Steel Forgings Research Articles

Optimizing Hot Forging of 38MnSiVS5 Steel: A Multi-Objective Approach with Grey-Fuzzy Method

The present research focuses on the hot forging of 38MnSiVS5 micro-alloyed steel, examining the impact of key process variables, such as working temperature, deformation percentage and rate of cooling on mechanical properties, notably the ultimate tensile strength and impact energy. To optimize the process, Taguchi's parametric design, utilizing an orthogonal array in combination with grey relational analysis and fuzzy logic analysis, has been implemented. By applying grey-fuzzy logic analysis, the optimization of complex multiple responses is streamlined into a single grey-fuzzy reasoning grade. The study employs the Grey fuzzy logic method to concurrently optimize both responses. The grey-fuzzy reasoning grade serves as a performance index, aiding in the determination of the optimal process parameter settings for both the ultimate tensile strength and impact energy responses simultaneously.

Numerical simulation and experimental validation of microstructure evolution during the upsetting process of a large size martensitic stainless steel forging

The microstructure evolution, plastic deformation, and damage severity during the open die hot forging of a martensitic stainless steel were investigated using finite element (FE) simulation. A microstructure evolution model was developed and combined with a visco-elastoplastic model to predict the strain, the strain rate, and the temperature distribution, as well as the volume fraction and the size of dynamically recrystallized grains over the entire volume of an industrial size forging. The propensity to damage during hot forging was also evaluated using the Cockcroft & Latham model. The three models were implemented in the FE code and the results analyzed in terms of microstructure inhomogeneity and stress levels in different regions of the forging. A good agreement was obtained between the predicted and the experimental results, demonstrating that the simulation provided a realistic representation of the forging process at the industrial scale.

Formation and removal mechanism of SiO2-MnO-Al2O3 inclusions in Al-killed 42CrMo4 wind turbine bearing steel forgings

SiO2-MnO-Al2O3 (SMA) inclusions were identified in the defective areas during the ultrasonic inspection of Al-killed 42CrMo4 wind turbine bearing steel forgings. To explore their formation mechanism, we systematically sampled 42CrMo4 steel through industrial experiments, analysing SMA inclusions’ morphology and composition at various stages. Thermodynamic calculations were also employed to assess the origin and formation of these inclusions. It was observed that these inclusions primarily formed during electric arc furnace tapping, where the mass ratio of SiO2 to MnO was close to 1, while the Al2O3 content varied. Despite undergoing the ladle furnace and vacuum degassing (VD) refining processes, these inclusions persisted in the molten steel. Following the conclusion of electric furnace smelting, the dissolved oxygen content in the molten steel could reach 193 ppm. During the tapping process, high oxidising steel comes into direct contact with silicon-manganese alloy. During this phase, the uneven distribution of Al content around the alloy results in the formation of SMA inclusions with varying Al2O3 content. Dynamic calculations suggest that in subsequent smelting processes, SMA inclusions with high Al2O3 content and large size are relatively easier to eliminate, while those with low Al2O3 content and small size are more likely to persist in the molten steel. During solidification, residual SMA inclusions agglomerate, forming larger sizes, consequently resulting in the ultrasonic inspection failure of 42CrMo4 steel forgings. After the process improvement, the SMA inclusions are greatly reduced and the effect is obvious.

Development of a heavy vehicle torque rod applying continuous fiber reinforced thermoplastic composite materials instead of forged steel material: Design, analysis and optimization

The torque rod is an important component of the suspension system that connects the axle to the chassis in heavy commercial vehicles. The main motivation of this study is the development of a torque rod made of (1) plus cross-section, (2) continuous carbon and glass fiber reinforced hybrid thermoplastic composites, which can replace a forged steel torque rod used in heavy vehicles, has superior mechanical properties, provides minimum cost and weight. This study aims to develop a torque rod before its production within the framework of integration with Computer Aided Design (CAD), Finite Element Analysis (FEA), and Multi-Criteria Decision Making (MCDM). In this study, the design data and the properties of the composite materials were chosen as control factors. The minimum displacement, the best mechanical properties such as tensile stress, compressive stress, torsional shear stress, maximum critical buckling load, and the minimum part weight minimum production cost per piece were selected as quality characteristics. As a result of the FEA study, considering the experimental set of the Taguchi Method L25 orthogonal array, the data on mechanical properties, weight, and production cost per piece were subjected to the MCDM process using the Entropy Weighted TOPSIS method. As a result of the MCDM study, a torque rod made of continuous fiber-reinforced thermoplastic composite material, instead of a torque rod produced by forged steel, had the highest mechanical properties produced, the weight of the torque rod can be reduced by 64.76%, and the production costs per piece can be reduced by 37.5%. This study’s findings have shown that the torque rod produced from continuous fiber-reinforced thermoplastic composite materials in a new geometry with a plus cross-section can be substituted for the torque rod produced by steel forging. Thus, it will contribute to reducing the fixed vehicle weight, especially in heavy commercial vehicles, reducing CO2 emissions, and increasing the range of the vehicles.

Improved Ability to Resist Corrosion of Selective-Laser-Melted Stainless Steel Based on Microstructure and Passivation Film Characteristics

The local corrosion resistance of forging and selective laser melting (SLM) 304 steels was explored by intergranular corrosion analysis, double-loop electrochemical potentiodynamic reactivation, dynamic polarization experimentation, structural analysis, and passivation film characteristics analysis. The ability to resist sensitization of SLM 304 steel is greater than that of forging 304 steel at a temperature of 650 °C for 9 h. Moreover, the pit corrosion resistance of forging and SLM 304 steels is weakened by sensitization, while the pit corrosion resistance of SLM 304 steel is much greater than that of forging steel. Therefore, SLM technology can improve the ability to resist sensitization and pit corrosion of 304 steel. Analysis showed that the ability to resist corrosion of the passivation film of SLM 304 steel is greater than that of forging steel. In addition, corrosion pits are easier to generate at the interface of forging steel and SLM 304 steel. The grain boundary corrosion of SLM 304 steel intensified while the corrosion of the melt pool boundaries weakened after the sensitization treatment, resulting in a decrease in pit corrosion resistance. The coupling effect of these different structures and passivation films decides the pit and sensitization resistance of forging and SLM 304 steels. Clarifying the corrosion mechanism of forging and SLM steels is of great significance for scientific research and the widespread use of SLM technology.

Formation mechanism of inspection defects in hundred-ton class 55NiCrMoV7 die steel forging

Using an ultrasonic flaw detector, this study precisely located the dimensions and distribution characteristics of defects during the manufacturing process of 55NiCrMoV7 die steel forgings weighing hundreds of tons. The probing defects of the forging are predominantly concentrated in the central region, spanning approximately 4200 mm in length, 400 mm height and 1500 mm width. Detailed research on the characteristics of these probing defects was conducted through dissection sampling and scanning electron microscope analysis. The research results reveal that the maximum diameter of an individual defect can reach Φ10 mm, and localised cracking phenomena exist in specific areas within the forging. The flaws exhibit characteristics such as millimetre-sized, large, elongated MnS inclusions, with spacing between inclusions ranging from 200μm to 500μm. Furthermore, based on elemental analysis, the sulphur content from the surface to the core of the forging increased from 0.001% to 0.002% to a maximum of 0.0085%. Through analysis using thermodynamic and growth kinetics models, it was determined that in regions with higher sulphur content (S = 0.0085) at a certain distance from the steel ingot surface, the radius of MnS inclusions can reach up to 380μm under low cooling rates (1 K/min). After forging deformation, these can evolve into millimetre-sized MnS inclusions, leading to internal inspection defects. Therefore, we propose that reducing the sulphur content in the molten steel and increasing the degree of undercooling can effectively inhibit the precipitation and growth of MnS inclusions. Practical results indicate that this improvement strategy effectively enhances the inspection quality of the 55NiCrMoV7 die steel forgings weighing hundreds of tons.

Evaluation of Tribological Characteristics of Environmentally Friendly Lubricants and Chemical Conversion Coatings during Cold Forging of Duplex Stainless Steel

Evaluation of Tribological Characteristics of Environmentally Friendly Lubricants and Chemical Conversion Coatings during Cold Forging of Duplex Stainless Steel

Establishing the hot working window for the forging of S32906 super duplex stainless steel through considering deformation parameter sensitivities

The evaluation of the hot workability of the super duplex stainless steel (SDSS) material still lacks scientific and theoretical basis, leading to the frequent occurrence of unacceptable defects in its forgings. In this study, a novel method for estimating the hot workability of S32906 SDSS was proposed and verified through forging. Firstly, the flow behavior and microstructural characteristics were demonstrated by conducting isothermal compression tests at the deformation temperature from 1000 °C to 1250 °C and the strain rate from 0.01 s−1 to 10 s−1. The influence of microstructure on flow and work hardening behaviors was correlated and displayed. Then, based on the deformation characteristics presented through the variations of strain rate sensitivity (SRS) and deformation temperature sensitivity (DTS) coefficients, the SRS and DTS maps were constructed and overlaid for obtaining the hot working window. Ultimately, a large plate type forging of S32906 SDSS applied in engineering was used to verify the applicability of the obtained window. The new method can provide an in-depth understanding of hot workability and enable control of the forming and microstructural properties for this unique material.

Regulation Law of Tempering Cooling Rate on Toughness of Medium-Carbon Medium-Alloy Steel.

Temper embrittlement is a major challenge encountered during the heat treatment of high-performance steels for large forgings. This study investigates the microstructural evolution and mechanical properties of Cr-Ni-Mo-V thick-walled steel, designed for large forgings with a tensile strength of 1500 MPa, under different tempering cooling rates. Optical microscopy (OM), scanning electron microscopy (SEM), and electron backscatter diffraction (EBSD) were employed to analyze the microstructural features. The results demonstrate that the embrittlement occurring during air cooling after tempering is attributed to the concentration of impurities near Fe3C at the grain boundaries. The low-temperature impact toughness at -40 °C after water quenching reaches 29 J due to the accelerated cooling rate during tempering, which slows down the diffusion of impurity elements towards the grain boundaries, resulting in a reduced concentration and dislocation density and an increased stability of the grain boundaries, thereby enhancing toughness. The bainite content decreases and the interface between martensite and bainite undergoes changes after water quenching during tempering. These alterations influence the crack propagation direction within the two-phase microstructure, further modifying the toughness. These findings contribute to the understanding of temper embrittlement and provide valuable guidance for optimizing heat treatment processes to enhance the performance of high-performance steels in large forgings.

Experimental characteristics of 316L stainless steel thin wall processed in wire-based arc additive manufacturing process

Wire arc additive manufacturing (WAAM) is an innovative technology for the fabrication of larger metal parts with complex geometry. It has a higher deposition rate, low wastage, production efficiency, and close tolerance. In this work, 316L stainless steel parts were manufactured by cold metal transfer-based WAAM process, and the effects of microstructure and mechanical properties were investigated. Microstructure studies reveal the formation of columnar and equiaxed grain morphologies with the development of epitaxial growth along the building direction. The radiographic test confirms various defects such as pores and cracks associated with the 316L deposited part. However, the microhardness studies show a uniform distribution of hardness values. The average value of microhardness of the as-deposited part was 220 HV. Tensile studies show the horizontal samples were ultimate tensile stress (UTS): 576 MPa, yield stress (YS): 302 MPa, and elongation (EL): 35% in comparison with the vertical samples were UTS: 469 MPa, YS: 295 MPa and EL: 39% and the sample exhibits the anisotropy properties. Further, the fracture surface of the tensile sample exhibits a ductile fracture with enough dimples, voids, and plastic deformation. The result shows that fabricated WAAM stainless steel 316L parts exhibit the finer microstructure and improved mechanical properties, which is extremely better than 316L stainless steel casting, forging, and wrought counterparts.

High-strength and high-toughness austenitic stainless steels based on type 316LN at 4.2 K

High-strength and high-toughness prototype steel forgings, N2, N3, and N4, were developed based on type 316LN as a cryogenic structural material. By extrapolating the proportional relationship between carbon plus nitrogen content (C + N) and 0.2 % proof stress (σ0.2) in the range of approximately 0.10–0.25 mass% C + N content, the C + N content was successfully designed to achieve the target σ0.2. To suppress the degradation of the plane-strain fracture toughness (KIC(J)) while increasing the nitrogen solid-solution content, the alloying level was designed by considering the stability of the austenite phase and stacking fault energy. The steel forgings showed a good balance of strength and toughness at 4.2 K, i.e., N2 (σ0.2 = 1142 MPa, KIC(J) = 228 MPa√m), N3 (σ0.2 = 1226 MPa, KIC(J) = 219 MPa√m) and N4 (σ0.2 = 1296 MPa, KIC(J) = 215 MPa√m). The σ0.2 and KIC(J) of ITER-grade 316LN (316LNL, 316LNM, and 316LNH) thick plates with low interstitial (C + N) content of 0.13–0.17 mass% were also evaluated at 4.2 K. Then, the effects of nitrogen content on strength and fracture toughness were successfully clarified in the full range of interstitials concentrations. An alloy design with higher Ni, Mn, and Mo contents in the chemical composition range of 316LN would be desirable for improving the fracture toughness by increasing σ0.2 due to the higher nitrogen content.

The Casting and Hot Forging of Low-Carbon Copper-Bearing Steel and Its Substructural Characterization

The casting of metal alloys followed by hot forging is a widely used manufacturing technology to produce a homogeneous microstructure. The combination of mechanical and thermal energy envisages the microstructural properties of metal alloys. In the present investigation, a metal alloy of composition 0.05C-1.52Cu-1.51Mn (in weight %) was cast in an induction furnace using a zirconia crucible. The melt pool was monitored using optical emission spectroscopy (OES) to maintain the desired composition. The as-cast block was then subjected to forging under a pneumatic hammer of 0.5 t capacity so that any casting defects were eliminated. The as-cast block was reheated to a temperature of 1050 °C and held at that temperature for 6 h to homogenize, followed by hammering with a 50% strain using a pneumatic hammer. The microhardness was calculated using a Vickers microhardness testing apparatus. The microstructure characterization of the processed alloy was carried out using an optical microscope, electron backscattered diffraction (EBSD), energy-dispersive X-ray spectroscopy (EDXA), and a transmission electron microscope (TEM). The sample for optical microscopy was cut using a diamond cutter grinding machine and surface polishing was carried out using emery paper. Further, mechanical polishing was performed to prepare the samples for EBSD using a TEGRAPOL polishing machine. The EBSD apparatus was operated at a 20 kV accelerating voltage, 25 mm from the gun, and with a 60 µ aperture size. HKL Technology Channel 5 Software was used for the post-processing of EBSD maps. The procedure of standard polishing for OES and TEM sample preparation was followed. Recrystallization envisages equiaxed grain formation in hot forging; hence, the strain-free grains were observed in the strained matrix. The lower distribution of recrystallized grains indicated that the driving force for recrystallization was not abundant enough to generate a fully recrystallized microstructure. The fractional distribution of the misorientation angle between 15 and 60° confirms the formation of grain boundaries (having a misorientation angle greater than 15°) and dislocations/subgrain/substructures (having a misorientation angle less than 15°). The fraction of misorientation angle distribution was higher between the angles 0.5 and 6.5°; afterwards, it decreased for higher angles. The substructure was observed in the vicinity of grain boundaries. The softening process released certain strains, but still, the dislocation was observed to be deposited mostly in the vicinity of grain boundaries and at the grain interior. The fine precipitates of the microalloying element copper were observed in the range of size in nanometers. However, the densities of these precipitates were limited and most of these precipitates were deposited at the grain interior. The microhardness of 210.8 Hv and mean subgrain size of 1.61 µ were observed the enhanced microhardness was due to the limited recrystallized grains and accumulation of dislocations/subgrain/substructures.

Tool Surface Degradation and Adhesion in Aluminium Forging

Tool surface deterioration is a crucial effect limiting the efficiency of forging processes. Prior work on wear is limited to steel forging while investigations on tribology in aluminium forging are limited to an abstract or simplified level. The presented work aims at contributing to filling this gap with a holistic analytic approach including ball-on-disc (BoD) tests, ring compression (RC) tests and serial forging (SF) tests close to industrial applications in order to gain insights on effects and influences of surface deterioration and evaluate the suitability of different tool coatings. The results show that the primary influence on surface adhesion in aluminium forging is the superposition of surface enlargement and contact pressure of the material flow. Duplex-treated tools with the combination of a nitriding in the first step and an additional coating with chromium nitride (CrN) afterwards show a significant reduction of aluminium adhesion in ring compression and serial forging tests, representing a promising approach to tool life enhancement in forging applications.

Analysis of Influencing Factors on the Conversion Efficiency of Laser-EMAT Ultrasound Detection with High-Temperature Carbon Steel Forgings

Abstract A method to improve the conversion efficiency based on surface cooling technology was proposed to achieve a low signal-to-noise ratio (SNR) of laser-electromagnetic acoustic transducer (EMAT) detection with high-temperature forgings. A finite element model of the laser-EMAT ultrasonic testing process operated with high-temperature forgings was established to study the effects of the laser source parameters and temperatures on laser-excited ultrasonic waves and their radiated acoustic field. The ratio of the magnetostriction and Lorentz force to the ultrasonic reception efficiency of the EMAT at different temperatures was analyzed and verified experimentally. The results indicate that the surface cooling technology can improve the energy conversion efficiency when the carbon steel temperature exceeds the Curie temperature. With the help of surface cooling technology, the SNR of the longitudinal wave increases by 26.5 dB at 766°C, and the SNR of the shear wave improves by 12.1 dB at 655°C.

Effect of milling parameters on machinability of SA508-3 steel in high-speed milling with uncoated and coated carbide tools

SA508-3 steel is popularly used to produce core unit of nuclear power reactors due to its outstanding ability of anti-neutron irradiation and good fracture toughness. Additive forging is a new technology for manufacturing SA508-3 steel forgings. However, the production efficiency and interface bonding quality of heavy forgings are respectively limited by the processing efficiency and surface quality of substrates in the additive forging process. High-speed milling technology is an effective method for improving machining efficiency and quality. Unfortunately, only a few studies on the milling of SA508-3 steel have been reported. In this study, we studied high-speed milling of SA508-3 steel and compared the cutting performances of uncoated, titanium aluminum nitride (TiAlN)-coated, and Al2O3-coated carbide tools. The tool life and cutting force were evaluated using various milling parameters under dry milling conditions. The wear modes and mechanisms were also investigated. The results show that adhesive wear occurs more frequently in the uncoated carbide tool, whereas coating flaking is predominant in the Al2O3- and TiAlN-coated carbide tools. Furthermore, the Al2O3-coated carbide tool showed better cutting performance than the TiAlN-coated and uncoated carbide tools considering the tool life and surface quality. The tool life of the Al2O3-coated carbide tool reached 200 min and the removed workpiece material was 182 × 103 mm3 under the blunt tool criteria. The study of tool life and wear behavior based on the practical cutting experiments contribute to the improvement of the milling quality and provides a theoretical basis for tool material selection and process optimization in milling SA508-3 steel.

Inhibiting the Leidenfrost Effect by Superhydrophilic Nickel Foams with Ultrafast Droplet Permeation.

Inhibiting the Leidenfrost effect has drawn extensive attention due to its detrimental impact on heat dissipation in high-temperature industrial applications. Although hierarchical structures have improved the Leidenfrost point to over 1000 °C, the current performance of single-scale structures remains inadequate. Herein, we present a facile high-temperature treatment method to fabricate superhydrophilic nickel foams that demonstrate ultrafast droplet permeation within tens of milliseconds, elevating the Leidenfrost point above 500 °C. Theoretical analysis based on the pressure balance suggests that these remarkable features arise from the superhydrophilic property, high porosity, and large pore diameter of nickel foams that promote capillary wicking and vapor evacuation. Compared to solid nickel surfaces with a Leidenfrost temperature of approximately 235 °C, nickel foams nucleate boiling at high superheat, triggering an order of magnitude higher heat flux. The effects of the pore diameter and surface temperature on droplet permeation behaviors and heat transfer characteristics are also elucidated. The results indicate that droplet permeation is dominated by inertial and capillary forces at low and high superheat, respectively, and moderate pore diameters are more conducive to facilitating droplet permeation. Furthermore, our heat transfer model reveals that pore diameter plays a negligible role in the heat flux at high surface temperatures due to the trade-off between effective thermal conductivity and specific surface area. This work provides a new strategy to address the Leidenfrost effect by metal foams, which may promise great potential in steel forging and nuclear reactor safety.

A Study on Electromagnetic Riveting Behavior of High-Strength Rivets Depending on Hardness

Recently, the application of aluminum based on ultra-high strength steel is expanding around high-end models of electric vehicles, so it is necessary to develop strategic welding/joining technologies for these materials. In the case of overseas advanced automobile companies, such development is being carried out at the level of introducing mass production facilities through the development of joining technology, but in Korea, the localization rate of original core technology and related equipment in the field of welding and joining is still very insufficient. Therefore, in this study, in order to develop a high-strength rivet suitable for the rivet process during the multi-material bonding process, cold forging steel was used to attain an appropriate level of hardness through changes in the microstructure through heat treatment. Rivets with different hardness were fabricated through heat treatment, and flaring and tensile test were conducted. As a result of flaring test of rivets, buckling occurred with hardness values of Hv 447 and 486, while cracks occurred without buckling in rivets with hardness values of Hv 506. But as a result of tensile shear test using GA980 and Al5052 materials, there was no significant difference in tensile shear load values according to hardness values of the rivets.

Research on new technology of laser forging coupled arc welding of E690 marine steel

PurposeThe purpose of this study is to reduce the cracks, pores and unfused defects in arc welding, improve the crystalline structure of the weld, refine its grains and improve the mechanical properties.Design/methodology/approachTaking E690 marine steel as the research object, the experiment adopts a new process method of laser forging coupled arc welding. Welding for comparative experiments. Experiments show that the “V”-shaped groove arc welding process has a larger fusion area, but has pores, the arc current is 168 A, the arc voltage is 28 V and the welding speed is 600 mm/min.FindingsIt can be seen from tensile tests that the coupling welding process has the highest tensile strength and yield strength, 872 MPa and 692 MPa, respectively, and the fracture elongation is 29.29%. The single-beam laser forging coupled arc welding process has a distance of laser and wire of 6–8 mm, a laser wavelength of 1,064 nm and the highest weld fusion ratio. The microhardness test shows that the average hardness of single-beam laser forging in the weld zone is 487.54 HV, which is 10.30% higher than that of arc welding. The average hardness in the fusion zone is 788.08 HV, which is 14.52% higher than that of the arc welding process.Originality/valueThe originality of the experiment: proposed a new process method of coupling arc repair for offshore steel forging; adopted a new process method of simultaneous coupling of single-beam short-pulse laser, double-beam short-pulse laser and arc welding; and obtained effect of pulsed laser and arc composite repair on porosity and fusion of E690 marine steel welds.

Studies on a Robotised Process for Forging Steel Synchronizer Rings in the Context of Forging Tool Life

This paper proposes a solution not previously used in the forging industry, which aims to reduce the proportion of arduous human labour. The concept of a prototype robotic station for hot forging includes a system that allows the selection of batch material with its heating, the execution of the process of lu-brication of forging tools and the forging itself, synchronised with the feeding and removal of material using full automation, in accordance with the idea of Industry 4.0. At the same time, by increasing the repeatability of the entire forging process and changing some of its key parameters, it will be possible to influence the durability of the tools used during its implementation. In order to verify the impact of such a modified technological process on forging tool life, computer simulations of forging were performed, where the currently applied technology using hand forging was compared with a conceptual automated process.

Air Cooling Martensites—The Future of Carbon Neutral Steel Forgings?

The air‐hardening ductile forging steels belong to the third generation of advanced high‐strength steels and achieve their final, martensitic microstructure simply by air cooling from the forging heat. The present conference paper reviews the 15 years of development, different alloying strategies, and metallurgical throwbacks like manganese embrittlement. Furthermore, the most recent results concerning microstructure, mechanical properties, and cyclic material behavior obtained from an industrial trial melt are discussed together with the implications of these results on the carbon footprint (CF) and their impact on the resource efficiency of forged steel components. It is demonstrated that the CF of a steel product needs to be discussed on different levels, as the material‐, process‐, and product‐level contributions need to be considered. Furthermore, a case is made for new high‐strength steels in the context of circular economy, as increase fatigue resistance enables lightweighting potentials.