Hardness Distribution Research Articles

Influence of B addition on the Mo diffusion-controlled eutectic dissolution process during homogenization of super austenitic stainless steel S31254

The influence of B addition on dissolution behavior of (σ + γ)e eutectics of a 6Mo super austenitic stainless steel S31254 during the homogenization process was investigated by SEM-BSE observations combined with EDS. The results showed that the addition of 0.005 wt% B accelerated the dissolution of the σ phase controlled by Mo diffusion, during homogenization from 30 to 90 min at 1180 °C. TOF-SIMS results showed that B segregated along the σ/γ interface in the as-cast samples. TEM observations combined with EDS investigated the phase interfaces in two as-cast samples in detail to correlate σ phase dissolution. Compared with the B-free sample, the wide transition zone (∼60 nm) with a composition gradient was more clearly observed at the σ/γ interface in the B-containing sample. The transition zone with B had two features: local segregation of B element and precipitation of R phases at the σ/γ interface. R phases owned larger contents of Mo, which was not almost observed in the as-cast S31254. The results indicated that B segregation changed the phase interface, accelerating Mo diffusion at the σ/γ interface. In addition, the results of nanoindentation indicated a more uniform distribution of hardness at the σ/γ interface after homogenization of the B-containing sample, which can be beneficial to improve the deformation compatibility of S31254 during hot working.

Deep-learning model for predicting hardness and phase distributions from two cross-sectional temperature distribution images in laser heat treatment of AH36 steel

Laser heat treatment of carbon steel is generally performed to increase the hardness of the specimen. However, when the heating temperature is high, softening of the specimen can occur along with melting. It is important to predict both hardening and softening processes, but such research has been limited so far. In this study, a deep learning model was developed that predicts both hardening and softening during laser heat treatment of AH36 steel using two cross-sectional temperature distributions obtained at 0.5-s intervals as inputs. Two temperature distributions were used as inputs to provide accurate information about cooling rate to the model. The input temperature distribution of the cross-section was calculated by solving the heat conduction equation using finite element method, and the hardness and phase distributions used as ground truth were obtained through a 2 kW multi-mode fiber laser experiment. The model was constructed based on a generative adversarial network with a residual network. It was found that when two temperature distributions were used, both softened and hardened areas were predicted accurately. However, when only one temperature distribution was used, only hardening could be predicted. On the other hand, both models could predict phase distributions, but much more accurate results were obtained when two temperature distributions were used as inputs.

Effect of build height on structural integrity of Ti-6Al-4V fabricated via laser powder bed fusion

The additive manufacturing process involves layer-by-layer fabrication of parts, where each layer potentially experiences unique thermal histories, including cooling rates and thermal gradients. These variations can impact the microstructure and, subsequently, mechanical properties of the final product, especially as the height of the build increases. This research aims to investigate the influence of build height on the structural integrity of Ti-6Al-4V specimens fabricated via laser powder bed fusion (LPBF). The microstructural features, microhardness values, and defect characteristics, such as size, location, and distribution of defects, were analyzed along the build direction. Tensile and fatigue tests were conducted to determine the potential height-dependency of fatigue and tensile failures. The findings of this study indicated influence of build height on the structural integrity of parts subjected to cyclic loading, as the majority of the fatigue specimens failed in the upper half of the gage section (with respect to the build direction). Microstructure characterizations and microhardness testing revealed consistent grain morphology along the build direction, with uniform hardness distribution throughout the build height. However, more process-induced defects were detected within the top half of the gage section, compared to the bottom half. The results suggest that as the build height increases, there is a higher likelihood of process-induced defect formation, ultimately leading to a reduction in the structural integrity at greater build heights.

Hardness prediction in the upsetting process of Al%ZrO2—an approach to machine learning using regression and classification models

The current study focuses on the prediction of metal hardness distribution in upsetting tests for different compositions of ZrO2 embedded with an aluminum matrix using machine learning algorithms and finite element (FE) analysis. The mass fraction of the ZrO2 particles varied from 4% to 8%, and three sets of solid cylindrical rods with Al4%ZrO2, Al6%ZrO2, and Al8%ZrO2 were prepared using the stir casting method. The upsetting process was simulated, and an equation for predicting hardness was developed from the equivalent strain distributions. Artificial neural networks (ANNs), multilinear regression (MLR) along with equations developed from FE analysis were used to train the model for regression analysis, considering the principal stresses, friction factor, anisotropy ratio, effective strain, and hoop strain as input and the magnitude of hardness as output parameters. Regression analysis reveals that ANN (tri-layer network), XGBoost, and MLR algorithms are the best suitable for the given data sets with a root mean square ( R2) greater than 0.95. XGBoost, ANN (narrow), and SVM are linear and are the most recommendable classifier algorithms for the current investigation. Hardness data from ring compression tests were used to validate the results obtained from the trained models with the test results.

Microstructure and mechanical properties of superficial surface and subsurface layers in the cutting of hardened steel under cryogenic cooling

Hardened steel parts extensively utilized in manufacturing fields, including automobiles and molds, are difficult to cut and process. Cryogenic cooling is an effective method for reducing tool wear and improving surface quality. However, knowledge about the microstructure and mechanical properties of the hardened steel cutting under a cryogenic cooling condition is severely limited. Herein, low-speed and high-speed cutting experiments with different wear tools were designed to investigate the characteristics and mechanisms of the microstructure, residual stress distribution, and hardness distribution of the superficial surface layer (SSL, including the white and transition layers) and subsurface layer (SL) of hardened steel cutting via cryogenic cooling. Results showed that microstructure changes caused by plastic deformation occurred in both the white and transition layers, whereas no changes occurred in the area below the transition layer. No phase transformation and recrystallization occurred in the white layer, the transition layer, and the area below the transition layer. The intense dislocation slip and strong plastic deformation are the keys to the formation of the white and transition layers. The hardness distribution curve included the surface hardening peak, SL softening valley, and SL hardening peak. The combined effect of fine grain strengthening and dislocation strengthening is the primary mechanism for forming the surface hardening peak. The peak residual tensile stress induces a SL softening valley in the hardness curve, whereas the peak residual compressive stress induces a SL hardening peak in the hardness curve.

Advanced Heat Treatment of Pearlitic Rail Steel.

The aim of this research is a systematic investigation of heat treatments of 60E1 profile rails made of steel R350HT, which would ensure the properties required by the standard EN 16273. Additionally, it presents a concept of cooling rails on a semi-industrial station, which will make it possible to obtain the desired properties. The dilatometric tests have demonstrated that the optimal cooling rate is within the scope of 3 °C/s to 6 °C/s, when both the EN 16273 standard's hardness distribution and microstructure requirements are fulfilled. The tests on the designed and built station showed that the optimal pressure with respect to the microstructure and properties of the rail equals 6.5 bar. For these parameters, measurements of the interlamellar distance were also performed-the cooling rate obtained at the surface was 3.68 °C/s, with an interlamellar distance of about 80 nm, whereas inside the rail the rate was 2.63 °C/s and the distance 110 nm. The achieved results confirm that the designed station can be used for controlled cooling of rail steels from R350HT steel.

Analysis of TB2 rivet forming quality and mechanical properties of thin sheet riveted joints based on different riveting methods

The riveting of high-strength rivets (such as TB2 (Ti-5Mo-5V-8Cr-3Al)) faces difficulties in forming. This article compares the electromagnetic riveting (EMR) and the hot riveting (HR) joints of two typical TB2 rivets (the flat cone head rivet and the countersunk head rivet). The interference and hardness distributions of the rivets were measured, and the strength of the joints was tested. Moreover, the microstructures of rivets after riveting and the fractured surfaces after the shear and pull-out tests were both observed. The results indicate that the interference of the EMR joints is greater and more uniform than that of the HR joints. The deformation of the EMR driven head is more severe than that of the HR. Higher hardness is measured in the driven head and the rivet shank at the positions of severe deformation. The hardness of the EMR driven head and rivet shank is higher than that of the HR. Additionally, it will not cause a decrease and even slightly improve in the mechanical properties of the joint when using the EMR riveting TB2. The pull-out strength of flat cone head rivet joints is significantly higher than that of countersunk rivet joints due to the influence of the structure strength of the manufactured head. The fracture mode of all joints is mixed fracture. However, the failure mode of joint varies greatly due to the influence of rivet structure and riveting method. When using the EMR instead of the HR to rivet the TB2 rivets, it will not cause a decrease in the mechanical properties of the joint. Therefore, it is indicated that the EMR can be used to replace the HR.

Experimental and first-principles calculation study on influence of stacking faults on hardness and anisotropy of M7C3 carbides

M7C3 often exhibits stacking faults (SFs). However, the influence of SFs on carbide properties are rarely studied. To explore effects of SFs, the carbide hardness, elastic modulus, and distribution of hardness and elastic modulus in the grain were analyzed using nanoindentation technology. The SFs structure of M7C3 carbides was analyzed using transmission electron microscopy (TEM). First-principles calculations revealed the influence mechanism of SFs on carbide hardness. The results showed that high-density SFs improved the carbide hardness by approximately 2 GPa. Uneven distribution of SFs leads to uneven hardness and elastic modulus of M7C3 carbides. The SFs disrupt the ordered arrangement of C-Cr bonds, which reduces the anisotropy of Cr7C3. The change in carbide strength was not due to the change in bond strength. Instead, the lattice distortion caused by the change in the C-Cr bond angle in Cr7C3-SFs increased the deformation resistance of the crystal and improved the hardness of Cr7C3.

Microstructure Evolution at Ni/Fe Interface in Dissimilar Metal Weld between Ferritic Steel and Austenitic Stainless Steel.

The formation and evolution of microstructures at the Ni/Fe interface in dissimilar metal weld (DMW) between ferritic steel and austenitic stainless steel were investigated. Layered martensitic structures were noted at the nickel-based weld metal/12Cr2MoWVTiB steel interface after welding and post-weld heat treatment (PWHT). The formation of the interfacial martensite layer during welding was clarified and its evolution during PWHT was discussed by means of scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), electron probe microanalysis (EPMA), focused ion beam (FIB), transmission electron microscopy (TEM), energy dispersive X-ray (EDX), transmission kikuchi diffraction (TKD), phase diagrams, and theoretical analysis. In as-welded DMW, the Ni/Fe interface structures consisted of the BCC quenched martensite layer and the FCC partially mixed zone (PMZ), which was the result of inhomogeneous solid phase transformation due to the chemical composition gradient. During the PWHT process, the BCC interfacial microstructure further evolved to a double-layered structure of tempered martensite and quenched martensite newly formed by local re-austenitization and austenite-martensite transformation. These types of martensitic structures induced inhomogeneous hardness distribution near the Ni/Fe interface, aggravating the mismatch of interfacial mechanical properties, which was a potential factor contributing to the degradation and failure of DMW.

Study on the Influence of Surface Integrity on Hydrogen Permeation Resistance of Hydrogen Production Reactor Materials

Hydrogen permeation reduces a material’s properties and increases the risk of brittle fracture, which causes a potential safety hazard. A workpiece’s hydrogen permeation resistance could be improved by improving its surface integrity through surface processing. This paper studies low-alloy steel’s surface integrity and its hydrogen permeation resistance in a hydrogen production reactor, using the electrochemical cathodic hydrogen-charging method to carry out electrochemical hydrogen-charging experiments. After the specimens were pretreated using different surface-grinding methods and shot peening pressure strengthening, they were hydrogen-charged on a self-designed and built electrolytic hydrogen charging platform. Before and after hydrogen charging, the specimens’ section hardness and tensile strength were tested, and the fracture morphology of the specimens was observed. The influence laws of surface roughness and surface residual compressive stress on the distribution of material hardness along the depth, the variation in material hardness, the fracture morphology, and the decline in the tensile properties of the low-alloy steel specimens after 5 h of hydrogen charging were analyzed. The reasons for the influence of surface integrity indexes on the hydrogen permeation resistance of the specimens were also analyzed. Based on the experimental results, a series of mechanical processing parameters were proposed to improve the material’s permeation resistance, which provides a theoretical and practical basis for the processing of materials with high surface integrity and hydrogen permeation resistance. Through the experiments, it was found that the hydrogen permeation resistance of the Ra 0.17 μm surface roughness specimen was the best of all specimens with different surface roughness values, and its hydrogen embrittlement sensitivity index was 20.96%. The specimen had the best hydrogen permeation resistance under 336 MPa surface residual compress stress, and its hydrogen embrittlement sensitivity index was 16.45%.

Studying the STA effects on aluminium alloy joints by friction welding

This article examines the properties of joints fabricated by friction welding (FW) using AA6061-T6 and AA7075 as examples of both similar and dissimilar metals. It also looks at how heat treatment after welding affects the metallurgical characteristics of the joint. The heat treatment method under investigation combines solutionizing heat treatment with synthetic ageing (STA). The tensile characteristics, microhardness, and microstructure of the as-welded and STA-treated welded specimens are assessed in the paper using mechanical testing equipment and metallurgical characterization methods. The findings demonstrate that the joint characteristics are enhanced by precipitate nucleation occurring in the joint interface of the FW similar and dissimilar joint under STA treatment. On the other hand, the STA influence on the tensile strength (TS) of joints made with AA7075 was greater than that of similar joints made with AA6061-T6, as well as dissimilar joints made with both AA6061-T6 and AA7075. Additionally, after STA treatment, the similar joints showed a uniform distribution of hardness. However, in the dissimilar joint after STA treatment, the hardness dropped suddenly on the AA6061-T6 side, specifically from the partially deformed zone (PDZ) towards the heat affected zone (HAZ).

Study on inhibition of interfacial compounds and improvement of joint properties by low temperature and high-pressure process in diffusion bonding of Ti/Cu

The vacuum diffusion bonding of Ti/Cu under low temperature and high pressure was prepared to explore a suitable process to inhibit the formation of Ti–Cu intermetallic compounds and thus effectively improve the strength of Ti/Cu joints. The conventional diffusion bonding of Ti/Cu joint was also compared and analyzed. The diffusion process, especially the bonding temperature, significantly influences the morphology of the joint interface. At a lower diffusion temperature (550–580 °C) and a larger bonding pressure (30∼40 MPa), the effective bonding of Ti/Cu was realized. Low temperature inhibited the nucleation and growth of intermetallic compounds, and the types and thicknesses of intermetallic compounds at the interface decreased significantly. The interface of the Ti/Cu joint prepared at 550°C- 40 MPa formed an amorphous transition layer with a width of approximately 10 nm, rather than a brittle intermetallic compound layer. The grain size of the transition layer was mainly concentrated in the range of 0.25–1.05 μm. The hardness distribution of the sample did not show an obvious increase. The shear strength of the Ti/Cu joint at 580°C-30MPa reached 181 MPa.

Application of the symmetric Poisson-Boltzmann theory to equilibrium thermodynamic properties of primitive model electrolyte mixtures

A symmetric Poisson-Boltzmann theory is applied to a primitive model electrolyte solution containing 7 different ion species. Only 7 coupled equations need to be solved for the mean electrostatic potential around the ions once the uncharged hard sphere radial distribution function is specified. Comparison is made with the individual activity and osmotic coefficients of a simulation study of a sea water mixture. Good overall agreement is found with the simulation results.

Microstructural evolution and intermetallic formation in Zn-3Mg (wt%) powder mixture processed by high-pressure torsion

Severe plastic deformation (SPD) techniques have been used extensively over the past 40 years for producing strong metals and alloys. High-pressure torsion (HPT) is one of the most promising SPD techniques for achieving high strength through nanoscale grain refinement and phase transformation. In this research, a mixture of pure zinc (Zn) and magnesium (Mg) powders, Zn-3Mg (wt%), was HPT-processed under a pressure of 6 GPa for 1, 5, 10, 20, and 30 turns at room temperature to achieve a high strength biodegradable material. In order to understand the effects of pre-consolidation on the resulting microstructure and hardness, HPT processing was performed on loose powders placed in the die and also on a pre-compacted powder mixture and the resulting HPT disks were characterized by X-ray diffraction, scanning electron microscopy, atom probe tomography, and Vickers microhardness. In both cases, the HPT disk microstructures contained nanoscale grains, and stable and metastable strain-induced intermetallics, but an unusual softening appeared at large shear strains. Grain size, grain morphology, and the formation of different intermetallics were analyzed to explain the unusual hardness distribution, and it was found that an inverse Hall-Petch relationship between hardness and grain size exists. It is suggested that thermally-activated phenomena such as grain boundary sliding contributed to the strain-induced softening of this nano-structured biomaterial due to its low melting point. The current results are compared with those for HPT-processed cast alloys and hybrids of the same composition.

Development of a cold spot joining method that enables sound joining of carbon steel below the A1 temperature

A novel solid-state joining method, which we call cold spot joining (CSJ), was successfully developed. In this joining concept, the material in the vicinity of the interface is plastically deformed using high pressure to form the joining interface, and impurities at the interface are expelled to the outside. Medium-carbon steel sheets were joined using the CSJ method under various process conditions. The joining temperature can be modified by the pressure applied during CSJ. Microstructural observations and hardness distributions revealed that proper pressurisation led to a joining temperature below the A1 point and prevented the formation of brittle martensitic phase. A sound S45C joint showing plug rupture at the base metal under both tensile shear and cross-tension tests was successfully fabricated by providing appropriate applied pressure and energising conditions.

Effects of Stacking Number on Microstructure and Mechanical Properties for Cold Roll Bonding Process of Dissimilar Aluminum Alloy Sheets

A cold roll-bonding (CRB) process is applied to study the effects of stacking number on the microstructure and mechanical properties of roll-bonded and age-treated Al sheets. Commercial AA1050 and AA6061 sheets with a thickness of 2 mm were stacked alternately on each other to two and four layers, and roll-bonded by multi-pass cold rolling. The roll-bonded Al sheets were then subjected to natural aging (T4) and artificial aging (T6) treatments. The as roll-bonded Al sheets showed a typical deformation structure, where the grains are elongated in the rolling direction regardless of the stacking number. However, after the T4 and T6 aging treatments, the Al sheets had a recrystallization structure consisting of coarse grains in both the AA5052 and AA6061 regions with different grain sizes in each. In addition, the sheets showed an inhomogeneous hardness distribution in the thickness direction, with higher hardness in AA6061 than in AA1050 after the T4 and T6 age treatments. The tensile strength of the T6-treated specimen was higher than that of the T4-treated one for both the 2 and 4-layer CRBs. In addition, both the tensile strength and elongation of the specimens processed by the 4-layer stack CRB were higher than those of the 2-layer stack CRB for all experimental conditions.

Microstructure and microhardness of electron beam melted Ti–6Al–4V components with differential thickness in initial deposition layers

Electron beam powder bed fusion (EB-PBF) is a process to additively manufacture Ti–6Al–4V. Along with process induced defects, the unique microstructure of EB-PBF Ti–6Al–4V leads to anisotropic properties, and therefore an understanding of how the microstructure evolves as layers are added is required. This experimental study presents the microstructural evolution of Ti–6Al–4V during the deposition of initial layers in EB-PBF process. Two geometries of specimens, ramp and step, were fabricated from 0.1 mm thickness (2 layers) to 0.7 mm (14 layers), and 0.2 mm (4 layers) to 1.4 mm (28 layers). The evolution of the microstructure was investigated through optical and electron microscopy, spatial microhardness mapping, and detailed microstructural characterization. Up to the deposition of seven layers, the microstructure comprised of α+β phases with partially retained α′ phase from rapid solidification cooling that resulted in higher microhardness. A unique microstructural gradient composed of three distinct regions (Region I, II, III) appears along the build direction from the deposition of 10 layers until 28 layers. Region I showed a finer α+β microstructure in irregular prior β grain with partial martensitic α’ phase and displayed greater microhardness. Region II showed coarser α+β microstructure and lower microhardness than both Region I and III. The average α-lath thickness and α-volume fraction increased as new layers were deposited. Perpendicular to the build direction, the hardness distribution was observed to be uniform along the longitudinal x-y direction.

Taguchi Optimization of Electrolytic Plasma Hardening Process Parameters on Ti‐6Al‐4V Alloy: Microstructure and Mechanical Properties

Herein, the effects of electrolytic plasma treatment (EPT) on the hardness distribution, wear resistance, and surface morphologies of titanium alloy (Ti‐6Al‐4V) at three different thermal cycles (4‐5‐6 times) are investigated. The microstructure is controlled by heat temperature and modification times of thermal cycles depending on EPT processing parameters. A novel technique to modify Ti‐6Al‐4V alloy by the process of EPT successfully occurs. The results show that the phase transformation is shown as follows: fine α and β for the low thermal cycle → irregular martensite α′ for the high thermal cycle → complete zigzag martensite α′ for the max thermal cycle. The hardness is increased from 350 ± 10HV0.05 to 530 ± 10HV0.05 after the modification. Wear tests are conducted according to the Taguchi L9 (3^3) orthogonal array. Three parameters (load, sliding speed, and sample type) with three levels examine wear rate and coefficient of friction. Optimum levels are obtained by Taguchi analysis from the experimental results. In addition, an analysis of variance is performed to find the effectiveness of the parameters. The wear surfaces are analyzed by scanning electron microscope. After the analysis, the best result is obtained in five thermal cycles.

Phase formability and nanomechanical properties in nanostructured multi-principal element alloys: Combinatorial and data-driven studies

The identification of multi-principal element alloys with optimal properties from a vast composition space is a daunting task, particularly for high-entropy alloys (HEAs) composed of five or more elements. Despite increasing theoretical and experimental investigations, the majority of HEAs are developed through a time-consuming trial-and-error approach. Here we demonstrate a combinatorial and data-driven methodology based on a composition gradient TiZrHfNbTa library. Using synchrotron X-ray diffraction and high-speed nanoindentation, we characterized the phase formability and mechanical properties, respectively. We correlated the compositions with the distributions of structures, elastic moduli, and hardness in the TiZrHfNbTa system and proposed a kinetic phase formation criterion based on critical cooling rates. Moreover, we evaluated high-throughput data extrapolation models including the volume fraction of triple junctions, the Hall-Petch relationship, and machine learning. Our methodology opens up new avenues to the accelerated discovery of multi-principal element alloys by revealing relationships among compositions, phase formability, and mechanical properties.

Correlation of Microstructure and Local Mechanical Properties Along Build Direction for Multi-layer Friction Surfacing of Aluminum Alloys

The process variant of friction surfacing (FS) depositing multiple layers on top of each other is known as multi-layer friction surfacing (MLFS). Due to the solid-state nature of the process, re-heating is significantly reduced compared to common fusion-based AM techniques. The work gives a detailed and fundamental insight into the microstructure along the MLFS build direction for two different aluminum alloys and different process parameters. Focusing on the grain size distribution and recrystallization ratio, the stacks show a higher degree of recrystallization and finer grains at the interfaces. The observed grain sizes at the interfaces were 2.0 µm (AA5083) and 1.1 µm (AA2024), and 5.8 µm (AA5083) and 3.1 µm (AA2024) at the layer center. For the non-precipitation-hardenable alloy (AA5083), the local microstructural trend could be related to the hardness distribution along the stacks, i.e., a slightly higher hardness at the layer interfaces (95 HV) compared to the layer center (90 HV). The relationship is more complex for precipitation-hardenable alloys (AA2024), which show a rise in hardness between 40 HV0.2 and 45 HV0.2 along the stack height. The effect of subsequent layer depositions on the microstructure and hardness is discussed and a distinctive grain size distribution along the build direction was shown to be a fundamental characteristic.