The rotating tool involved in the process has a shoulder and pin responsible for heat generation for plastic deformation and localised mixing. The rotating tool is inserted and traversed on the desired surface, tailoring the material properties. The tool’s exposure to the surface causes localised plastic deformation and thermal gradient, and microstructural changes occur locally. The present investigation uses Friction Stir Processing (FSP) to fabricate an aluminium metal matrix composite. Recently, the use of aluminium alloy has been replaced by composites because of their increased mechanical and physical properties (specific properties). The experiment leads to manufacturing an aluminium metal matrix composite using aluminium oxide, boron carbide and commercially pure copper dust. Later, the effect of heat treatment on the respective metal matrix composite is studied. A comparative study among three different types of FSP techniques viz. FSP, Reinforced FSP, and Heat-treated Reinforced FSP have been performed. The tool revolution speed (RPM) and tool traverse speed of 400 RPM and 10 mm/min had been implemented, respectively. The T4 Heat-Treatment cycle was used during the current investigation. This investigative study was performed to analyse the changes in grain sizes and hardness values at the stir zone (SZ), thermo-mechanically affected zone (TMAZ), heat affected zone (HAZ) and on the base materials (BM) of the samples. The reinforced FSP metal matrix composite (MMC) showed an 81.26% increase in the micro-hardness value (HV) compared to the base metal. Further on analysing the microstructures, the reinforced FSP composite showed a 65.20% reduction in grain size. Moreover, the Heat-Treated sample showed an increase in the micro-hardness value by 99.8%.

Numerical and experimental studies on the effect of cryogenic treatment on welding residual stress of TIG welded EN8 steel plate

Most of the conventional welding process induces Welding Residual Stress (WRS), hydrogen embrittlement and distortions to welded components. The post-weld mechanical behaviour has an impact on both structural integrity and operational effectiveness of the welded component. Traditional Post Weld Heat Treatment (PWHT) is capable of relieving WRS to some extent. Based on recent research, Heat Treatment (HT) cycles are comprised of conventional HT and Cryogenic Treatment (CT) gives better fatigue life to welded components by redistributing the residual stress field. There is a need for further research to explore the impact of different parameters of CT affects the mechanical behaviour of welded specimens. In this study, numerical and experimental investigations are conducted to understand the impact of HT cycles comprised of austenitizing, quenching, CT and tempering process, over the TIG welded EN8 plates. Numerical model is developed for predicting the variation in WRS with each stage of HT cycles and observed a considerable redistribution of WRS after the completion of proposed HT cycle. Using the proposed HT cycle, the influence of different soaking periods of CT over the welded components are studied experimentally and shows that 36 hours soaking period have higher impact on the welded component’s mechanical behaviour.

The improvement of dry sliding tribological properties by designing nano-primary cementite in bainitic/martensitic matrix microstructure in hypereutectoid PM components

The production of nano-sized primary cementite in bainite/martensite matrix (NCBM) microstructure was designed to improve the dry sliding wear properties of high carbon PM parts. A different heat treatment cycle was carried out for the production of novel the NCBM microstructure. High purity iron powder 1.5 wt%. natural graphite powder was added and it was compacted in the form of a dry sliding wear test specimen in a mold and sintered at 1200 °C in a pure Ar gas atmosphere. The novel NCBM microstructure in the PM material was produced by quenching at 950 °C, then annealing at 600 °C for 12 min, then quickly cooling from 730 °C to 250 °C in a salt bath and keeping it isothermal for 100 s. The friction coefficient of materials with NCBM microstructure was less than other samples. It was found that while the wear coefficient were higher in the tempered martensitic microstructure sample having higher hardness, they were less than in the sample having bainitic/martensitic microstructure with similar hardness.

Characterization of the properties of arc-welded aluminum matrix syntactic foam-filled tubes

Abstract In this research, the authors aimed to manufacture and weld in-situ composite foam-filled tubes from expanded clay aggregate particles, AlSi12 aluminum matrix, and AlMgSi0.5 tubes using tungsten inert gas welding. Subsequently, the quality of the welded joints was examined after precipitation hardening heat treatment and without heat treatment, followed by the evaluation of the results. The welded joints were characterized by microstructural examinations, microhardness measurements, and hardness testing. It was found that the hardness of the tube can be increased with heat treatment after the welding by 23 % on average and that the heat input of the welding process causes silicon enrichment due to diffusion within the AlMgSi0.5 tube, which is accelerated by the heat treatment cycle.

Variations of VHCF Characteristics by Microstructure of a Spring Steel to UNSM Treatment

The bainitic structure resulting from the austempering of spring steel exhibits high strength and ductility. On the other hand, there appears to be no study on the effects of very high cycle fatigue (VHCF) and ultrasonic nanocrystal surface modification (UNSM) of this bainite structure. Therefore, this study compared the fatigue properties of VHCF using spring steel with bainitic and martensitic structures and bearing steel data. This study analyzed the characteristics of microstructure transformation associated with the heat treatment cycles and studied and evaluated the fatigue strength characteristics because of the UNSM in terms of fracture mechanics method and fracture surface analysis through electron backscatter diffraction, scanning electron microscopy fracture analysis, and energy-dispersive spectroscopy analysis. The fatigue limit of UNSM-treated spring steel was improved significantly by approximately 33% to 50% compared to the fatigue test results of the untreated material in the VHCF. In the long life range of bainized spring steel, fish-eye cracks appear in the form of the fine granular area, and fatigue cracks occur in the form of fish-eye cracks that occur in the bainite facet and matrix, resulting in a significant increase in fatigue strength and fatigue life.

Simulation-guided design of novel precipitation-strengthened eutectic high entropy alloy

Eutectic high entropy alloys (EHEAs) with hard and ductile phases are promising for high-temperature applications. The mechanical properties of EHEAs can be improved by incorporating precipitates in the ductile phase. The study focuses on the CALPHAD-guided alloy design approach for developing EHEA with cuboidal L12 precipitates in the ductile phase. The newly designed alloy (Al0.17CoCrFeNiTa0.22) is subjected to a simulation-guided heat treatment cycle. The Al0.17CoCrFeNiTa0.22 alloy shows FCC phase with a needle-like Ta-rich precipitate at 12 h and Ni-Al-rich cuboidal precipitate at 24 h of heat treatment. The calculated entropy of mixing of cuboidal precipitate is higher than that of needle-like precipitate. The detailed TEM characterisation confirms the characteristics of precipitates and microstructural changes correlated with microhardness measurements. The study proposes a novel EHEA system with a nano-scale precipitation-strengthened FCC phase and eutectic colony.

Indentation parameters and corrosion resistance of explosive welded S30400/Q345R clad plates with heat treatment cycles

This study aims to clarify the indentation parameters and corrosion resistance of explosive welded S30400/Q345R clad plates with heat treatment cycles. A series of tests on the mechanical properties of the clad plate in the unseparated state of clad material (CM) and base material (BM) and its free surface corrosion resistance, as well as their evolution with stress relief heat treatment are studied and discussed. The results show that the severely carburised layer (SCL) that occurs on the stainless steel side of the heat treatment was the peak hardness of the entire clad plate, which was significantly reduced after four heat treatments. The worst mechanical performance was observed in three heat treatments. The reduction in free surface corrosion resistance of CM is linearly correlated with the number of heat treatments, but this does not hold true for BM. This study provides valuable references for the assessment of performance loss under heat treatment of clad plates.

Coarsening of alloy carbides during a cyclic heat treatment for grain refinement in ultrahigh-strength steels

Strength–ductility trade-off dilemma is acute in materials science, especially for ultrahigh-strength steels. The improvement of toughness requires careful tuning of grains and precipitates. Thermal cyclic treatment and annealing before quenching are two effective ways of microstructural refinement for steels. However, a combination of the two methods has never been studied. Complex alloy carbides form in the process of annealing, but their effects on grain refinement in the subsequent quenching are unclear. Here, a systematic comparison of microstructure and mechanical properties is established between a thermal cyclic treatment with annealing (CHT) and traditional quench-temper treatment (QT). The results indicate that the CHT treatment leads to the coarsening of alloy carbides and subgrains, and the decrease in strength and toughness.

Influence of heating elements layout on temperature uniformity in a large size heat treatment furnace

Computational Fluid Dynamics simulations were used to optimize heating elements placement on the walls of a large size electrical heat treatment furnace in order to reduce temperature gradients within the furnace and uneven temperatures on different faces of the blocks which could result in variabilities in final mechanical properties. Initial evaluations of different layouts highlighted the effectiveness of equipping two side walls. Subsequently, an optimal percentage of side wall coverage was identified through simulations and multi-objective evolutionary optimization. Genetic and pareto search algorithms yielded 10 % and 14.2 % as optimum values, respectively. Implementing an optimal coverage demonstrated significant reductions in surface temperature non-uniformity, surface-to-center temperature differential, and temperature differences between loaded blocks. These improvements suggest a potential for enhanced uniformity in mechanical properties across a batch of products. This approach presents a promising strategy for obtaining consistent and efficient heat treatment cycles in industrial heat treatment furnaces resulting in energy saving and improved product quality.

Influence of heat treatment on the structure and mechanical properties of pseudo α-titanium alloy in a welded joint

The object of this study was the weld material of a new Ti-6.1Al-6.0Zr-6.3Sn-3.2Mo-1.1Nb-1.2Si alloy, which was obtained by electron beam welding. Electron beam welding (EBW) provides rapid melting and cooling with crystallization under significant temperature gradients. For the pseudo α-titanium alloy, this leads to the appearance of significant residual stresses in the joint and determines the specificity of the dispersion decay of the β-phase. Residual stresses are reduced by preliminary heating, removed by heat treatment. Such processing exerts a critical influence on the formation of the structure and phase composition of the weld and the zone of thermal influence of the electron beam; it can form macro defects, undesirable phases, and structural states. The conditions of heat treatment have been determined to bring the welded joint from complex alloyed pseudo α-titanium alloy to the required level of mechanical characteristics. The structure, phase morphology, elemental composition, and mechanical characteristics of welded joints without additional heat treatment have been compared, with preliminary local heating of 400 °C, with additional post-weld local annealing at ТТ=750 °С, tT=4 minutes and sequential annealing in the furnace at ТТ=850 °C, tT=60 minutes. It has been established that a full cycle of heat treatment of a welded joint provides the highest characteristics of strength and plasticity, but local heat treatment also makes it possible to obtain a defect-free joint with satisfactory characteristics for less responsible products. It is shown how heat treatment of pseudo α-titanium alloy makes it possible to get rid of unwanted phase formations (Zr,Ti)5Si3Al and transform them into (Zr,Ti,Nb,Mo)3SiAl. The results are promising for use in the production of aircraft engine parts

Using fuzzy logic based-modeling and simulated annealing approaches to optimize the hardness distribution of 2024 aluminum alloy during precipitation hardening heat treatment cycles

The present study assesses the impact of age hardening parameters, including aging temperature, aging time, and solution time, on the ultimate hardness of heat-treated 2024 aluminum alloys. Using a numerical approach, fuzzy logic systems were utilized as a robust tool to forecast the mechanical characteristics of high copper aluminum solid solutions throughout the age hardening process. In addition, an attempt was made to use a novel simulated annealing technique to determine the optimum hardness and its corresponding process parameters to achieve the highest mechanical properties. Comparing a fuzzy logic model with experimental results obtained from the Brinell hardness test showed the accuracy and confidence of the fuzzy model in representing such properties. The optimization results indicated that the maximum hardness can be obtained with a solution aging temperature of 173.5 °C, an aging time of 19 hours, and a solution time of 58 minutes. Overall, the variation in the experimental peak hardness obtained using the optimized process parameters was the deciding factor in believing the model.

Increasing Exploitation Durability of Two-Layer Cast Mill Rolls and Assessment of the Applicability of the XGBoost Machine Learning Method to Manage Their Quality.

The increase in exploitation durability of two-layer cast rolls with the working layer made of high chromium cast iron allows one to significantly improve the quality of rolled metal as well as to increase the economic efficiency of the manufacturing process. However, it is severely hindered due to the massiveness of castings, the impossibility of both evaluating mechanical properties along the depth of the working layer, and providing the structural uniformity of the working surface and the decrease in stresses. In our research, aiming to enhance the exploitation durability of sheet rolls, it is recommended to achieve structural uniformity by CuMg alloying, which increases the concentration of copper up to 2.78 wt.% in certain zones and, owing to the accelerated austenite decomposition at a high temperature during the cool-down of the castings, led to the reduction in excessive strength and the level of heat stresses in the castings. We propose the regimes of cyclic heat treatments which, due to the decomposition of retained austenite and the fragmentation of structure, control the level of hardness to reduce and uniformize the level of stresses along the length of a barrel. A further improvement in the predictions of exploitation durability using XGboost method, which was performed based on the chemical composition of the working layer of high-chromium cast iron and heat treatment parameters, requires taking into account the factors characterizing exploitation conditions of specific rolling mills and the transformations of structural-phase state of the surface obtained by a non-destructive control method. As the controlled parameter, the hardness measured on the roll's surface is recommended, while the gradient change in mechanical properties along the working layer depth can be feasibly analyzed by a magnetic method of coercive force measuring.

Hierarchically heterogeneous microstructure and mechanical properties in laser-directed energy deposition of γ-TiAl alloy through intrinsic cyclic heat treatment

The complex thermal effects of laser direct energy deposition (L-DED) provide significant advantages for production of high-performance γ-TiAl alloy, whereas challenges still exist in microstructure tailoring and mechanical properties. This work focuses on the influence of intrinsic cyclic heat treatment (ICHT) on the evolution of microstructures and mechanical properties in different building height regions of an L-DED TiAl alloy thin-wall sample. The results indicate that ICHT induces discontinuous coarsening (DC) effects by consuming the lamellar interface energy of the initial lamellae, resulting in grain refinement. With the increase in building height, the thermal accumulation leads to an increase in the initial lamellar spacing, which weakens the DC effect. At the top, insufficient thermal cycles prevent fine grain growth and erode coarse grains, hindering overall grain refinement. Ultimately, the hierarchically heterogeneous microstructure forms in the L-DED TiAl alloy, including refinement of hierarchical lamellar colony structure decorated with fine (α2+γ) lamellar structure and (α2+6H-LPS) lamellar structure (6H-LPS refers to 6H long-period structure phase). Specifically, the bottom region exhibits the best combination of ultimate tensile strength (706 ± 33 MPa) and strain (0.68 ± 0.05 %). The high tensile strength can be attributed to the hindrance of dislocation movement by the fine lamellae and the 6H-LPS phase ,caused by the high cooling rate of L-DED, while the elongation is attributed to the reduction in crack propagation energy due to the presence of fine grains.

Improved mechanical behavior of friction stir drilled 6082 aluminum alloy via T6 treatment

6082 Al-alloy underwent a friction stir drilling (FSD) processing. Subsequently, a two-stage post-heat treatment (PHT) procedure, i.e., solution treatment at 550 °C for 2 h, followed by artificial aging at 175 °C for 18 h, was implemented to significantly enhance microstructure and mechanical performance of the alloy. The microstructure was characterized by optical, laser, scanning electron and electron backscattered diffraction microscopes, while the mechanical behavior was assessed by a micro-indentation hardness tester, employing the indentation hardness (HIT) technique. Corrosion behavior of FSD as well as PHT specimens was investigated through electrochemical techniques.The microstructure of the base metal (BM) manifested an α-Al matrix with an average grain size of approximately 50 μm. FSD resulted in the creation of stirring zone (SZ) and thermo-mechanical affected zone (TMAZ), with respective widths of 400 ± 50 and 950 ± 100 μm. The SZ exhibited a very fine structure with an average grain size of 0.5 μm, thereby displaying increased hardness. The PHT microstructure displayed the formation of fine βʹ and βʺ second phase precipitate types, whereas the HIT hardness of the PHT α-aluminum matrix in the SZ, was lower than TMAZ and BM, due to reductions of βʹ in the SZ compared to TMAZ and BM. Moreover, the corrosion rate of the SZ decreased after the heat-treatment cycle, attributed to the recovery of strain energy induced during friction drilling and the increased solubility of solute atoms within the α-Al matrix.

Effect of Cycling Heat Treatment on the Microstructure and Properties of H13 Steel Prepared for Hot-Extrusion Die

Effect of Cycling Heat Treatment on the Microstructure and Properties of H13 Steel Prepared for Hot-Extrusion Die

Superelastic Cu68.5Al17.5Mn14 single crystal with an ultra-wide working temperature range for elastocaloric cooling

Superelastic shape memory alloys with elastocaloric cooling ability suitable for working at a broad temperature range are crucially lacking in facing various scenarios of cooling applications. Low-cost Cu-Al-Mn shape memory alloys are very promising candidates because of their low temperature dependence of critical driving stress of martensitic transformation. Here, a <105>A oriented Cu68.5Al17.5Mn14 single crystal is developed based on cyclic heat treatments, showing large superelastic response and elastocaloric cooling ability covering an ultra-wide temperature range spanning from 77 K to 450 K. Such enhanced temperature span also contributes to an exceptional refrigeration capacity of 5012 J kg–1, well surpassing those in the elastocaloric materials reported so far.

Impact of machine parameters and wall thickness on microstructural characteristics and microhardness of laser powder bed fusion Inconel 718 parts following heat-treatment

This study investigates a series of geometric feature build plates manufactured by multiple laser powder bed fusion (L-PBF) machine configurations, examining seven different wall thicknesses ranging from 0.1 to 2.0 mm. These build plates and thin wall specimens completed a full heat treatment cycle: stress relief (SR), HIP, solution, and aging per standards. The fully heat-treated (FHT) Inconel 718 wall specimens were sectioned from sixteen different geometric feature build plates built across fifteen different L-PBF machines. They were characterized by optical microscopy and EBSD image mapping. The microstructural evolution from the As-built sample, SR, HIP to FHT wall specimens from a single machine configuration was also obtained along with cooling rate simulations for 0.1 mm, 0.2 mm, 0.5 mm, and 0.8 mm wall thicknesses. The difference in cooling rates between the thick and thin walls was simulated to provide an understanding of microstructural evolution and evaluate the computer simulation as a tool to predict microstructural features. For FHT wall specimens, results indicate mostly equiaxed grain structures containing annealing twins, ranging in size from ∼21 μm to 93 μm parallel and perpendicular to the build direction. For most of the samples, the grain size was shown to increase with the increasing wall thickness due to slower solidification rates. The double aging composing the fully heat-treated thin walls also fully age-hardened the grain structures with gamma double-prime precipitates. This precipitation produced a median Vickers (HV) hardness for nominal section thicknesses >0.6 mm of ∼ HV 472; consistent with commercially heat-treated and optimized Inconel 718 products. Feature sizes >0.6 mm were reproducible for all L-PBF machine configurations.

Influence of Cyclic Heat Treatment Temperature on Microstructure and Mechanical Properties of 18Ni(C250) Maraging Steel.

Cyclic heat treatment is an effective approach for enhancing the mechanical properties of 18Ni(C250) maraging steel, and the selection of cyclic heat treatment temperature is a key factor. In this study, a cyclic heat treatment process with a two-step solution treatment is employed to investigate the influence of cyclic heat treatment temperature, specifically the first solution treatment temperature (920 °C, 950 °C, and 980 °C), on the microstructure and mechanical properties of 18Ni(C250) maraging steel. The results indicate that with an increase in the cyclic heat treatment temperature, the average grain size of the 18Ni(C250) maraging steel decreases initially and then increases. When the cyclic heat treatment temperature reaches 950 °C, the grain size is at its minimum, exhibiting optimal grain uniformity. Additionally, the increase in cyclic heat treatment temperature results in a reduction in the size of martensitic lath with the same orientation inside the grains, along with an increase in the relative quantity of low-angle grain boundaries. Furthermore, the volume fraction and size of retained austenite show a monotonous increase with the rise in the temperature of the cyclic heat treatment, and the rate of increase becomes notably larger when the temperature is raised from 950 °C to 980 °C. Based on the observed microstructural changes, the variation in the mechanical properties of the 18Ni(C250) maraging steel was analyzed. Specifically, as the cyclic heat treatment temperature increases, the tensile strength of the 18Ni(C250) maraging steel initially increases and then stabilizes, while the elongation and fracture toughness exhibit a monotonic increase.