Metallographic Structure Research Articles

EFFECT OF NITROGEN ON THE THERMAL DEFORMATION BEHAVIOR OF MARTENSITIC STAINLESS BEARING STEEL

The thermal deformation behaviors of martensitic stainless bearing steels (0.16N, 0N) in the temperature range 850–1150 °C, strain rate 0.01–10 s–1, and deformation of 60 % were studied using a single-pass compression experiment. After adding 0.16 % nitrogen, the peak stress of the martensitic stainless bearing steel increased under all thermal forming conditions, and the average peak stress increased by about 33.724 MPa. The strain-rate sensitivity diagram, power dissipation diagram, instability factor diagram, and thermal processing diagram under different strains were constructed based on the stress-strain curve. The thermal deformation activation energy under different strains was constructed and combined with a metallographic structure analysis. The results show that under the same conditions, the occurrence of DRX in 0.16N bearing steel is less than that of 0N bearing steel, but the grains are finer than those of 0N bearing steel.

Superpixel-based principal feature clustering annotation method for dual-phase microstructure segmentation

Metallographic analysis is one of the most commonly used techniques by materials scientists for studying metal materials. The deep learning methods, which have been widely applied in metallographic images analysis, demonstrate excellent performance in this task. However, the optimization of deep learning models often relies on a substantial amount of accurately labeled samples for effective supervision. To address this issue, this paper proposes a novel automatic annotation method based on brightness and spatial distribution which is suitable for deep learning-based segmentation of optical dual-phase metallographic microstructure. The proposed automatic annotated method includes the superpixel segmentation, principal feature extraction, and clustering algorithm therefore it is referred as the superpixel-based principal feature clustering annotation (SPFCA) method. SPFCA employs discriminative criteria similar to those used by metallurgists to differentiate between metallographic structures. Furthermore, it can mitigate the occasional errors inherent in manual annotation, leading to improved performance compared to models trained with expert annotations. Experimental validation was conducted using four self-built datasets with different image qualities to test the performance of models from different perspective. Initially, hyperparameter optimization for the SPFCA method tailored to our dataset was performed. Subsequently, SPFCA was utilized to guide the optimization of the convolutional neural network employed for segmentation. The results demonstrate that the segmentation model optimized with SPFCA guidance achieved an F1 score of 0.9226 in the single dataset without the need for manual labeling, surpassing the segmentation models optimized with expert annotations.

A soft scanning electron microscopy for efficient segmentation of alloy microstructures based on a new self-supervised pre-training deep learning network

To provide an on-site metallographic segmentation using only optical microscopy images, sSEM-Net, a soft scanning electron microscopy network, is developed based on a self-supervised pre-training deep learning framework. During model training, only a sparse collection of SEM images is necessary for annotation assistance. By integrating CNN and Transformer, sSEM-Net efficiently utilizes global context information while mitigating data dependency and computational resource constraints. Using only readily available optical microscopy images as input, sSEM-Net achieves metallographic segmentation comparable to SEM images, catering to rapid and cost-effective industrial needs. This methodology leverages non-destructive inspection attributes, catering to rapid and cost-sensitive industrial requirements. The efficacy of the proposed sSEM-Net is demonstrated through metallographic structure analysis of TC4 titanium alloy, with potential extensions to other alloy types.

Causes and analysis of failure of bearing cage at non-driven end of wind turbine generator

The non-driving end bearing cage of a wind turbine generator experienced a fracture and subsequent failure. In order to understand the reasons behind this failure, various analyses were conducted including examination of the metallographic structure, mechanical properties, fracture surface morphology, bearing vibration, and operating temperature of the cage. Through this analysis, the fracture process of the cage was deduced. The findings indicate that the fracture of the bearing cage was directly caused by the abnormal installation of the spacer. The eccentricity of the axial component resulted in ductile fracture, while the eccentricity of the radial component led to brittle fractures.

Analysis of cracking failures in water-cooled wall fins and thermal peaking unit mitigation strategies

Abstract The causes of leakage in the submitted superheater tubes were analyzed using the analysis of macroscopic morphology, chemical composition, and metallography. The analysis results indicate that the chemical composition of the failed superheater tube is within the standard range, and the metallographic structure is ferrite + pearlite, with no abnormalities in the metallographic structure. The main reason for the failure of water-cooled wall tubes and superheater tubes may be the formation of fatigue cracks on the inner and outer walls of the superheater tubes under cyclic stress. As the two fatigue cracks grow and converge, penetrating cracks form, ultimately leading to the initial leakage of the superheater tubes. In addition, the excessive depth of the weld pool in the fins of the superheater tube is another crucial factor that promotes accelerated cracking of the superheater tube. It is recommended that power plants reasonably regulate the temperature difference fluctuation rate of boilers to prevent similar failure accidents from occurring.

Failure analysis on cracking and leakage of 304 stainless steel flange in petrochemical butyl device

Abstract During the pressure test process in a petrochemical butyl device in China, it was found that the 304 stainless steel flange of the ethylene pipeline appeared to be cracking and leakage. This article analyzed the reasons for failure using macroscopic inspection, chemical composition analysis, metallographic structure analysis, scanning electron microscope, energy dispersive spectroscopy, mechanical properties test, and intergranular corrosion test. The results show that the carbon content of the flange base material exceeds the standard, many carbides precipitate at the grain boundary, the material itself is seriously sensitized, and the intergranular corrosion resistance is reduced. At the same time, under corrosive media such as sulfur and chlorine and high stress, the flange displays stress corrosion cracking, which leads to cracking and leakage failure. This article reports the reasons for the failure of the flange, and some reasonable suggestions are put forward to avoid similar leakage accidents.

Study on the influence of trace elements H on the properties of A356 aluminum alloy

Abstract The vacuum melt purification refining technology can significantly reduce the content of hydrogen elements in alloy melts and prevent defects such as hydrogen-induced pinholes. This article investigates the effect of hydrogen content on the chemical composition, mechanical properties, and structural defects of A356 alloy melt by using vacuum melt purification refining technology to reduce the hydrogen content in A356 alloy melt. The experimental results show that: 1) there is basically no loss of chemical elements during the vacuum melting process; 2) The use of vacuum refining and purification control technology can control the hydrogen content inside the melt to be ≤ 0.10ml/100g; 3) The effect of H content on the metallographic structure of A356 alloy is not significant, but it has a certain improvement on the tensile strength at room temperature, but the increase is ≤ 5%.

Low cycle fatigue behavior and failure mechanism of 34CrNiMo6 steel used as connecting rod for diesel engine

Abstract In this paper, for the 34CrNiMo6 steel material used in diesel engine connecting rods, the low-cycle fatigue properties and failure mechanism were studied. The metallographic structure of 34CrNiMo6 has been investigated by using optical microscopes, scanning electron microscopes, and transmission electron microscopes. Tensile tests and low-cycle fatigue experiments were performed at different levels of strain amplitudes, and the microstructural changes were monitored. The examination indicates that the structure of 34CrNiMo6 steel consisted primarily of a ferrite base and small spherical and rod-shaped carbides, with a mean particle size measuring 2 μm. It had exceptional mechanical characteristics of high strength and moderate plasticity. The total strain amplitude (TSA) of 34CrNiMo6 steel affected the cycling behavior, which was stable at low TSA (0.2% ~ 0.3%). At high TSA (0.4% ~ 0.7%), a large number of dislocations were annihilated through the dynamic recovery process, showing a typical cyclic softening phenomenon. The low-cycle fatigue failure behavior was mainly a combined mode of quasi-cleavage fracture and cross-grain fracture.

The Influence of Weld Interface Characteristics on the Bond Strength of Collision Welded Aluminium-Steel Joints.

Collision welding is a promising approach for joining conventional materials in identical or dissimilar combinations without heat-related strength loss, thereby opening up new lightweight potential. Widespread application of this technology is still limited by an insufficient state of knowledge with respect to the underlying joining mechanisms. This paper applies collision welding to a material combination of DC04 steel and EN AW 6016 aluminium alloy. Firstly, the welding process window for the combination is determined by varying the collision speed and the collision angle, the two main influencing variables in collision welding, using a special model test rig. The process window area with the highest shear tensile strength of the welded joint is then determined using shear tensile tests and SEM images of the weld zone. The SEM investigations reveal four distinct metallographic structures in the weld zones, the area fractions of which are determined and correlated with collision angle and shear tensile strength.

Silicon-Based Nanocomposite Anodes with Excellent Cycle Life for Lithium-Ion Batteries Achieved by the Synergistic Effect of Two Silicides

Nanocomposite electrodes comprising LaSi2 and Si exhibit satisfactory charge–discharge cycling performances but their capacity is degraded after repeated cycles. A metallographic structure, in which the Si phase was finely dispersed in the LaSi2 matrix phase, was formed before cycling. The elastic LaSi2 relieved Si-generated stress and suppressed electrode disintegration. Contrarily, the LaSi2 phase in the metallographic structure was surrounded by the Si matrix phase after cycling. The positional relationship between the two phases was reversed, and LaSi2 could not relieve the stress. For a nanocomposite electrode containing CrSi2, which exhibits stiffness to withstand the Si-generated stress, the structural changes were suppressed after cycling, resulting in good cycling stability. Here, we considered that the addition of stiff silicides as a third phase to the LaSi2/Si composite could improve the cycle life. Thus, this study prepared nanocomposite electrodes containing elastic LaSi2, stiff MSi2 (where M = Cr, Mo, Nb, Ta, Ti, or W), and elemental Si and investigated their electrochemical performances. Reaction behaviors, such as the metallographic structure, electrode thickness, and phase transition, were also clarified. The LaSi2/NbSi2/Si electrode exhibited the best cycle life without changes in its metallographic structure owing to the synergistic effect of stiff and elastic silicides.

Effects of Er2O3 contribution on microstructure and mechanical properties of high entropy and dual phase alloys

The study aimed to look at the differences between a high entropy alloy and a dual phase high entropy alloy with high iron and Mn content. It also wanted to find out what happened when a small amount of the rare earth element erbium oxide (Er2O3) was added to these alloys, especially on the mechanical and microstructure of the alloy. The first step in this study was to get 99 % pure metal powders, which were then made by dividing the powders into 30 g of equal weight. The powders were mixed evenly and then pressed into 10-g blocks under 6 tons of pressure. They were then set up to be melted in an arc. Four of the eight samples that were melted in an arc under vacuum were treated with heat. The four different compositions were then turned into small metallographic samples for SEM, EDX, Mapping, XRD, and microhardness tests. The study's imaging and analysis processes were also carried out. After that, SEM images were taken at various magnifications (100X, 500X, 1000X, 2500X, and 5000X), and EDS and XRD analyses were done on different structures found in these images. These analyses were based on literature research about the clarity of the metallographic images in the alloy, which showed the study's metallographic differences. The samples were put through microhardness and wear tests to see which one was stronger and less worn. The dual phase high entropy alloy (A2) was stronger and less worn than the high entropy alloy (A1). Er2O3 had little effect on the alloys' mechanical properties or microstructure. The heat treatment that was done to the samples helped the metallographic structure. In terms of physics, it didn't change the hardness much, but it did make the material wear less quickly.

Microstructural Optimization and Corrosion Resistance Enhancement of Austenitic 317L Stainless Steel through Tailored Heat Treatment

Austenitic 317L stainless steel was favored in many industrial applications due to its excellent corrosion resistance and mechanical properties. The study involved heat treating Austenitic 317L stainless steel samples at temperatures of 500℃, 950℃, and 1100℃ to explore the effects of heat treatment temperature on microstructure and corrosion resistance. Electrochemical analysis showed that the 317L sample treated at 1100℃ exhibited the lowest passive current density, indicating the best improvement in corrosion resistance at this temperature. Results from corrosion weight loss experiments confirmed that the least weight loss occurred under the heat treatment conditions of 950℃ and 1100℃, suggesting enhanced corrosion resistance of the material. Microstructural characterization revealed that after heat treatment at 950℃, the metallographic structure transformed from a complex, irregular size and chaotic growth pattern to uniformly grown and comparatively equal-sized metallographic structures. Furthermore, heat treatment at 1100℃ resulted in larger metallographic structures with reduced boundary width and distribution density. Consequently, enhanced corrosion resistance was observed at both temperatures. Based on these findings, a heat treatment range of 950℃ to 1150℃ appeared to be a suitable post-processing method for optimizing the microstructure of 317L while concurrently improving its corrosion resistance.

Inconel 740H Prepared by Additive Manufacturing: Microstructure and Mechanical Properties

An Inconel 740H nickel-based alloy was fabricated via wire arc additive manufacturing. The as-welded and heat-treated samples were analyzed to investigate their phase composition, microstructure, crystal structure, and mechanical properties. After heat treatment, the sample exhibited a columnar crystal zone microstructure consisting of a γ matrix + precipitated phase, the remelting zone metallographic structure was a γ matrix + precipitated phase, and the HAZ metallographic structure was a γ matrix + precipitated phase. Transmission electron microscopy (TEM) and electron backscatter diffraction (EBSD) were used to show that the welded sample exhibited many dislocations, a few inclusions, and carbides, nitrides, and γ’ precipitates in its crystal structure. In contrast, the crystal structure of the heat-treated sample exhibited a lower number of dislocations and significantly higher carbide and γ’ precipitate content. Moreover, the mechanical performance of these samples was excellent. This heat-treatment process improved the sample strength by about 200 MPa, leading to better high-temperature mechanical properties. This work is anticipated to offer theoretical and experimental support for using additive manufacturing methods in the manufacturing of nickel-based superalloy components.

Molybdenum Disilicide (MoSi2) and Ferrophosphorus Particles (FemPn) Improve the Anti-Seizure Properties of Copper-Tin-Bismuth Composites under Conformal and Nonconformal Contacts

Seizure is a severe accident that can abruptly stop or even damage running equipment. Improving the anti-seizure properties of friction pair materials is also crucial as lubricating and wear resistance. While the tribological performances of molybdenum disilicide (MoSi2) and ferrophosphorus (FemPn) particle-doped copper-tin-bismuth (Cu-Sn-Bi) composites have been investigated in previous studies, the specific effects of MoSi2 and FemPn particles on the anti-seizure property of Cu-Sn-Bi materials remain unclear. This study explores the seizure resistance of Cu-Sn-Bi composites containing MoSi2 and/or FemPn under conformal and nonconformal contact conditions. The materials were prepared using powder sintering technology, and the metallographic structures of four types of self-lubricating copper composites were observed. Seizure resistance under starved lubrication conditions was investigated, and the worn surfaces under different contact types were discussed and analyzed. The results indicate that the addition of MoSi2 and/or FemPn particles effectively refines the grain size, and these particles exhibit different distribution trends after powder sintering. The MoSi2 and FemPn particles improved the maximum seizure load of copper-based composite samples by 66.67% and 84.62%, respectively. The seizure forms under different contact types were also discussed.

DOCOL 1100M WELDING IN THE CONSTRUCTION OF ELECTRIC MEANS OF TRANSPORT

Advanced high-strength steels are important for the automotive sector. Metal active gas (MAG) is the most popular method for joining grades of steel. The goal of the paper is to analyze the mechanical properties of the MAG welding joint made of high-strength DOCOL 1100M intended for the construction of electric vehicles. The manuscript shows a basic understanding of the properties of DOCOL joints. This type of material is characterized by a martensitic microstructure, which makes it difficult to make a proper joint. The tensile strength, metallographic structure, and type of non-metallic inclusions were analyzed as a function of the oxygen amount in the protective gas mixture. Investigations of oxide non-metallic inclusions were carried out using scanning electron microscopy. This article attempts to obtain high joint strength of the electric vehicle structure by controlling the average size of non-metallic inclusions in the weld, which is influenced by shielding gas in the MAG welding process. The solution has application potential for the automotive industry, especially for electric vehicles.

Comprehensive corrosion failure analysis of HAl77-2 alloy tubes serving in a low temperature multi-effect distillation plant: From feature analysis to corrosion mechanisms

Premature perforation and leakage of HAl77-2 alloy heat exchanger tubes occurs after 2.5 years of service in the largest low temperature multi-effect distillation (LT-MED) plant in China. The root reasons of perforation and leakage of tubes were investigated through macroscopic morphology, chemical composition, metallographic structure, seawater quality, flowing simulation and microstructure characterization. The results show that the HAl77-2 alloy tubes with perforation leakage meet the standard requirements. And the failure of the tubes was mainly attributed to the synergistic effect of serious pitting corrosion and stress cracking caused by the high fluid pressure and polluted seawater with Fe2+/Fe3+, sulfide and NH4+. Especially, the velocity and pressure spatial distribution of liquid film on the outside of horizontal tubes well verified the interesting observation that corrosion pits concentrating in one strip on the top of the tube. Moreover, corrosion mechanism was proposed that the loose corrosion products of Cu2S, FeS and Cu2(OH)3Cl lead to the formation of some defect points on the homogeneous protective Cu2O layer. For these defect points, the direct expose of the alloy matrix to corrosive substances such as Cl− and NH4+, significantly accelerates the dissolution of Cu in form of CuCl2− and Cu(NH3)2+ from the alloy. Finally, the tube occurs pitting corrosion and even perforates under the strong hydraulic erosion after long-terms of operation.

Semi-Solid Forging Process of Aluminum Alloy Connecting Rods for the Hydrogen Internal Combustion Engine

As an important piece of equipment for hydrogen energy application, the hydrogen internal combustion engine is helpful for the realization of zero carbon emissions, where the aluminum connecting rod is one of the key core components. A semi-solid forging forming process for the 7075 aluminum alloy connecting rod is proposed in this work. The influence of process parameters, such as the forging ratio, sustaining temperature, and duration time, on the microstructures of the semi-solid blank is experimentally investigated. The macroscopic morphology, metallographic structure, and physical properties of the connecting-rod parts are analyzed. Reasonable process parameters for preparing the semi-solid blank are obtained from the experimental results. Under the reasonable parameters, the average grain size is 41.48~42.57 μm, and the average shape factor is 0.80~0.81. The yield strength and tensile strength improvement ratio of the connecting rod produced by the proposed process are 47.07% and 20.89%, respectively.

Design, fabrication, and clinical characterization of additively manufactured tantalum hip joint prosthesis

Abstract The joint prosthesis plays a vital role in the outcome of total hip arthroplasty. The key factors that determine the performance of joint prostheses are the materials used and the structural design of the prosthesis. This study aimed to fabricate a porous tantalum (Ta) hip prosthesis using selective laser melting (SLM) technology. The feasibility of SLM Ta use in hip prosthesis was verified by studying its chemical composition, metallographic structure, and mechanical properties. In vitro experiments proved that SLM Ta exhibited better biological activities in promoting osteogenesis and inhibiting inflammation than SLM Ti6Al4V. Then, the topological optimization design of the femoral stem of the SLM Ta hip prosthesis was carried out by finite element simulation, and the fatigue performance of the optimized prosthesis was tested to verify the biomechanical safety of the prosthesis. A porous Ta acetabulum cup was also designed and fabricated using SLM. Its mechanical properties were then studied. Finally, clinical trials were conducted to verify the clinical efficacy of the SLM Ta hip prosthesis. The porous structure could reduce the weight of the prosthesis and stress shielding and avoid bone resorption around the prosthesis. In addition, anti-infection drugs can also be loaded into the pores for infection treatment. The acetabular cup can be custom-designed based on the severity of bone loss on the acetabular side, and the integrated acetabular cup can repair the acetabular bone defect while achieving the function of the acetabular cup.

Failure analysis and heat treatment process optimization of NOS525 rotary flat binaural hot forging die

A NOS525 steel rotary flat binaural hot forging die frequently failed too early due to collapse and wear in service. In this paper, the rotating planar binaural failure die was taken as the research object. Firstly, the sample design and sample processing of the failure die with different depths and directions were carried out. The material composition, hardness and metallographic structure of the samples were analyzed, and the tensile and impact properties were tested by direct-reading spectrometer, Rockwell hardness tester, optical microscope, scanning electron microscope, MTS testing machine and impact testing machine, etc. Meanwhile, with the help of Deform-HT software and JMatPro software, the coupling simulation of hardness, temperature and structure of the heat treatment of NOS525 steel was realized, and the hardness change of the material after heat treatment was predicted and verified by heat treatment test. The research results show that the composition of the die material is abnormal, especially the excessive P and C elements, at the same time, there is a phenomenon of quenching overheating and insufficient tempering, resulting in insufficient strength, toughness and hardness of the die material, in addition, the die surface is subjected to the cold and hot alternating load, and finally, the die surface collapses and wear too soon, resulting in its failure. Through the combination of heat treatment simulation optimization and test, the optimal heat treatment temperature of NOS525 steel was finally determined, that is, the quenching temperature of 1090℃, the first tempering temperature of 560℃, the second tempering temperature of 600℃, the third tempering temperature of 600℃, so that the mechanical properties of the material have been significantly improved.

Bonding Behavior and Mechanism of Composite Interface Between Carbon Steel/Stainless Steel Laminates at Different Temperatures and Strain Rates

Compared to hot roll and explosive bonding, there are relatively few studies on warm/cold roll bonding under low temperature conditions. In this article, the warm/cold roll bonding simulation experiment is conducted to research the deformation, interface bonding rate, microstructure, element diffusion behavior, metallographic structure, and phase of carbon steel/stainless steel. The results show that the plastic deformation remains consistent below 400 °C but exhibits temperature sensitivity above 400 °C. The lower strain rate can increase the bonding rate, while insulation treatment may reduce the bonding rate. The formation of cracks is inhibited at 25 °C and 45% reduction rate due to the challenge of cracking the surface oxide film. Temperature significantly affects bonding, with improved performance observed above 600 °C. Uneven element distribution of bonding area may be related to the precipitated compounds, while insulation treatment increases the mutual diffusion ability of elements. The increase in temperature leads to an increase in pearlite, a decrease in ferrite, and decarburization occurs within the carbon steel matrix. The carbon elements diffuse from carbon steel to the surface of stainless steel. The increase in temperature increases the content of surface compounds.