Microstructure Of Zone Research Articles

Forming control and the relationship between microstructure and mechanical property in TIG-assisted friction stir welded joint of Ti-6Al-3Nb-2Zr-1Mo titanium alloy

In this paper, T-joints of Ti-6Al-3Nb-2Zr-1Mo titanium alloy were joined with friction stir welding, and microstructure evolution and forming mechanism were studied. The effect of using tungsten inert gas welding to heat additionally the FSW was investigated. Results show a strong effection microstructure of stir zone (SZ) due to the temperature gradient and fast cooling rate. The top and middle sections of SZ have a basketweave microstructure, while there is duplex microstructure at the bottom. When welding at 750 rpm-50 mm/min, the maximum tensile strength of the joint is similar to that of the base metal (BM). As the heat input increases, grain coarsening occurs, which reduces the joint tensile strength and the ability to plastically deform. The fracture mode changes from mixed fracture to ductile one. When TIG-assisted heat source is 20 mm in front of the tool and the power input is in 600 W, the temperature field produced is relatively uniform, which has a positive effect on the weld.

Experimental Investigation of Temperature Field, Fusion Zone Microstructure and Mechanical Properties During Dissimilar Laser Welding of Nickel-Base Alloy and Duplex Stainless Steel

Experimental Investigation of Temperature Field, Fusion Zone Microstructure and Mechanical Properties During Dissimilar Laser Welding of Nickel-Base Alloy and Duplex Stainless Steel

Influence of polyethylene terephthalate (PET) flakes coating on the microstructure and mechanical properties of alkali activated composites

The objective of this research is the improvement of the mechanical strengths of the alkali activated slag composites with polyethylene terephthalate (PET) flakes content. The main drawback when large PET flakes (2–9 mm) are used in these composites is reduced adhesion between plastic surface and binding matrix. Therefore, the PET flakes were coated with two types of adhesives – based on polyvinyl acetate or sodium silicate solution, and then covered with fly ash, waste glass or slag powders. The microstructure (assessed by scanning electron microscopy) of interfacial transition zone between the PET flakes coated with waste glass and slag powders is denser than for uncoated PET flakes; this explains the improvement of the compressive strength of these mortars especially after longer curing times (28 days). The flexural strengths of the mortars with PET flakes are higher than for reference mortar (with sand aggregate) and the apparent density of the alkali activated composites with PET flakes are in general smaller than for the reference mortar. Thus, the coating of PET flakes improves the mechanical behaviour of mortars, preserving also a low apparent density. These results can lead to a wider recycling of PET waste, slag and waste glass powder, promoting circular economy and reducing the CO2 footprint without compromising the critical mechanical strength of mortars.

Microstructure and mechanical properties of Ti60–Ti2AlNb functionally graded materials fabricated by laser directed energy deposition

The increasing demands for materials that service under high temperature environments in advanced aero-engines with high thrust-to-weight ratios have led to the exploration of functionally graded materials, which can offer unique advantages for addressing these challenges, such as the ability to achieve multiple properties at different positions of the components. In this study, Ti60–Ti2AlNb functionally graded materials were fabricated via laser directed energy deposition (L-DED) with 20% compositional step and various step widths in the transition zone. The distribution of chemical composition, microstructure, and microhardness in the transition zone of functionally graded materials with different compositional paths along the deposition direction were investigated. Meanwhile, the mechanical properties and fracture mechanisms were also evaluated. Smooth composition transition has been achieved in the joint zone between Ti60 and Ti2AlNb. By decreasing the width of each composition zone in the transition area or removing the Ti60-60% Ti2AlNb zone, the precipitation of the hard and brittle α2 phase can be effectively suppressed, thereby enhancing the tensile strength of the graded material. Through this approach, Ti60–Ti2AlNb functionally graded material with a tensile strength of 1030.9 MPa and elongation of 2.0% was fabricated.

Microstructure-Linked Mechanical Properties of P91-Incoloy 800HT Dissimilar Metal Welds

Dissimilar metal welds (DMWs) between P91 steel and Incoloy 800HT® using shielded metal arc welding (SMAW) with ENiCrCoMo-1 filler electrode were characterized in detail. The impact of multiple weld passes on microstructure in the heat-affected zone (HAZ) and weld fusion zone (WFZ) was thoroughly investigated. Postweld heat treatment (PWHT) impacts on mechanical characteristics and microstructure were also observed. The DMW was observed with heavy C, Cr, and Mo microsegregation in the WFZ, which deteriorated mechanical strength. The microstructural changes directly affected the mechanical behavior of the DMW. The ultimate tensile strength of the weld fusion zone was low at 576 MPa compared to the base metals’ strength. The tensile specimens failed in the IN 800HT base metal and WFZ. The WFZ had significant microsegregation near the solidified grain boundaries (SGBs). The metallurgical heterogeneity in the WFZ caused the formation of localized stress zones, which directly affected the mechanical behavior of the WFZ. The carbide particles influenced the microhardness in the WFZ and P91 HAZ regions. The PWHT successfully homogenized the microhardness in the WFZ and P91 HAZ regions. The impact toughness decreased to 64 J from 82 J after PWHT due to precipitation at SGBs and its coarsening. The SMAW process involves multiple thermal cycles during welding. The deposition of filler metal in multiple welding passes created uncontrolled variations in the solidification behavior of the WFZ. Microsegregation had a detrimental impact on the microstructure and mechanical properties of the P91 and IN 800HT dissimilar metal welds.

Analysis of High and Low Temperature Performance of Titanium Zirconium Molybdenum Alloy and High Temperature Alloy Brazed Joint

Abstract Using niobium as the intermediate layer and gold nickel (Au82-Ni) filler metal, TZM alloy and high-temperature alloy GH3128 were brazed. The brazed specimens were subjected to 400 cycles of high and low temperature cycling tests at temperatures ranging from 650 °C ∼ 680 °C (high temperature) to -196 °C (low temperature) for 10 minutes seperately. Then the microstructure variation before and after the experiment were observed and the shear strength of the specimens were tested at room temperature for 50 cycles of 400 high and low temperature testing.. The results show that the microstructure of the transition zone at the brazing interface after brazing is uniform and dense, with good wettability with the substrate and no defects such as cracks. The solder and substrate undergo diffusion reactions, and the molybdenum alloy, niobium, and niobium, high-temperature alloy had each form diffusion layers, formed intermetallic compounds on the brazing surface. After high and low temperature cycling, cracks exist in the braze seam between molybdenum alloy and niobium alloy. The cracking mode should be thermal fatigue based on the fracture morphology and phase analysis. The reasons of interface cracking are that due to different thermal expansion coefficients, low mutual solid solubility, and the formation of a large number of different types of intermetallic compounds, Mo and Nb materials have poor brazing compatibility and lower interface strength. Under cold and hot cycling conditions, brittle intermetallic compounds are prone to form crack source areas. As the number of cycles increases, the cracks gradually expand, ultimately leading to product leakage. In addition, the shear strength of brazed joints shows a decreasing trend with the increase of high and low temperature cycles in 400 high and low temperature tests.

Improvement of fatigue life by aluminizing of additive manufactured Fe- and Ni-base alloy

Laser powder bed fusion (PBF-LB/M) is used in various industries to manufacture complex parts with high precision. High surface roughness and porosity have a negative impact on fatigue resistance. This work presents aluminum pack cementation as a method to reduce surface roughness and improve fatigue resistance of AM parts. An Fe-base alloy (Alloy 800H) and a Ni-base alloy (Alloy 699XA) are selected. Some of the specimens made from PBF-LB/M were treated by pack cementation with aluminum, while others were subjected to the vibratory finishing process. The surface roughness, microhardness distribution and the microstructure of the interface zone were measured and analyzed for the as-built, vibratory finished and aluminized specimens. Rotating bending fatigue test was performed at room temperature. Conventionally fabricated specimens of both investigated alloys were tested under the same conditions to evaluate the effects of pack cementation. The aluminized samples (PBF-LB/M) show a significant reduction in surface roughness with a decrease of 45 % for Alloy 800H and 65 % for Alloy 699XA. This leads to an improvement in fatigue life for both Alloy 800H and Alloy 699XA. In contrast, the conventionally fabricated specimens exhibited increased surface roughness after pack cementation compared to their initial condition and showed a significant reduction in fatigue resistance.

Influence of replacing Portland cement with anionic asphalt emulsion on vibration damping, mechanical and microstructural properties of concrete

The effect of anionic asphalt emulsion (AE) as partial replacement of Portland cement to enhance the damping properties of concrete was examined. Five concrete mixtures were designed and prepared, increasing AE content from 0 to 40% in overall binder volume, in 10% increments. Loss factor, dynamic moduli, resonant frequencies, and compressive strength were obtained at the age of 7, 28, 90, and 180 days. Results show that the loss factor of concrete increased as the asphalt content increased, whereas the dynamic modulus and resonant frequency decreased. In addition to the viscous damping contributed by asphalt droplets, the more porous microstructure and weaker interfacial transition zones in AE modified concrete can also enhance the damping properties. However, an inverse correlation between concrete strength and damping can be observed with increasing AE content, where the substitution of AE results in a significant decrease in the compressive strength of concrete. Therefore, the anionic AE modified concrete seems to be more suitable for non-structural application where strength is not a key requirement.

Hybrid Additive Manufacturing for Site‐Specific Tensile Response in 316L Stainless Steel

Herein, an alternative way of achieving site‐specific mechanical properties is explored—the hybridization of a directed energy deposition technology with a secondary deformation process (hammer peening (HP)) which acts between deposited layers. By applying the peening in a selective manner, microstructure and hence mechanical properties can be locally varied. Microstructural characterization reveals recrystallization in the HP‐induced deformation zone. The columnar grains of as‐built regions with a grain size of ≈26 μm are transformed into a recrystallized zone with equiaxed grains having a size of ≈8 μm. There is also a highly strain‐hardened region below this recrystallized zone where the dislocation density is more than two times higher than in the as‐built condition. Subsequent tensile testing reveals that these microstructural zones corresponded to local enhancement in tensile strength normal to the build direction. The strengthening mechanisms are identified as Hall–Petch and dislocation (Taylor) strengthening, and their relative contributions are studied. The local strength enhancement comes at the expense of ductility in the build direction, which is studied via finite element modeling and attributed to strain localization into non‐strengthened areas. The results from this work show the possibility of achieving site‐specific properties via interlayer processing.

Microstructure and mechanical properties of 2195 Al-Li alloy via friction stir additive manufacturing with different stirring paths

Friction stir additive manufacturing (FSAM) is increasingly becoming a feasible method for aluminum alloy structure due to the unique forming characteristics. In this study, two different stirring paths were explored for 2195 Al-Li alloy and the microstructure evolution and mechanical properties were ‌investigated. An ultrafine grained microstructure was formed in the FSAMed zone with an average grain size ranging from 1 to 5μm. The microstructure in the FSAMed zone at the bottom exhibited a consistent direction trend and a significant increase in dislocation density. Different stirring paths had minimal impact on the phase distribution. Frictional heating led to the re-dissolution and re-precipitation of precipitates, resulting in T1, θ', and δ'/β' were distributed within the grains. The samples of intersecting stirring path showed similar mechanical properties in different directions, while the UTS of LD was 52.56 MPa higher than TD of the reciprocating path samples. The microhardness range for the intersecting stirring path ranged from 87.0 HV0.2 to 126.6 HV0.2, while the reciprocating stirring path exhibited a microhardness range of 83.8 HV0.2 to 132.4 HV0.2. In summary, this study provides valuable insights into designing processing paths for FSAM of 2195 Al-Li alloy.

Analysis of Structures at the Boundary of Contact Melting Al–Mg–Mn and Zn Based Alloys

The processes of contact melting of the AMg6 (Al-6%Mg-1%Mn) alloy with Zn–Cu–Al solder and the model Zn–Al alloy, as well as the structure of the contact fusion zone, are studied. Samples were obtained in two stages. At the first step, the solder was mechanically applied (tinned) to the surface of the AMg6 plates. Аt the second step, the resulting composite samples were subjected to heat treatment with a varied exposure time in the liquid state. According to the data of metallographic and X-ray diffraction analyses, as well as differential scanning calorimetry, it was shown that already at the tinning stage the active interaction between Zn and Al occurs, which leads to the formation of a developed microstructure in the joint zone. The presence of copper in the solder HTS-2000 reduces the melting point of the Zn-Al alloy by 30-40°C and improves the conditions for contact interaction with the grade AMg6 matrix. Active diffusion of zinc ensures the formation of an extensive melting zone during heat treatment, while zinc-rich areas during crystallization contain the Zn5Cu intermetallic phase, which prevents the formation of intermetallic ZnxMgy compounds, which does not lead to embrittlement of the contact zone.

The Influence of the Parameters of the Skew Rolling Process for Bimetallic Elements on the Mechanical Properties and Structure of Materials.

This paper presents selected results of theoretical and experimental research into the manufacture of axisymmetric bimetallic components using three-tool skew rolling technology. In the tests, it was assumed that the outer layer would be a material intended for heat treatment. However, low-carbon steel was used for the core. Experimental investigations were carried out in an innovative CNC skew rolling mill. Tests were carried out at different technological parameters of the process. In addition, the geometric parameters of the billet and the way it was heated were analyzed in relation to the quality of the resulting weld between the two materials. The quality of the weld was assessed based on metallographic observation and on strength tests (shear method). On the other hand, theoretical studies were based on numerical modeling (FEM). The numerical analysis made it possible to determine the distribution of temperature, deformation and stress in the rolling bimetallic component. The results obtained indicated that it is possible to produce bimetallic materials from the proposed steel grades. In addition, a significant effect of the method of heating the billet in the chamber furnace on the microstructure in the joining zone and the shear strength was found. There was an increase in Rc strength of about 35% when using oxidation protection. The results indicated better strength when the billet is rolling with a smaller outer layer thickness (about 50 MPa). This was confirmed by the results obtained from the FEM analysis, which indicated higher values of plastic strain and the occurrence of higher compressive stresses in the near-surface zones of the rolled bimetallic forging, both of which facilitate the welding process. From the temperature distribution (in the range of (600-1200) °C) obtained during the rolling of the bimetal forging, it can be seen that contact with cold tools does not affect the temperature in the welding zone.

Low and High Gas Tungsten Arc Welding Heat Inputs Influence on Corrosion of Stainless Steel Weldments

In this study, influence of low and high heat inputs on corrosion susceptibility of 304L austenitic stainless steel (ASS) in simulated 0.5 molar solution of NaCl was investigated. Gas tungsten arc welding (GTAW) was used to generate low and high levels welding heat input. Microstructures of the weldments were examined, using metallurgical optical microscope (OMM) (Olympus GX51), while the corrosion behaviours were evaluated by potentiodynamic polarization tests, and corrosion data were recorded, using a computer-based data logging system – Autolab PGSTAT 204N. From the results, the evolving microstructures of the weldments before corrosion were characteristically heterogeneous; austenite (γ) was the leading phase, while ferrite (α) grains were dispersed within the γ matrix. Fusion zone (FZ) and heat affected zone (HAZ) microstructures after corrosion were characterised by pits of varying sizes with different alignments. And at GTAW speed, current and voltage of 7.2 mm/s, 200A and 40V, corresponding to low heat inputs, there were few number and size of pits relative to 1.7 mm/s, 200A and 40V, corresponding to high heat input. Shift in corrosion potentials (Ecorr) toward less negative direction, that is more nobility was observed at the low heat inputs induced GTAW parameters as compared to the corresponding high heat inputs induced GTAW parameters. In general, corrosion susceptibility of 304L ASS in the simulated 0.5 molar solution of NaCl was heightened at high heat inputs induced GTAW parameters as compared to the corresponding low heat inputs parameters.

Effect of hybrid lead-PVA fibers on microstructure and radiation shielding properties of high-performance concrete

With the widespread application of nuclear technology in the medical and energy fields, the demand for efficient radiation shielding materials is increasing. Employing only lead or polyvinyl alcohol (PVA) fiber reinforcement cannot achieve improvements in the brittleness of high-performance concrete (HPC) while also enhancing radiation shielding efficiency and mechanical properties. This study develops a novel HPC for radiation attenuation, incorporating magnetite as the aggregate and reinforced with hybrid lead-PVA fibers (RSHPC). The synergistic effects of various proportions of hybrid lead-PVA fibers on the mechanical properties, three-dimensional microstructure, pore structure, and interfacial transition zone (ITZ) were investigated. In addition, the radiation attenuation capacities of RSHPC with different hybrid lead-PVA fiber proportions were evaluated through experimental and simulation analysis. The results show that hybrid lead-PVA fibers notably improve the air-void structure of RSHPC. The incorporation of PVA fibers, by improving the ITZ of matrix, effectively mitigates the negative impact of lead fibers on mechanical performance. The refinement of pore structure and the introduction of light and heavy nuclides lead to a significant enhancement in the gamma-ray and neutron radiation attenuation capabilities of RSHPC. Utilizing X-ray computed tomography (X-CT) for three-dimensional reconstruction further indicates the optimization impact of hybrid lead-PVA fibers on the microstructure, notably in the improvement of pore distribution and fiber dispersion, thus enhancing the overall properties and radiation attenuation performance of RSHPC.

Effect of heat input on the microstructure and hydrogen embrittlement susceptibility of the coarse-grain heat-affected zone of CrMo steels generated using a Gleeble 3500 welding simulator

The changes in microstructure and hydrogen embrittlement (HE) susceptibility of the simulated coarse-grain heat-affected zone (CGHAZ) of CrMo steels under three distinct heat input conditions were investigated. The cooling time from 800 °C to 500 °C, represented by t8/5, increased from 100 s to 200 and 400 s.. The sample with t8/5 = 100 s has a microstructure consisting of martensite and a small amount of lower bainite. When the t8/5 was increased to 200 s and 400 s, the HAZ consisted of 65.43 % martensite and 34.57 % lower bainite and 4.53 % martensite with 95.47 % bainite, respectively. The HE susceptibility was assessed by slow strain rate tensile (SSRT) testing of hydrogen-charged samples, and the HE susceptibility index (IHE) declined from 87.89 % to 61.37 % when t8/5 increased from 100 to 400 s. The high dislocation density and hydrogen concentration in the sample with t8/5 = 100 s led to intergranular fracture and incresaed HE susceptibility. The martensite lath and cementite/ferrite interface are the sites of crack initiation in the sample with t8/5 = 200 s. In the sample with a cooling time of 400 s, the martensite/ferrite interfaces are the main crack initiation sites under hydrogen charging.

Microstructure and mechanical properties of 1 mm thin plate TC4 titanium alloy joint by ring laser welding

Abstract Ring laser welding was used to weld 1 mm thin plates TC4 titanium alloy, and the effects of different ring laser powers on the microstructure and mechanical properties of the weld were studied. The results indicate that the microstructure in the weld zone under different powers all contain basket structures, although the morphology of the martensite within the baskets differs. The microstructure in the weld zone is mainly composed of acicular α′ martensite, secondary α phase, and residual β phase. The microstructure in the heat-affected zone of the weld is mainly composed of acicular α′ martensite, initial α phase, secondary α phase, and residual β phase. The hardness of the weld is higher than that of the base metal, showing an overall trend of first increasing, then decreasing, and then increasing again before decreasing. The tensile specimens under different powers all fractured in the heat-affected zone of the weld, and the type of fracture is quasi-cleavage. At a laser power of 900 W, the weld has good formation, with minimal spatter on the surface, and good weld penetration. The microstructure of the weld is mainly composed of acicular α′ martensite, initial α phase, secondary α phase, and residual β phase. The hardness of the weld is 387.76 HV. The tensile strength and elongation are 1098.3 MPa and 12%, respectively.

The effect of pin diameter, tool penetration depth and plate arrangement on mechanical and metallurgical properties of 6061-T6 and 5052-T32 aluminum dissimilar joints in friction stir spot welding (FSSW)

In solid-state welding, the basis of joining is the combination of materials in the weld area using the tool. The tool pin is a key parameter that can facilitate tool penetration into the parts and result in better material mixing. On the other hand, the presence of the end cavity of the process can be a factor in reducing the mechanical properties of the weld. To address these two conflicting issues, this study examined the effect of pin thickness on the mechanical and metallurgical properties of aluminum 6061 and 5052 plates. The variable parameters included pin diameters (4 mm, 8 mm, and no pin) and three tool penetration depths (0.5 mm, 1.5 mm, and 2.5 mm). The impact of changing the arrangement of the plates on each other was also investigated regarding the properties and quality. Experimental results showed that decreasing the pin diameter and increasing the tool penetration depth improved the weld breakage force. The failure modes of all welds were button pull-out and ductile failure. Using a pinless tool increased microhardness in the weld nugget area and led to more uniform microhardness variations. Placing the aluminum 6061 alloy on top of the arrangement improved shear tensile strength and microhardness of the joints. The microstructure in the heat-affected zone showed an increase in grain size, which was accompanied by a decrease in microhardness. The microstructure in the stirred zone was dense and compacted, and with increasing tool penetration depth and decreasing pin diameter, the grain size became finer.

Influence of friction stir processing (FSP) on arc directed energy deposited 316L stainless steel: a corrosion science study

Friction stir processing (FSP) was employed as a post-printing surface modification technique to enhance surface properties of arc-directed energy deposited 316L austenitic stainless-steel parts. Corrosion properties and passivity of stir zone and base metal were investigated in 3.5 wt.% NaCl solution. Results reveal a gradual improvement in corrosion protection ability of formed passive film on the alloy's surface over time. Specifically, FSPed region exhibited superior passive behavior and uniform corrosion resistance compared to base metal. This improvement was attributed to a more homogeneous microstructure of stir zone, which hindered micro-galvanic coupling effect. However, it was observed that FSP-treatment did not effectively impede the propagation of pitting corrosion.

Postweld Heat Treatment of 15Cr-6Ni-2Mo-1Cu Supermartensitic Stainless Steel Welds

Supermartensitic stainless steels with 15Cr-6Ni- 2Mo-1Cu and 135 ksi minimum yield strength (15Cr- 135 SMSS) offer high strength and good toughness through a complex hierarchical microstructure of nanoscale precipitates, tempered martensite, and reverted austenite. Upon welding and postweld heat treatment, substantial changes to heat-affected zone microstructure and hardness may occur. Here, we reveal spatially heterogeneous microstructure and microhardness in the HAZ of 15Cr-135 SMSS; correlate these changes to measured phase transformation temperatures; and demonstrate that HAZ hardness changes depend strongly on postweld heat treatment (PWHT) temperatures. Furthermore, we demonstrate that PWHT may lead to undesired reductions in base metal yield strength and formulate a design guide for PWHT that quantifies the trade-offs in desired reductions of HAZ hardness with undesired changes to base metal yield strength. These findings have important practical implications for welding procedure design and qualification.

Study on the damage mechanism of hydraulic concrete under the alternating action of freeze-thaw and abrasion

This study investigates the damage mechanism of hydraulic concrete under the alternating action of freeze–thaw (F) and abrasion (W) in cold regions. To this end, three groups of working conditions were established with a constant water-binder ratio. The mass loss and relative dynamic elastic modulus (RDEM) of each cycle were evaluated using the fast-freezing method and underwater method. The phase composition and relative content change of hydration products, pore characteristic parameters and pore size distribution, morphology and microstructure of interfacial transition zone (ITZ) were analyzed by X-ray diffraction (XRD), mercury intrusion porosimeter(MIP), scanning electron microscopyn (SEM) and image recognition technology, respectively. The results indicate that the alternating effect will accelerate the mass loss of concrete and the reduction of the RDEM compared with the single factor. Following four consecutive alternating cycles, the mass loss rates of working conditions W and F group were found to be 4.61 % and 97.66 % lower, respectively, than those of working condition F-W group. The RDEM damage coefficient (γ < 1) was also observed. At the micro level, the freeze-thaw effect will result in the formation of a considerable number of micropores and the expansion of microcracks, with the abrasion effect continuing to promote this process. In the process of alternating action, the dissolution of Ca(OH)2 by external water through microcracks and interconnected pores is accelerated. Concurrently, the pores and microcracks in the ITZ expand, the morphology is roughened, and the microstructure is complicated. The interfacial bonding ability and compactness of different material components decrease. Under the action of external disturbance, cement paste and aggregate fall off, resulting in mass loss and a decreased RDEM.