Dimple Size Research Articles

Fabrication and characterization of austenite-ferrite stainless steel bimetals by twin wire arc additive manufacturing

In this work, gas metal arc welding (GMAW) based twin wire arc additive manufacturing (TWAAM) system has been employed to deposit to wire materials simultaneously to fabricate austenite-ferrite stainless steel (AFSS) bimetal of austenite stainless steel (SS304L) and ferrite stainless steel (SS430L). A combination of high voltage and wire feed with low torch speed and gas flow resulted in optimal deposition as determined through response surface analysis based on experimental data of single-track bimetal bead on plate depositions. Mechanical and microstructural characterization of the AFSS bimetal was carried out using tensile test, hardness tests, fractography, SEM with EDS, and phase analysis. Tensile properties of the AFSS bimetal were seen to improved with the yield strength of 343 MPa, ultimate strength of 613 MPa and elongation of 67%, and a hardness value of 225 HV. The interface of the AFSS bimetal was found defects free and microstructures contained both austenite and ferrite phases with higher amounts of Ni-content. The fracture morphology of the fabricated AFSS bimetal was seen to contain dimple sizes lying between that of individual steels and resulted in higher elongation than that of the pure ferrite steel. This study demonstrated defects free fabrication of bimetallic structures with unique microstructural features and enhanced mechanical properties.

Experimental and numerical study on ferrohydrodynamic and magneto-convection of Fe3O4/water ferrofluid in a sudden expansion tube with dimpled fins

BackgroundThis study experimentally and numerically addresses magnetohydrodynamic forced convection including dimpled fins, Fe3O4/water ferrofluid, and DC magnetic field. In this research, focusing on the thermo-hydraulic performance improvement of a sudden expansion tube. It has been used different inlet diameters, dimple sizes, ferro nanoparticle concentrations, and magnetic field strengths to examine the heat transfer and fluid dynamics characteristics of the system. MethodsThe study consists of two parts, i) experimental and ii) numerical. Steady-state, incompressible, Newtonian flow were considered but chemical reaction, viscous dissipation, buoyancy, and radiative heat transfer were neglected in this study. On the other hand, numerical solutions were carried out for single-phase method. This study was first compared with the studies in the literature on the flow in a sudden expansion tube without dimpled fins and the error rate was found to be less than 10 %. In the analysis, dimpled fins with d=3, 5, and 7 mm at each P=15 mm (P/d=5.0, 3.0, and 2.14) have been used. As working fluid, Fe3O4/water ferrofluid with volume concentration of φ=1.0 % and 2.0 % have been analyzed. Additionally, DC magnetic fields, which strength of Ha=0.1, 0.3, 0.5, 1.1, 3.2, and 5.3 (B =0.01, 0.03, 0.05, 0.1, 0.3, and 0.5T), have been applied on the sudden expansion tube surface as external force. Significant findingsDimpled fins enhance the heat transfer by disrupting the boundary layer and forming secondary flows, while the ferrofluid increases the thermal conductivity and viscosity of the base fluid. Based on these explanations, dimpled fins increased the convective heat transfer rate at the rate of 96.0 % compared with smooth tube. In addition, Fe3O4/water ferrofluid with φ=2.0 % performed the highest performance and performance evaluation criteria increased by 8.5 %. The magnetic field also contributes to the heat transfer enhancement by inducing Lorentz force and mixing the flow. Excessive increasing of magnetic field strength adversely affected the system performance, and the highest performance evaluation criterion is acquired at Ha=3.2 by increasing 3.9 %. Compared with smooth tube, compound effect of dimpled fins, Fe3O4/water ferrofluid, and magnetic field improved the average Nusselt number and performance evaluation criterion at the rate of 279.8 % and 207.9 %, respectively.

Optimized control of laser processing parameter on microstructural evolution and mechanical behavior in CoCrNi medium entropy alloy

In this study, the processing parameters of a laser powder bed fusion (LPBF)-fabricated CoCrNi alloy were systematically investigated for their impact on mechanical properties, microstructure, and fracture characteristics when the relative density exceeds 99%. The maximum relative density of 99.89% was attained at a laser power of 225 W, and scan speed of 1000 mm/s, accompanied by a hardness value of 276.83 HV. However, it is important to note that the highest relative density did not correspond to the maximum σUTS. Tensile testing revealed that increasing the laser power at the same scan speeds led to a decrease in elongation. The LPBF-fabricated CoCrNi alloy exhibited enhanced defect tolerance due to its cellular microstructure, which confined ductile dimple sizes to the nanoscale and impeded crack propagation through pinning effects. At scan speeds of 1000 mm/s and energy densities below 83 J/mm³, an increased presence of unmelted powder and pores was observed. Besides, it was confirmed that the <110> crystallographic texture displayed the strongest orientation within the sample. Theoretical calculations indicated that over 50% of the yield strength is attributed to the dislocation structure. These findings contribute to the process optimization of LPBF, providing a valuable reference for adjusting process parameters to enhance material mechanical properties, particularly when targeting relative densities above 99%.

Effect of Deep Cryogenic Treatment on the Artificial Aging Behavior of 6082 Aluminum Alloy

This study investigates the impact of cryogenic treatment duration on the mechanical properties and microstructural evolution of 6082 aluminum alloy subjected to subsequent artificial aging. Tensile tests were conducted using an electronic universal testing machine, and the microstructure was characterized by employing optical microscopy (OM), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). The results indicate that both the tensile strength and elongation of the alloy first increase and then decrease with the extension of cryogenic treatment duration. The alloy treated with 12 h of cryogenic treatment followed by artificial aging at 180 °C for 8 h achieved a peak strength of 390 MPa. Meanwhile, the alloy treated with 8 h of cryogenic treatment and the same artificial aging process reached a maximum elongation of 13%. All specimens of 6082 aluminum alloy subjected to cryogenic and aging treatments exhibited ductile fracture under room temperature tensile conditions. The size of dimples at the fracture surface first increased and then decreased with increasing cryogenic treatment duration, indicating a transition from deeper to shallower dimples. The cryogenic treatment did not significantly affect the grain size of the alloy, which remained approximately 230 µm on average. Cryogenic treatment facilitated the precipitation of fine, densely distributed precipitates, enhancing the pinning effect of dislocations and thus improving the tensile strength. Additionally, cryogenic treatment increased the dislocation density and promoted the formation of subgrains, while the grain boundary precipitates transitioned from a continuous to a discontinuous distribution, all of which contribute to the enhancement of the plasticity.

Tribological behaviour of microindented 100Cr6 steel surfaces in dry contact conditions

In the present work, we studied the dry tribological behaviour of a 100Cr6 steel, the spherical surface of which was texturized with microindentation. The purpose of adopting a mechanical indentation technique on a non-planar surface was to simultaneously evaluate the effectiveness of adopting a fast, deformation-based technique for improving the contact tribological properties. Specifically, dimples were created using an automatic microhardness tester equipped with a Vickers indenter, setting a load of 0.5 N. Friction tests were performed at different speeds considering textured surfaces with two different void ratios (VRs). Textured and untextured surfaces were tested using a ball-on-disc tribometer. In addition, the effect of dimple size was evaluated by producing Vickers indented surfaces at a load of 5 N per each indentation, while keeping the VR values unchanged and testing the frictional properties of such surfaces at a fixed speed of 4.18 mm/s. Textured surfaces were deeply investigated to motivate the improvement of tribological properties. Notably, compared to the untextured samples, the microindented samples exhibited a much lower coefficient of friction (COF), with a friction reduction compared to the untextured case ranging from 45 to 65%, depending on the VR values. The adoption of large dimples allowed the reduction of the COF, already at smaller VR value but, in such a case, the presence of bulges at the edge of the dimple worsens the wear resistance of the counter surface. In addition to reducing the contact area and the capability to trap any debris in the dimples, the local measurement of strength allowed to clarify that the friction reduction is also determined by the work hardening effect produced by the microindentation texturing. Considering the significant improvements recorded in terms of COF and the high ability to indent even non-planar surfaces, the proposed approach can be considered very promising and, therefore, industrially applicable (e.g. using a specifically designed multi-indenter tool) to affect the friction behaviour of components, even locally, during both their use and their production.

Optimizing friction stir welding of AA7075 and AA8090 aluminum alloys: a desirability-driven investigation into mechanical and microstructural enhancement

This research explores the multifaceted analysis of a friction-welded joint, employing Central Composite Design of Response Surface Methodology. The study integrates microstructural investigations and fracture analyses to explain the effect of process parameters on mechanical properties. The optimum settings for Friction Stir Welding of AA7075 and AA8090 were determined by assessing desirability indices. These settings comprised a tool rotation speed of 1927.7 rpm, a tool travel speed of 35 mm min−1, and a tool tilt angle of 0.9°. This specific combination yielded a noteworthy combined desirability index of 0.79, considering both Ultimate Tensile Strength (UTS) and Tensile Elongation (TE). Microstructural examinations revealed distinct characteristics in the Heat-Affected Zone (HAZ), Thermo-Mechanically Affected Zone (TMAZ), and Nugget Zone (NZ). Notably, fine grain structure in the NZ was attributed to the stirring effect created by the tool pin. Fracture analyses indicated ductile fractures, with dimple size variation correlating to tensile strength. Lower dimple density in low-strength joints suggested insufficient material mixing during welding. The maximum tensile strength sample exhibited a high dimple density. These findings contribute to a comprehensive understanding of the welding process’s influence on microstructure and fracture characteristics, providing valuable insights for optimizing mechanical properties in friction-welded joints.

Analysis of thermohydraulic flow and enhancement heat performance in 3D dimple tube based on varying geometrical configurations

AbstractThis research work investigates how different dimple designs affect the flow field and thermal performance of three‐dimensional pipes. The study focuses on the effect of the number of improved dimples NOD (3, 4, and 5), different groups numbers DGNs (1, 2, and 3 groups), arranged around the pipe, and different distances between dimples (DBDs). Dimple geometry affects flow: Changing dimple parameters alters the velocity and pressure distribution within the pipe. Performance evaluation factor (PEF) varies with dimple configuration: The PEF, which balances heat transfer enhancement and pressure drop penalty, ranges from 1.187 to 1.23 for NOD and from 1.292 to 1.31 for DGN, and also from 1.26 to 1.302 for DBD. Reynolds number range, Re = 4000–15,000; turbulence model, standard k–ε model; numerical scheme, second‐order upwind scheme; test tube conditions, inlet temperature (Tin) = 25°C; pipe diameter D = 23 mm; thickness = 2 mm; heat flux q = 25,500 W/m²; and material (Cu). This research focuses on improving heat transfer efficiency in pipes using dimples. Dimple size and arrangement significantly impact flow dynamics and heat transfer. PEF is used to evaluate the overall performance considering both heat transfer improvement and pressure drop penalty. The study found a specific range for PEF under various conditions for different dimple configurations. The average enhancement in Nusselt number for model 2 was 15.16% compared with a smooth pipe and the heat transfer performance by 10.028%–28.963% at the effect of NOD, the DGN has slightly higher Nu values than smooth pipes, indicating improved heat transfer due to the dimples (around 7%–58% at Re 4000–15,000 and 9%–13% at Re 12,000), and at DBD (13.5%) at a Reynolds number of 12,000 and 4.6%–59% at Re 4000–15,000.

Correlation between microstructure and fracture mechanism of 960 MPa Grade ultra-high toughness steel

This study investigated the correlation between microstructure and fracture mechanisms in a 960 MPa grade ultra-high toughness high strength low alloy steel produced through controlled rolling and off-line heat treatment. The steel features a low-carbon composition (≤0.1 wt%) and a fine-grained(≤10 μm) bainitic microstructure. Through microstructural characterization and fractographic analysis, extensive quantitative analysis of grain, packet, dimple, and cleavage facet sizes was conducted. Fracture surfaces were examined to identify crack initiation sites. The findings indicate that grain refinement significantly enhances toughness. In fine-grained conditions, bainitic packets that approximate the size of the grains modulate crack propagation pathways. The near-oriented bainite across adjacent grains forms structures comparable to abnormally large grains, crucial for crack nucleation. Moreover, martensite/austenite (M/A) islands, while crucial to the initiation of cracks, require the synergistic interaction with grain boundaries and inclusions to significantly influence fracture initiation. This investigation elucidates the complex interplay between microstructural refinement and fracture mechanisms.

Electropulsing of low-density duplex steel for strengthening and ductilization by microstructural refinement

The present investigation finds the effect of electropulsing treatment on the mechanisms of refining and reprecipitation of ordered L20 structure (B2) and its impact on tensile properties of low-density duplex steel of Fe-18Mn-10.5Al-1 C-6Ni composition. The selected composition without manganese is melted at 1600°C by induction heating in a vacuum but Mn is added into the melt at 1560°C, in the argon atmosphere to reduce the loss. The melt is cast into a plate form in a copper mold. The cast steel is homogenized, hot rolled, and annealed (PD1-A sample) to get elongated bands, spheroids, and platelets of B2 phase with an austenitic matrix which results in a yield strength of 1015 MPa, and tensile strength of 1285 MPa with a plastic elongation of 16.3%. Electropulsing partially dissolves the B2 phase at a temperature much lower than the equilibrium solvus by reducing barrier energy because of electron wind. As a result, the sizes of bands and spheroids are reduced, and platelets are disintegrated. Electron wind force deforms coarse precipitates, and fragments as well as spheroidized it. Electropulsing of annealed steel (PD1-AE) mobilizes dislocations, and recovers it in B2, but induces localized recrystallization of austenite. At a later time of the signal, the temperature rapidly falls and the matrix becomes supersaturated but electropulsing accelerates low-temperature precipitation of the B2 phase. Therefore, electropulsing can be adopted as a fast manufacturing process to dissolve, deform, fragment, spheroidize and reprecipitate high temperature phase at much lower temperature by dominant athermal effect of electron wind energy over thermal effect. Electropulsing also induces recovery and recrystallization at a relatively low temperature and reduces defect density. Reduction in the overall size of B2 and its distribution towards better uniformity provided an increased yield strength of 1077 MPa, tensile strength of 1355 MPa, and a plastic elongation of 21.6%. The selected duplex low-density steel follows two-stage work hardening of Ludwigson model with an additional stage of dynamic recovery. Fractography analysis confirms that both samples show mixed modes of ductile and brittle fracture, with an increase in size and area percentage of dimples.

Electrochemically structured tantalum surfaces via anodization for core-shell nanostructures: Optimization and characterization of Zn-ZnO nanoparticle deposition using magnetron sputtering

This study explores the electrochemical anodization of tantalum surfaces to create nanostructured substrates for the deposition of Zn-ZnO nanoparticles (NPs) through magnetron sputtering. The anodization process, conducted at different potentials (25 V and 50 V), resulted in tantalum surfaces with distinct dimple structures. The formation of these nano-level dimples is attributed to the dynamic equilibrium between the continuous formation and dissolution of the anodic TaOx layer. The dimple diameter is observed to increase with applied potential, correlating with the dissolution rate of the anodic oxide. The NP deposition parameters were studied in two steps. First, the effect of the deposition conditions on the nanoparticle size and distribution was evaluated and optimized on silicon substrates. Second, the conditions that resulted in the optimum size and distribution of the nanoparticles were utilized in tantalum substrates and evaluated to which extent these conditions were reproduced onto the anodized Ta substrate. Comparisons of Zn-ZnO nanoparticle depositions on silicon and tantalum substrates reveal similar island growth trends, with differences in nanoparticle size and distribution attributed to substrate properties. Further investigation involves anodized tantalum substrates with varying dimple sizes, and deposition conditions are adjusted with bias voltage, pressure, and deposition time to control nanoparticle characteristics. Characterization of the Zn-ZnO nanoparticles deposited on anodized tantalum surfaces is performed using scanning electron microscopy, high-angle annular dark-field scanning transmission electron microscopy, and energy-dispersive x-ray spectroscopy. The resulting core-shell structures are confirmed through structural analysis, revealing a core of hexagonal close-packed Zn and a shell of ZnO. The study demonstrates the influence of substrate properties and deposition conditions on the morphology and composition of Zn-ZnO nanoparticles, providing insights for applications in nanoelectronics and catalysis.

Reverse effects of pre-deformation and traverse speed on the mechanical properties of friction stir processed pure copper

In the present work, the effects of pre-strain and traverse speed on the microstructural evolution and tensile behavior of friction stir processed (FSPed) pure copper were investigated. In the samples without pre-deformation (0% samples), with the increment of the traverse speed from 100 mm min−1 to 200 mm min−1, the grain size decreased from 5.2 to 2.5 μm due to heat input domination. In the 60% pre-rolled samples (60% samples), interestingly, with an increase in the traverse speed (from 100 mm min−1 to 200 mm min−1), the average grain size increased from 2.4 to 6.8 μm owing to the domination of deformation degree. With the increment of speed from 100 mm min−1 to 200 mm min−1 in the 0% samples, the YS and UTS increased from 158.6 and 244.6 MPa to 190.7 and 253.9 MPa, respectively, due to decrement in the mean grain size. In addition, the increment of speed from 100 mm min−1 to 200 mm min−1 in the 60% samples reduced the YS and UTS from 177.9 and 261.7 MPa to 138.9 and 234.8 MPa, respectively, due to the increase in the mean grain size. In the 0% FSPed copper, by increasing the speed, the depth and size of dimples reduced, while, in the 60% FSPed samples, when the traverse speed increased, the dimples became larger.

The Effects of Strain Rate and Anisotropy on the Formability and Mechanical Behaviour of Aluminium Alloy 2024-T3

The present study focuses on the mechanical behaviour and formability of the aluminium alloy 2024-T3 in sheet form with a thickness of 0.8 mm. For this purpose, tensile tests at quasi-static and intermediate strain rates were performed using a universal testing machine, and high strain rate experiments were performed using a split Hopkinson tension bar (SHTB) facility. The material’s anisotropy was investigated by considering seven different specimen orientations relative to the rolling direction. Digital image correlation (DIC) was used to measure specimen deformation. Based on the true stress–strain curves, the alloy exhibited negative strain rate sensitivity (NSRS). Dynamic strain aging (DSA) was investigated as a possible cause. However, neither the strain distribution nor the stress–strain curves gave further indications of the occurrence of DSA. A higher deformation capacity was observed in the high strain rate experiments. The alloy displayed anisotropic mechanical properties. Values of the Lankford coefficient lower than 1, more specifically, varying between 0.45 and 0.87 depending on specimen orientations and strain rate, were found. The hardening exponent was not significantly dependent on specimen orientation and only moderately affected by strain rate. An average value of 0.183 was observed for specimens tested at a quasi-static strain rate. Scanning electron microscopy (SEM) revealed a typical ductile fracture morphology with fine dimples. Dimple sizes were hardly affected by specimen orientation and strain rate.

Fracture behaviour of Sn-58Bi alloy reinforced by activated bamboo charcoal

Sn-Bi solders are considered by PV manufacturers as acceptable Pb-free alternative due to its low operating temperature and cost, despite being prone to brittleness caused by coarse Bi phases. Bamboo charcoal (BC) is a sustainable and environment-friendly resource with high surface area and its addition to Sn-Bi solder meets the requirement of a green solder, in line with environmental regulations. This study aims to improve the shear strength and reduce brittleness of the Sn-Bi solder alloy by using a sustainable reinforcement, the activated bamboo charcoal. Sn-58Bi solder paste was reinforced with 0.25, 0.50, 0.75 and 1.00 wt.% of activated BC, respectively and reflowed to create a single lap shear joint. Aging response was determined through accelerated aging at 120 °C for 7 days and 14 days. Shear strength of the joints increased as the activated BC content increased in the as-reflowed condition and there was lower degradation in shear strength for heat-aging specimens compared to pure Sn-Bi solder. No failures occurred via Mode 3 when the as-reflowed samples contained 0.50 wt.% or more of activated BC, and the 7- and 14-day heat-aged samples were free from Mode 3 failures when the activated BC composition was at 0.75 wt.% and above. Fracture surfaces showed transitions from flat and smooth surface to elongated-dimple structures even with just 0.25 wt.% of activated BC addition. While prolonged heat-aging increased cleavage presence, increasing amounts of activated BC reduced facet numbers and dimple sizes, indicating successful suppression of Bi phase segregation.

Investigate the Impact of Dimple Size and Distribution on the Hydrothermal Performance of Dimpled Heat Exchanger Tubes

Investigate the Impact of Dimple Size and Distribution on the Hydrothermal Performance of Dimpled Heat Exchanger Tubes

The mechanics of prestress and elastic recovery resulting from dimple formation in steel sheets: Comprehensive numerical and experimental studies

Residual stress is rarely considered as an initial condition for Finite Element Analysis (FEA), or used in the component design. A comprehensive numerical and experimental investigation into prestressed steel sheets is conducted. Residual stresses at specific locations were introduced into the steel sheets by dimple formation. FEA is used to simulate dynamic dimple forming of a mild steel disk due to a tool impact and detect the existence of prestress after dimple formation. A physical drop-hammer was used to form a range of dimple sizes in disks to experimentally validate the FEA predictions associated with dimple depth. Dimples were then created using a screw press and the prestress was measured by strain gauges beyond the zone of permanent out-of-plane deformation associated with a dimple. The experimental strain gauge measurements during dimple formation were found to be consistent with FEA predictions. The results demonstrated that the predicted and measured radial and tangentially projected stress components remain in steel sheets after forming a dimple. Furthermore, the predicted prestress was greater near to the dimple formation and occurred at higher magnitudes in the tangential direction than the radial direction. The highest prestress remaining in the disk was at the magnitude of the material’s ultimate tensile stress, predicted in the tangential direction at the edge of the dimple. The numerical and experimental results showed the three stages of prestress formation: the development of stresses during dimple formation, the elastic recovery after the dimple forming, and the final prestressed equilibrium state of the rimmed disk.

On the importance of nano-oxide control in laser powder bed fusion manufactured Ni-based alloys to enhance fracture properties

In this study, a series of Ni-Cr-Mo based alloys (IN625, C22 and NA282), sourced from various powder suppliers and having varying oxygen concentrations (200 ppm to 800 ppm), were printed under similar conditions using laser powder bed fusion (LPBF). Nano-oxides in the range of 20–50 nm were observed in each alloy in the as-printed state, albeit with different number densities. Room temperature tensile tests and liquid nitrogen (LN2, -196 °C) Charpy impact tests were performed to assess the mechanical response of each alloy. The IN625 and C22 samples showed considerably lower impact energy values than the NA282, as well as lower room temperature post-necking tensile elongations, despite showing similar yield strengths and strain hardening behaviours. Fracture surface dimple sizes were shown to correlate with nano-oxide particle spacings. Nano-oxides were found in the middle of most dimples on fracture surfaces suggesting that the nano-oxides are the sites of void nucleation during fracture, despite being only 20–50 nm in size. The precursor metal powders were identified as the primary origin of the nano-oxide particles. This study highlights the critical, detrimental role that nano-oxides, typically present in LPBF metals, have on the fracture properties of these materials. In the case of the Ni-Cr-Mo alloys examined here, limiting oxide formation is critical to achieving optimal fracture properties.

Influence of Oil Viscosity on the Tribological Behavior of a Laser-Textured Ti6Al4V Alloy.

Laser texturing with a dimple pattern was applied to modify a Ti6Al4V alloy at the micro level, aiming to improve its friction and wear resistance in combination with oil lubrication to optimize the performance in demanding industrial environments. The tribological analysis was performed on four different dimple-textured surfaces with varying dimple size and dimple-to-dimple distance and under lubrication with three different oils, i.e., T9, VG46, and VG100, to reflect the oil viscosity's influence on the friction/wear of the laser-textured Ti6Al4V alloy. The results show that the surfaces with the highest texture density showed the most significant COF reduction of around 10% in a low-viscosity oil (T9). However, in high-viscosity oils (VG46 and VG100), the influence of the laser texturing on the COF was less pronounced. A wear analysis revealed that the laser texturing intensified the abrasive wear, especially on surfaces with a higher texture density. For low-texturing-density surfaces, less wear was observed for low- and medium-viscosity oils (T9 and VG46). For medium-to-high-texturing densities, the high-viscosity oil (VG100) provided the best contact conditions and wear results. Overall, reduced wear, even below the non-texturing case, was observed for sample 50-200 in VG100 lubrication, indicating the combined effect of oil reservoirs and increased oil-film thickness within the dimples due to the high viscosity.

Insights into the dynamic impact behavior of intercritically annealed automotive-grade Fe–7Mn–4Al −0.18C steel

Recently, medium manganese steels (MMnS) have been developed due to their excellent strength and improved ductility to meet automotive manufacturer demands. However, research on the impact toughness of automobile parts developed from these steels needs considerable attention to meet safety standards. Therefore, the present investigation focuses on the effect of annealing time (30, 60 and 180 min) on the impact behavior of intercritically annealed (750 °C) Fe–7Mn–4Al-0.18C (wt. %) steel. The microstructure of intercritically annealed steel, as revealed by scanning electron microscopy (SEM) and transmission electron microscopy (TEM), consists of blocky and lath-type reverted austenite (RA), fine intercritical ferrite (IF), lath-type martensite (M) and coarse elongated ferrite (EF). The impact toughness of the samples is evaluated at room temperature using a Zwick/Roell HIT450P Charpy impact machine. The sample annealed for 60 min absorbs the highest amount of impact energy among the three annealed samples. This is due to an increased volume fraction of RA, the transformation-induced plasticity (TRIP) effect, and an increase in the fraction of high angle grain boundaries (HAGBs). The microtexture analysis reveals that the presence of γ-fiber {111}//ND texture in ferrite and Rotated Goss texture {011} <011> in austenite contributes to the improved impact toughness in the specimen annealed for 60 min. The SEM fractographs of the sample annealed for 60 min exhibit crack branching and larger dimple size with inhomogeneous dimple distribution indicating higher energy absorption during crack initiation. Martensitic transformation nucleation sites are activated by a high volume fraction of RA in the sample annealed for 60 min, leading to increased impact toughness and the development of secondary cracks. In addition, the impact energy decreases when the sample annealed for 60 min is subjected to an impact test at temperatures lower than room temperature.

Evolution of in-plane stresses induced fracture behaviors of Tailor Welded Blanks subjected to non-uniformly distributed load

Due to remarkable difference in material properties of Tailor Welded Blanks (TWBs), when subjected to uniform forming load, severe non-uniform metal flow and strain localization occur on TWBs’ “weaker” side, which accelerates the forming failure. In this work, non-uniformly distributed normal pressure generated by heterogeneous elastomer was used to balance the deformation on SS304/SS316 stainless steel TWBs’ two sides. Effects of load patterns (i.e., uniformly and non-uniformly distributed load) on strain distribution, stress states, and fracture morphology of TWBs were studied to clarify the change of failure mechanism based on bulge tests and analytical analysis. The results showed that, when subjected to non-uniformly distributed load, with the ratio of Young’s modulus (φ) of heterogeneous elastomers increasing from 1 to 5.33, normal pressure on the “weaker” side of TWBs (i.e., SS304 side) decreased from 8.68 MPa to 4.34 MPa while that on the “stronger” side (i.e., SS316 side) remained constant. The corresponding radial and circumferential stresses on the “weaker” side decreased by 34.76 MPa and 21.08 MPa, respectively. Excessive plastic deformation on the “weaker” side was decreased and deformation uniformity on both sides was improved. Meanwhile, in the microscopic scale, fracture morphology of materials on the “weaker” and “stronger” sides changed from fracture mode I (i.e., dimples combined with tearing edges) to fracture mode Ⅱ (i.e., two sizes of dimples). Dimples in fracture mode Ⅱ showed similar sizes with these on fractured SS304 and SS316 tensile specimens after uniaxial loading, which implied sufficient plastic deformation on both sides of TWBs.

Structure–Property Correlation between Friction-Welded Work and Hardened Al-4.9Mg Alloy Joints

Friction welding of aluminum alloys holds immense potential for replacing riveted joints in the structural sections of the aeronautical and automotive sectors. This research aims to investigate the effects on the microstructural and mechanical properties when AA5083 H116 joints are subjected to rotary friction welding. To evaluate the quality of the welds, optical and scanning electron microanalysis techniques were utilized, revealing the formation of sound welds without porosity. The microstructural examination revealed distinct weld zones within the weldment, including the dynamically recrystallized zone (DRZ), thermo-mechanically affected zone (TMAZ), heat-affected zone (HAZ), and base metal (BM). During the friction-welding process, grain refinement occurred, leading to the development of fine equiaxed grains in the DRZ/weld zone. Tensile testing revealed that the weldment exhibited higher strength (YS: 301 ± 6 MPa; UTS: 425 ± 7 MPa) in the BM region compared to the base metal (YS: 207 ± 5 MPa; UTS: 385 ± 9 MPa). However, the weldment demonstrated slightly lower elongation (%El: 13 ± 2) compared to the base metal (%El: 15 ± 3). The decrease in ductility observed in the weldment can be attributed to the presence of distinct weld zones within the welded sample. Also, the tensile graph of the BM showed serrations throughout the curve, which is a characteristic phenomenon known as the Portevin–Le Chatelier effect (serrated yielding) in Al-Mg alloys. This effect occurs due to the influence of dynamic strain aging on the material’s macroscopic plastic deformation. Fractography analysis showcased a wide range of dimple sizes, indicating a ductile fracture mode in the weldment. These findings contribute to understanding the microstructural and mechanical behavior of AA5083 H116 joints subjected to rotary friction welding.