Microstructure Of Zone Research Articles

Enhancing microstructure and mechanical properties of dissimilar TIG welded duplex 2205 and Ni-based inconel 718 superalloy through post weld heat treatment

In demanding applications, maintaining structural integrity in dissimilar welded joints like those between duplex stainless steel and Ni-based superalloys requires achieving the best possible mechanical properties. This work examines the impact of post-weld heat treatment (PWHT) on the mechanical characteristics of joints made via double-sided tungsten inert gas (TIG) welding. The dissimilar welded joint was investigated by exposing it to the PWHT for 12 h at 650 °C. Reducing the negative impact of heat generated by welding on the mechanical characteristics and microstructure of the fusion zone was the main goal. To study for changes in the microstructure before and after PWHT, optical microscopy and scanning electron microscopy methods were used for microstructural analysis. To determine the effect of PWHT on the welded joints, mechanical properties such as tensile strength, toughness, and ductility were also assessed. The mechanical properties showed significantly enhanced characteristics and refined grain structures in the fusion zone.

Thermal Cycle Simulation of Heat Affected Zone in the Welded Mild Steel

The aim of this work was to study the microstructure evolution of simulated heat affected zone in mild steel using thermal cycle simulation and it was compared to the heat affected zone in the real welded joint. The optical microscopy, micro-hardness measurements, X-ray diffraction were used as characterization techniques. The microstructures and mechanical properties of the simulated heat affected zone were also determined. The use of the thermal cycle simulation technique revealed in detail the different microstructures in the heat affected zone (HAZ) of the welded joint. Some similarities were observed between the heat affected zone obtained by the thermal cycle simulation technique and the heat affected zone observed in the real welded joint. The thermal cycle simulation technique revealed more details about the microstructure and mechanical behavior of the heat-affected zone. The HAZ microhardness values were lowest hardness in the welded joint. Moreover, the lowest hardness value is obtained for the HAZ simulated at 850°C.

Synergistic effects of Monel 400 filler wire in gas metal arc welding of CoCrFeMnNi high entropy alloy

Weldability plays a crucial role in the journey of high entropy alloys towards their engineering applications. In this study, gas metal arc welding was performed to join an as-rolled CoCrFeMnNi high entropy alloy using Monel 400 as the filler wire. The present research findings demonstrate a favorable metallurgical chemical reaction between the Monel 400 filler and the CoCrFeMnNi high entropy alloy, resulting in compositional mixing within the fusion zone that promotes a solid-solution strengthening effect, counteracting the typical low hardness associated to the fusion zone of these alloys. The weld thermal cycle induced multiple microstructure changes across the joint, including variations in the grain size, existing phases and local texture. The grain size was seen to increase from the base material toward the fusion zone. An FCC matrix and finely sparse Cr-Mn-based oxides existed in both base material and heat affected zone, while in the fusion zone new FCC phases and carbides were formed upon the mixing of the Monel 400 filler. The role of the filler material on the fusion zone microstructure evolution was rationalized using thermodynamic calculations. Texture shifted from a γ-fiber (in the base material) to a strong cubic texture in the fusion zone. Digital image correlation during tensile testing to fracture coupled with microhardness mapping revealed that, stemming from the process-induced microstructure changes, the micro and macromechanical response differed significantly from the original base material. This study successfully established a correlation between the impact of the process on the developed microstructural features and the resultant mechanical behavior, effectively assessing the processing-microstructure-properties relationships towards an improved understanding of the physical metallurgy associated to these advanced engineering alloys. In conclusion, this work provides an important theoretical framework and practical guidance for optimizing the engineering applications of high entropy alloys.

Microstructure evolution of ATI718 plus alloy during high-speed machining: Experiments and a combined FE-CA approach

Excellent surface integrity is an eternal pursuit in high performance manufacturing, with microstructure being a crucial component of the surface integrity dataset and a key factor controlling surface properties such as fatigue and creep. The multi-physical fields generated by thermo-mechanical loads during high-speed machining act on the processed surface layer, influencing the evolution of microstructures. To investigate the microstructural evolution mechanisms of ATI718 plus during high-speed machining, cutting experiments and techniques such as Electron back scatter diffraction (EBSD), Transmission Kikuchi diffraction (TKD), and Precession electron diffraction (PED) is conducted to quantitatively analyze the microstructures in the chip shear zone and the machined surface. Subsequently, a combined finite element (FE) and cellular automata (CA) model is developed to simulate the microstructure evolution during the cutting process. The discontinuous dynamic recrystallization (DDRX) mechanism is employed to demonstrate the nucleation and growth of grains under the influence of multiple physical fields. The simulation and experimental results show similar dynamic recrystallization (DRX) grain sizes, indicating acceptable accuracy of the CA model in terms of DRX grain size. The comparison between experimental and simulation results confirms the occurrence of both continuous dynamic recrystallization (CDRX) and DDRX during the cutting process. The synergistic competition between CDRX induced grain lamellar refinement and DDRX induced grain growth emerge as the primary mechanism driving microstructural evolution. A layer of ultrafine grains, with a thickness within 20 μm, is formed on the machined surface. Results under different parameters demonstrate that the temperature has a more significant impact on the thickness of the ultrafine grain layer and the diameter of grains within the layer compared to the strain rate.

Analysis of Microstructure and Mechanical Properties of Copper Friction Stir Welding Zone

Analysis of Microstructure and Mechanical Properties of Copper Friction Stir Welding Zone

Role of TiB2 inoculation particles during welding of a AlCoCrFeNi high entropy alloy

High entropy alloys (HEAs) are a novel class of materials that represent an evolution of common engineering alloys to a wider array of compositional and properties possibilities. As such, the exploration of methodologies to achieve improved microstructure and mechanical characteristics of these materials for potential applications in industry is a requirement that is experiencing extended research efforts. One example of a processing method able to expand the potential applications of these alloys is Gas Tungsten Arc Welding (GTAW), which allows to evaluate the metallurgical evolution and corresponding mechanical performance, associated to the impact of a localized heat input on the material. However, GTAW and related fusion-based welding processes are known to generate large grain sized-structures in the fusion zone, which often is detrimental to the joint performance. Thus, the integration of high temperature inoculant particles on the fusion zone during welding is a potential way to improve this region’s microstructure and, therefore, its mechanical performance. In this work, we discuss the effect that the addition of TiB2 micron-sized particles have on the microstructure of a GTAW AlCoCrFeNi-based HEA. For this, the microstructure of the welds was evaluated by means of optical and electron microscopy, synchrotron X-ray diffraction and CalPhaD-based simulations. Mechanical testing was performed using microhardness mapping and tensile testing coupled with digital image correlation. The results evidenced that successful inoculation with TiB2 proved capable of altering the microstructure of the fusion zone (FZ), refining it. Nevertheless, preferential deformation in the relatively softer heat affected zone during tensile testing resulted on premature failure of the inoculated joints, due to the concomitant higher hardness of the FZ.

Effect of nanosilica and fiber on mechanical properties and microstructure of recycled coarse aggregates road concrete

Recycled coarse aggregate has its own characteristics of large porosity, high water absorption and high crushing index, which adversely affects the mechanical strength and durability of recycled aggregate concrete. In this study, the mechanical properties, durability and microstructure of recycled aggregate concrete (RAC) modified with nano-SiO2 (NS) and fibres were investigated to prepare road RAC, using NS polypropylene fibres (PPF) and basalt fibres (BF) as test variables. Compared with RAC only incorporating NS, NS and fibre synergism can significantly enhance the mechanical properties of recycled concrete, compressive strength increased by 27–51 %, flexural strength increased by 12 %, and abrasion resistance increased by 25–72 %. The synergistic effect of NS and PPF significantly improves the frost resistance of recycled concrete. NS has a volcanic ash effect which can react with calcium hydroxide to produce a large number of C-S-H in the secondary hydration reaction, making the internal structure of the cement matrix denser. Interfacial transition zone microstructure is more compact, thus interfacial transition zone porosity is effectively reduced. The hydration products are attached to the fibre surface, which enhances the bonding ability between the fibers and matrix. Therefore, the fibres effectively inhibit the generation and development of internal micro-cracks. NS optimises the internal pore structure of recycled aggregate concrete and enhances the interfacial transition zone, and NS synergistically with PPF can improve the strength and durability of various mechanical properties of recycled concrete. The research results provide the scientific basis for the application of road RAC.

Recrystallized hard zone and resultant tri-modal microstructure produces superior mechanical properties in a single-phase heterostructured high-entropy alloy

Heterostructured high-entropy alloys (HS-HEAs) integrate two innovative concepts in metallic materials that encompass alloy design and microstructural engineering. HS-HEAs have demonstrated outstanding mechanical properties. However, it remains challenging to explore these materials due to the intricate nature of their composition and microstructure. In this study, we introduced heterostructures into a single-phase FCC HEA through cold rolling and partial recrystallization. This process resulted in an exceptionally high density of nanoscale recrystallization twins, leading to significant hardening and the formation of heterogeneous hard zones in recrystallized regions with small grain sizes. This tri-modal heterostructure results in improved balance between strength and ductility, high zone boundary density and strong hetero-deformation induced (HDI) effects, and a unique two-stage strain partitioning mechanism that postpones necking. As a result, the alloy exhibits enhanced strength and ductility, resulting in superior mechanical properties. The identification of the recrystallized hard zones is crucial for gaining a proper understanding of the hetero-zones in HEAs and provides valuable insights for the future design of HS-HEAs.

Micro-zone and macro mechanical behavior of SiCf/Si3N4 composite modified by intra-bundle matrix

In this work, the microstructure of the interfacial zone was optimized to improve the mechanical properties of SiCf/Si3N4 composite, and the relationship between micro-zone and macro mechanical behavior was revealed. For SiCf/Si3N4, the interphase destruction occurred during the Si3N4 deposition process, leading to the existence of discontinuous interphase in the outside of intra-bundle area. After incorporating SiBCN and SiC matrices into the fiber bundle, the BN interphase can be well protected, and the uniformity of the matrix microstructure within the fiber bundle was further enhanced, which increased the Weibull modulus of the interfacial shear strength (IFSS), resulting in the higher load sharing efficiency in fiber bundle and the enhanced macro-mechanical properties. Especially after incorporating SiC matrix into intra-bundle area, the higher IFSS also can be obtained, corresponding to the higher load transferring efficiency, and the strength and toughness of the composites were improved significantly.

Microstructural Characteristics and Properties of Laser-Welded Diamond Saw Blade with 30CrMo Steel.

In order to enhance the quality of diamond composite materials, this work employs a Cu-Co-Fe and Ni-Cr-Cu pre-alloyed powder mixture as a transition layer, and utilizes laser-welding technology for saw blade fabrication. By adjusting the laser-welding process parameters, including welding speed and welding power, well-formed welded joints were achieved, and the microstructure and mechanical properties of the welded joints were investigated. The results demonstrate that the best welding performance was achieved at a laser power of 1600 W and a welding speed of 1400 mm/min, with a remarkable tooth engagement strength of up to 819 MPa. The fusion zone can be divided into rich Cu phase and rich Fe phase regions, characterized by coarse grains without apparent preferred orientation. The microstructure of the heat-affected zone primarily consists of high-hardness brittle quenched needle-like martensite, exhibiting a sharp increase in microhardness up to 550 HV. Fracture occurred at the boundary between the fusion zone and the heat-affected zone of the base material, where stress concentration was observed. By adjusting the welding parameters and transition layer materials, the mechanical properties of the joints were improved, thereby achieving a reliable connection between diamond composite materials and the metal substrate.

Two fatigue fracture modes at different temperatures of 10%Cr heat-resistant steel weldment filled with Ni-based alloy

9–12%Cr heat-resistant steels are widely used as ultra-supercritical thermal power generation components for their excellent high temperature performance and economic applicability. In order to overcome the problems of welding cracking and carbon migration of 9–12%Cr heat-resistant steels’ welded joints, Ni-based alloy welding materials are being more and more widely used. However, a very distinct interface will form between 9–12%Cr heat-resistant steels and Ni-based alloy welding materials due to their different chemical compositions and microstructures. In this work, the microstructure of the interfacial transition zone between a 10%Cr heat-resistant steel and Ni-based alloy welding material is investigated. The influence of temperatures on the fatigue behavior of the welded joint is studied. Two fatigue fracture modes at different temperatures are found, and the underlying mechanism of the different fracture modes are discussed in detail.

Investigation of Microstructure, Oxides, Cracks, and Mechanical Properties of Ti-4Al-2V Joints Prepared Using Underwater Wet Laser Welding.

Developing advanced underwater welding technology for titanium, which is the key structural material for underwater applications, is of great significance for the design, fabrication, and maintenance of submarine equipment. In this study, in order to investigate the underwater welding microstructure and mechanical properties of Ti-4Al-2V alloy, underwater wet laser welding was conducted on Ti-4Al-2V alloy using varying laser power. The microstructure and properties of the welding joints were characterized and analyzed. The microstructure of the heat-affected zone and fusion zone in the welding joints are not significantly different from those of welding in air, but a mixed oxide layer composed of Al2O3 and TiO2 is formed on the surface of the fusion zone. Due to internal stress, a large number of cracks initiate on the oxide layer and propagate to the joints. In the 4 kW and 5 kW joints, a penetrating crack formed due to the excessive accumulation of internal stress breaking up the α phase. The mechanical properties of the joints are significantly affected by the laser power. The tensile strength of the 3 kW and 4 kW joints is comparable to that of the base metal, which is about 600 MPa, while the 5 kW joint shows brittle fracture with no plastic deformation and 228 MPa strength. This research lays a solid foundation for understanding the underwater wet laser welding behavior of titanium alloys.

Effect of beam current on microstructure, tensile properties and corrosion behaviour of electron beam welded zircaloy-4 joints

ABSTRACT Butt joints of zircaloy-4 were made using electron beam (EB) welding. The effect of beam current (15–20 mA) on weld zone size, microstructure, porosity, mechanical and corrosion properties has been investigated. Local temperature and cooling rate were estimated, and the average cooling rate increased from 2.4 to 6.3°C ms–1 with a decrease in beam current in the said range. Joints prepared at lower beam current possessed smoother weld surface, narrow weld bead, and fine lamellar type widmanstätten structure in the fusion zone (FZ). The length of the α-Zr lamella (from 105 to 37 µm) and interlamellar space (from 0.8 to 0.3 µm) decreased with a decrease in beam current. The XCT result revealed that porosity increased with an increase in beam current, and large-size micro pores of 180 µm were present in joints prepared at high beam current. The hardness of the welded samples increased by 13–20% than the base metal. The joint prepared with a low beam current possessed higher ductility (29%) and a minimum corrosion rate (0.0085 mmpy in 3.5 wt-% of NaCl solution) than the joint made with a higher beam current.

Microstructure and Mechanical Properties of Similar/Dissimilar Resistance Spot‐Welded Aluminum Alloys for Aerospace Applications

2195 aluminum–lithium (Al–Li) and 2XXX series aluminum alloys are joined using resistance spot welding for the first time. The macrostructure, microstructure, element distribution, microhardness, and tensile‐shear property of spot‐welded joints are investigated. The microstructure of the fusion zone of 2195/2195, 2195/2219, and 2195/2A14 joints is fine equiaxed spherical grains. It is found that solute segregation of Cu occurs in the grain boundaries in the fusion zone, forming Al2Cu. The microhardness shows that due to the dissolution of strengthening phase T1, the hardness of the fusion zone of the three types of joints is lower than that of the base material. The 2195/2195 joint has the best mechanical performance among the three combinations, with maximum tensile‐shear force and absorbed energy reaching 16893.7 N and 24.9 J, respectively. The fracture surfaces of all three types of joints exhibit mixed ductile‐brittle characteristics.

Numerical simulation of friction extrusion: process characteristics and material deformation due to friction

This study employs a finite element thermo-mechanical model, using a Lagrangian incremental setting to investigate friction extrusion (FE) under varying process conditions. The incorporation of rotation in FE generates substantial frictional heat, leading to significantly reduced process forces in comparison to conventional extrusion (CE). The model reveals the interplay between temperature, strain, and strain rate across different microstructural zones of the resulting wire. Specifically, the sticking friction condition in FE enhances initial shear deformation, aligning with a homogeneous spatial strain distribution and predicting complete grain refinement in the extruded wire, as per Zener-Hollomon calculations. On the other hand, under the sliding friction condition in FE, the shear deformation is reduced which results in an inhomogeneous microstructure in the extruded wire. The analysis of material flow in the workpiece reveals distinct transitions from the base material to the thermo-mechanically affected zones. The simulated process force, thermal history, and microstructure during sliding friction conditions align well with the findings from performed friction extrusion experiments.

Effect of Output Conditions on Microstructure and Properties of SKD61 Laser Cladding

This study investigated the effect of cladding on tool steel (SKD61) by using 5%Cr-1.5%Mo-Fe powder (SKD61), which is expected to be economically effective when used to manufacture and mend die-casting parts. The cladding conditions were as follows: the distance between the coaxial powder supply head and the substrate surface was 20 mm, and Ar was used as the supply gas. The laser outputs applied in the cladding procedure were 3, 4, and 5 kW. The microstructure of the heat-affected zone in the processed specimens was analyzed, and the macrostructure and morphology of the substrate material were studied. Specimen hardness measurements were performed at intervals of 0.1 mm from the substrate surface to the core. As the laser output increased from 3 to 4 and 5 kW, the dilution rate increased from 10.6% to 11.8 and 13.2%. It was confirmed that the fraction of carbides increased as the laser output increased from 3 kW to 5 kW.

Effect of al/si multilayer foil on microstructure and mechanical properties of SiCр/Al composites vacuum diffusion bonded joints

The peculiarities of joint formation in vacuum diffusion bonding through an intermediate multilayer foil (MF) of Al/Si produced by electron beam physical vapour deposition (EB-PVD) in vacuum were studied on SiCр/Al aluminium matrix composites with different alloying systems of the aluminium matrix. It is shown that Al/Si interlayer enables making permanent joints without degradation of the composite properties at the temperature of 500°С, which corresponds to the start of intensive plastic deformation of the interlayer at thermomechanical loading. It is found that the microstructure and phase composition of the joint zone (JZ) depend on the interlayer and aluminium matrix of the composite. It is demonstrated that reduction of the bilayer thickness of Al/Si MF and its alloying by manganese ensures intensive mass transfer of the components in the butt joint and equivalent joint formation. The maximum value of shear strength was 105 MPa in the case of an interlayer with a nano-scale period of the layers.

Laser welding of ultra-high strength steel rocket engine shell

The microstructure and mechanical properties of 30Cr3-30CrMnSiA ultra-high strength steel rocket engine shell welded joint were investigated in detail. The results indicated that the microstructure of the fusion zone was martensite of columnar and equiaxial due to the fast cooling rate of the laser welding. At the as-weld (AW) state, the average grain size of the 30Cr3 base metal was 4.63 μm, which was much smaller than that of the 30CrMnSiA base metal, which averaged 6.85 μm. After the post-weld heat treatment (PWHT), all the microstructures of the base metal, fusion zone and heat affected zone (HAZ) of 30Cr3 were tempered martensite. Meanwhile, at both AW and PWHT state, the tensile specimens of the welded joints of dissimilar materials were all fractured in the 30CrMnSiA base metal side at both 25 °C and 800 °C. After the PWHT, the tensile strength of 30CrMnSiA and 30Cr3 base metal at 25 °C were 1517.4 MPa and 1795.3 MPa, respectively. The welded joints of dissimilar materials by laser welding also showed excellent tensile properties at high temperature (800 °C), because of the small average grain size.

Laser Melting and Surface Texture Technology: Effect on Friction Properties

This paper discusses the role of laser surface texturing and laser melting technology in enhancing surface lubrication and wear resistance under starved lubrication conditions. The aim is to enhance the wear resistance of laser surface texturing and to explore the role of surface texturing in enhancing lubrication. This paper observes the microstructure of the melting zone, transition zone and matrix of the base material Cr12MoV after laser melting and condensing, detects and analyses the metallographic composition, and tests the micro-hardness. The effects of laser surface texturing technology and laser melting technology on the coefficient of friction under different friction and wear environments were comparatively investigated. The laser melting zone consists of martensite with fine grain size and a large amount of residual austenite. After laser melting, the hardness reaches 1.4 times the hardness of the matrix. The laser surface texture increases lubrication significantly at low rpm. The fully fusion-coagulated treatment is wear-resistant in a variety of different frictional wear environments.

Effect of Wire Preheat and Feed Rate in X80 Steel Laser Root Welds: Part 1 — Microstructure

Laser welding with cold versus hot wire feed was employed as a root pass to weld X80 pipeline steel. The influences of wire feed rate and preheat on the fusion zone microstructure were investigated. Increasing the wire feed rate helped generate acicular ferrite in the weld metal, and preheating the wire further suppressed the formation of bainite. The acicular ferrite in the upper region of the fusion zone was finer than that in the lower region, which was due to an increase in nucleation sites available. Five fill and cap passes were applied by gas metal arc welding to fill the remaining top part of the groove. Compared to arc welding with a higher heat input, laser welding led to finer prior austenite grains and smaller bainite packet size in the coarse-grained heat-affected zone and limited the formation of martensite-austenite constituents in the intercritically reheated coarse-grained heat-affected zone.