Influence of Imposed Strain on Weldability of Dievar Alloy.

The presented work is focused on the influence of imposed strain on the weldability of Dievar alloy. Two mechanisms affecting the microstructure and thus imparting changes in the mechanical properties were applied-heat treatment (hardening and tempering), and rotary swaging. The processed workpieces were further subjected to welding with various welding currents. In order to characterize the effects of welding on the microstructure, especially in the heat-affected zone, and determine material stability under elevated temperatures, samples for uniaxial hot compression testing at temperatures from 600 to 900 °C, optical and scanning electron microscopy, and microhardness testing were taken. The testing revealed that, although the rotary swaged and heat-treated samples featured comparable microhardness, the strength of the swaged material was approximately twice as high as that of the heat-treated one-specifically 1350 MPa. Furthermore, it was found that the rotary swaged sample exhibited favorable welding behavior when compared to the heat-treated one, when the higher welding current was applied.

Effect of Stacking Sequence on Mechanical Properties and Microstructural Features within Al/Cu Laminates.

The study presents a method to prepare Al/Cu laminated conductors featuring two different stacking sequences using rotary swaging, a method of intensive plastic deformation. The primary focus of the work was to perform detailed characterization of the effects of room temperature swaging on the development of microstructures, including the Al/Cu interfaces, and internal misorientations pointed to the presence of residual stress within the laminates. The results revealed that both the Al and Cu components of the final laminates with 5 mm in diameter featured fine, more or less equiaxed, grains with no dominating preferential texture orientations (the maximum observed texture intensity was 2.3 × random for the Cu components of both the laminates). This fact points to the development of dynamic restoration processes during swaging. The analyses of misorientations within the grains showed that residual stress was locally present primarily in the Cu components. The Al components did not feature a substantial presence of misorientations, which confirms the dynamic recrystallization. Tensile testing revealed that the laminates with both the designed stacking sequences exhibited comparable UTS (ultimate tensile strength) of almost 280 MPa. However, notable differences were observed with regard to the plasticity (~3.5% compared to less than 1%). The laminate consisting of Al sheath and Cu wires exhibited very low plasticity as a result of significant work hardening of Al; this hypothesis was also confirmed with microhardness measurements. Observations of the interfaces confirmed satisfactory bonding of both the metallic components.

Influence of Structure Development on Performance of Copper Composites Processed via Intensive Plastic Deformation.

Designing a composite, possibly strengthened by a dispersion of (fine) oxides, is a favorable way to improve the mechanical characteristics of Cu while maintaining its advantageous electric conductivity. The aim of this study was to perform mechanical alloying of a Cu powder with a powder of Al2O3 oxide, seal the powder mixture into evacuated Cu tubular containers, i.e., cans, and apply gradual direct consolidation via rotary swaging at elevated temperatures, as well as at room temperature (final passes) to find the most convenient way to produce the designed Al2O3 particle-strengthened Cu composite. The composites swaged with the total swaging degree of 1.83 to consolidated rods with a diameter of 10 mm were subjected to measurements of electroconductivity, investigations of mechanical behavior via compression testing, and detailed microstructure observations. The results revealed that the applied swaging degree was sufficient to fully consolidate the canned powders, even at moderate and ambient temperatures. In other words, the final structures, featuring ultra-fine grains, did not exhibit voids or remnants of unconsolidated powder particles. The swaged composites featured favorable plasticity regardless of the selected processing route. The flow stress curves exhibited the establishment of steady states with increasing strain, regardless of the applied strain rate. The electroconductivity of the composite swaged at elevated temperatures, featuring homogeneous distribution of strengthening oxide particles and the average grain size of 1.8 µm2, reaching 80% IACS (International Annealed Copper Standard).

Optimizing Thermomechanical Processing of Bimetallic Laminates.

Thermomechanical processing combining plastic deformation and heat treatment is a favorable way to enhance the performance and lifetime of bimetallic laminates, especially those consisting of metals, which tend to form intermetallic layers on the interfaces when produced using methods involving increased temperatures. The presented work focuses on optimizing the conditions of thermomechanical treatment for an Al + Cu bimetallic laminate of innovative design involving a shear-strain-based deformation procedure (rotary swaging) and post-process heat treatment in order to acquire microstructures providing advantageous characteristics during the transfer of direct and alternate electric currents. The specific electric resistivity, as well as microhardness, was particularly affected by the structural features, e.g., grain size, the types of grain boundaries, and grain orientations, which were closely related to the applied thermomechanical procedure. The microhardness increased considerably after swaging (up to 116 HV02 for the Cu components), but it decreased after the subsequent heat treatment at 350 °C. Nevertheless, the heat-treated laminates still featured increased mechanical properties. The measured electric characteristics for DC transfer were the most favorable for the heat-treated 15 mm bimetallic laminate featuring the lowest measured specific electric resistivity of 22.70 × 10-9 Ωm, while the 10 mm bimetallic laminates exhibited advantageous behavior during AC transfer due to a very low power loss coefficient of 1.001.

Residual Stress Distribution in a Copper-Aluminum Multifilament Composite Fabricated by Rotary Swaging.

Rotary swaging is a promising technique for the fabrication of clad Cu/Al composites. Residual stresses appearing during the processing of a special arrangement of Al filaments within the Cu matrix and the influence of the bar reversal between the passes were studied by (i) neutron diffraction using a novel evaluation procedure for pseudo-strain correction and (ii) a finite element method simulation. The initial study of the stress differences in the Cu phase allowed us to infer that the stresses around the central Al filament are hydrostatic when the sample is reversed during the passes. This fact enabled the calculation of the stress-free reference and, consequently, the analysis of the hydrostatic and deviatoric components. Finally, the stresses with the von Mises relation were calculated. Hydrostatic stresses (far from the filaments) and axial deviatoric stresses are zero or compressive for both reversed and non-reversed samples. The reversal of the bar direction slightly changes the overall state within the region of high density of Al filaments, where hydrostatic stresses tend to be tensile, but it seems to be advantageous for avoiding plastification in the regions without Al wires. The finite element analysis revealed the presence of shear stresses; nevertheless, stresses calculated with the von Mises relation show similar trends in the simulation and in the neutron measurements. Microstresses are suggested as a possible reason for the large width of the neutron diffraction peak in the measurement of the radial direction.

Effect of the Composition of Hybrid Sands on the Change in Thermal Expansion.

In the foundry industry, silica sands are the most commonly used type of sands for the production of sand foundry moulds using various types of binders. Their greatest disadvantage is their significant volume changes at elevated temperatures, which are associated with the formation of many foundry defects from stress, such as veining, and thus have a direct influence on the final quality of the casting. In the case of non-silica sands and synthetic sands, the volume stability is more pronounced, but this is accompanied by a higher purchase price. Therefore, a combination of silica sand and synthetic sand CERABEADS is considered in order to influence and reduce the thermal expansion. The hybrid mixtures of sands, and their most suitable ratios, were evaluated in detail using sieve analysis, log W and cumulative curve of granularity. It was found that the addition of 50% CERABEADS achieves a 32.2% reduction in dilatation but may increase the risk of higher stresses. The measurements showed a significant effect of the granulometric composition of the sand on the resulting thermal expansion, where the choice of grain size and sorting can achieve a significant reduction in dilatation with a small addition of CERABEADS.

Affecting Microstructure and Properties of Additively Manufactured AISI 316L Steel by Rotary Swaging.

The presented work focused on the development of the microstructural and mechanical properties of a AISI 316L stainless steel workpiece prepared through additive manufacturing and subsequently processed by hot rotary swaging. In order to characterize the effects of swaging on the structural development, samples were taken for electron microscopy scanning and microhardness measurements were taken after each swaging reduction. The as-built and final swaged pieces were also subjected to tensile testing at room temperature and at 900 °C. The structural analyses showed that the hot swaging introduced a substructural formation; low angle grain boundaries prevailed over high angle ones after each pass. The swaging also imparted an almost complete elimination of the porosity and significant grain size; the average grain area decreased from the original value of 365.5 µm2 to 4.4 µm2 after the final swaging pass. The changes in the texture between the passes were negligible, however, the grain refinement went hand in hand with the microhardness increase (up to almost 300 HV1). The results of the tensile testing confirmed that the mechanical properties of the swaged pieces which improved dramatically and remained favorable up to high temperatures.

Grain Structure Engineering of NiTi Shape Memory Alloys by Intensive Plastic Deformation.

To explore an effective route of customizing the superelasticity (SE) of NiTi shape memory alloys via modifying the grain structure, binary Ni55Ti45 (wt) alloys were fabricated in as-cast, hot swaged, and hot-rolled conditions, presenting contrasting grain sizes and grain boundary types. In situ synchrotron X-ray Laue microdiffraction and in situ synchrotron X-ray powder diffraction techniques were employed to unravel the underlying grain structure mechanisms that cause the diversity of SE performance among the three materials. The evolution of lattice rotation, strain field, and phase transformation has been revealed at the micro- and mesoscale, and the effect of grain structure on SE performance has been quantified. It was found that (i) the Ni4Ti3 and NiTi2 precipitates are similar among the three materials in terms of morphology, size, and orientation distribution; (ii) phase transformation happens preferentially near high-angle grain boundary (HAGB) yet randomly in low-angle grain boundary (LAGB) structures; (iii) the smaller the grain size, the higher the phase transformation nucleation kinetics, and the lower the propagation kinetics; (iv) stress concentration happens near HAGBs, while no obvious stress concentration can be observed in the LAGB grain structure during loading; (v) the statistical distribution of strain in the three materials becomes asymmetric during loading; (vi) three grain lattice rotation modes are identified and termed for the first time, namely, multi-extension rotation, rigid rotation, and nondispersive rotation; and (vii) the texture evolution of B2 austenite and B19' martensite is not strongly dependent on the grain structure.

Characterising Correlations between Electric Conductivity and Structural Features in Rotary Swaged Al/Cu Laminated Conductors.

This study aims to characterize the correlations between electric characteristics and selected structural features of newly designed Al/Cu laminated conductors manufactured via room temperature rotary swaging. After swaging, the laminates with diameters of 15 mm were subjected to two different post-process annealing treatments. Structure analyses performed to evaluate the effects of thermomechanical processing were performed via scanning and transmission electron microscopies. Electric conductivity and resistivity of the laminates were experimentally measured and numerically simulated using models designed according to the real conditions. The results showed that the electric resistivity was affected by the grain size, bimodal grains' distribution (where observed), the presence of twins, and, last but not least, dislocation density. Among the influencing factors were the area fractions of Al and Cu at the cross-sections of the of the laminated conductors, too. The results revealed that fabrication of the laminate via the technology of rotary swaging introduced more advantageous combinations of electric and mechanical properties than fabrication by conventional manufacturing techniques. The lowest specific electric resistivity of 20.6 Ωm × 10-9 was measured for the laminated conductor subjected to the post-process annealing treatment at 350 °C, which imparted significant structure restoration (confirmed by the presence of fine, equiaxed, randomly oriented grains).

Influence of (Sub) Structure Development within Rotary Swaged Al-Cu Clad Conductors on Skin Effect during Transfer of Alternating Current.

The nature of alternating current transfer via metallic materials is specific, since the current density tends to be inhomogeneous across the cross-section of the conductor and the skin effect tends to occur. However, the influence of this effect on the behaviour of the conductor can be optimized via the design and fabrication procedures. The study presents innovative design of an Al-Cu clad conductor, which is supposed to affect favourably the influence of the skin effect. The clad conductors of various diameters (20 mm, 15 mm, and 10 mm) were fabricated via rotary swaging at room temperature, and their electric characteristics were subsequently examined both experimentally and via numerical simulations. Structure analyses performed to document the effects of the swaging technology on the development of substructure and characteristic structural features were carried out by scanning electron microscopy (electron backscatter diffraction analyses), and transmission electron microscopy. The results showed that the design of the composite has a favourable effect on decreasing the power losses during alternating current transfer and that the substructure development affected favourably the electric resistance of the conductor. The highest electric resistance was measured for the composite conductor with the diameter of 20 mm (1.8% increase compared to electric resistance during transfer of direct current). This value then decreased to 0.6%, and 0.1% after swaging down to the diameters of 15 mm, and 10 mm; the 10 mm composite featured the finest grains, partially restored structure, and texture randomization compared to the 20 mm and 15 mm composites. Manufacturing of the clad composite via rotary swaging imparted advantageous combinations of both the electric and mechanical properties, as swaging also introduced increased microhardness.

Determining Johnson-Cook Constitutive Equation for Low-Carbon Steel via Taylor Anvil Test.

Tristal steel is low-carbon construction-type steel widely used in the automotive industry, e.g., for braking components. Given the contemporary demands on the high-volume production of such components, these are typically fabricated using automatic sequential machines, which can produce components at strain rates up to 103 s-1. For this reason, characterising the behaviour of the used material at high strain rates is of the utmost importance for successful industrial production. This study focuses on the characterisation of the behaviour of low-carbon steel via developing its material model using the Johnson-Cook constitutive equation. At first, the Taylor anvil test is performed. Subsequently, the acquired data together with the results of observations of structures and properties of the tested specimens are used to fill the necessary parameters into the equation. Finally, the developed equation is used to numerically simulate the Taylor anvil test and the predicted data is correlated with the experimentally acquired one. The results showed a satisfactory correlation of the experimental and predicted data; the deformed specimen region featured increased occurrence of dislocations, as well as higher hardness (its original value of 88 HV increased to more than 200 HV after testing), which corresponded to the predicted distributions of effective imposed strain and compressive stress.

Monotonic Tension-Torsion Experiments and FE Modeling on Notched Specimens Produced by SLM Technology from SS316L.

The aim of this work was to monitor the mechanical behavior of 316L stainless steel produced by 3D printing in the vertical direction. The material was tested in the "as printed" state. Digital Image Correlation measurements were used for 4 types of notched specimens. The behavior of these specimens under monotonic loading was investigated in two loading paths: tension and torsion. Based on the experimental data, two yield criteria were used in the finite element analyses. Von Mises criterion and Hill criterion were applied, together with the nonlinear isotropic hardening rule of Voce. Subsequently, the load-deformation responses of simulations and experiments were compared. Results of the Hill criterion show better correlation with experimental data. The numerical study shows that taking into account the difference in yield stress in the horizontal direction of printing plays a crucial role for modeling of notched geometries loaded in the vertical direction of printing. Ductility of 3D printed specimens in the "as printed" state is also compared with 3D printed machined specimens and specimens produced by conventional methods. "As printed" specimens have 2/3 lower ductility than specimens produced by a conventional production method. Machining of "as printed" specimens does not affect the yield stress, but a significant reduction of ductility was observed due to microcracks arising from the pores as a microscopic surface study showed.

The Effect of Predeformation on Creep Strength of 9% Cr Steel.

Martensitic creep-resistant P92 steel was deformed by different methods of severe plastic deformation such as rotation swaging, high-pressure sliding, and high-pressure torsion at room temperature. These methods imposed significantly different equivalent plastic strains of about 1-30. It was found that rotation swaging led to formation of heterogeneous microstructures with elongated grains where low-angle grain boundaries predominated. Other methods led to formation of ultrafine-grained (UFG) microstructures with high frequency of high-angle grain boundaries. Constant load tensile creep tests at 873 K and initial stresses in the range of 50 to 300 MPa revealed that the specimens processed by rotation swaging exhibited one order of magnitude lower minimum creep rate compared to standard P92 steel. By contrast, UFG P92 steel is significantly softer than standard P92 steel, but differences in their strengths decrease with increasing stress. Microstructural results suggest that creep behavior of P92 steel processed by severe plastic deformation is influenced by the frequency of high-angle grain boundaries and dynamic grain coarsening during creep.

Special Issue: Mechanical Properties in Progressive Mechanically Processed Metallic Materials.

The research and development of modern metallic materials imparts not only the introduction of innovative alloys and compounds, but also the increasing lifetime of existing materials via optimized deformation processing. Among the essential features of progressive metallic materials used for modern applications are enhanced mechanical properties, but also other high-level functional characteristics, such as thermal-physical parameters, corrosion rate, and electric resistance. The properties of materials and alloys ensue from their structures, which can primarily be affected by the preparation/production process. The Special Issue "Mechanical Properties in Progressive Mechanically Processed Metallic Materials" was established to present recent developments and innovations particularly in the engineering field. The Special Issue comprises papers dealing with modern materials, such as metallic composites and pseudoalloys, as well as developments in various processing technologies.

Deformation Behavior of Al/Cu Clad Composite During Twist Channel Angular Pressing.

The research and development of modern metallic materials goes hand in hand with increasing their lifetime via optimized deformation processing. The presented work deals with preparation of an Al/Cu clad composite with implemented reinforcing Cu wires by the method of twist channel angular pressing (TCAP). Single and double pass extrusion of the clad composite was simulated numerically and carried out experimentally. This work is unique as no such study has been presented so far. Detailed monitoring of the deformation behavior during both the passes was enabled by superimposed grids and sensors. Both the sets of results revealed that already the single pass imparted significant effective strain (higher than e.g., conventional equal channel angular pressing (ECAP)), especially to the Al matrix, and resulted in notable deformation strengthening of both the Al and Cu composite components, which was confirmed by the increased punch load and decreased plastic flow velocity (second pass compared to first pass). Processing via the second pass also resulted in homogenization of the imposed strain and residual stress across the composite cross-section. However, the investigated parameters featured slight variations in dependence on the monitored location across the cross-section.

Texture and Differential Stress Development in W/Ni-Co Composite after Rotary Swaging.

Knowledge of texture and residual stresses in tungsten heavy pseudoalloys is substantial for the microstructure optimization. These characteristics were determined in cold and warm rotary swaged W/NiCo composite with help of neutron diffraction. The results were discussed in view of the observed microstructure and mechanical properties. The investigated bars consisted of tungsten agglomerates (bcc lattice) surrounded by NiCo-based matrix (fcc lattice). No preferential crystallographic orientation was found in the as-sintered bar. A strong texture was formed in both the tungsten agglomerates (<101> fiber texture parallel to the swaging axis) and in the NiCo-based matrix (<111> fiber texture) after rotary swaging. Although usually of double-fiber texture, the <001> fiber of the fcc structures was nearly missing in the matrix. Further, the cold-swaged bar exhibited substantially stronger texture for both phases which corresponds to the higher measured ultimate tensile strength. The residual stress differences were employed for characterization of the stress state of the bars. The largest residual stress difference (≈400 MPa) was found at the center of the bar deformed at room temperature. The hoop stresses were non-symmetrical with respect to the swaging axis, which was likely caused by the elliptical cross section of the as-sintered bar.

Effects of Sintering Conditions on Structures and Properties of Sintered Tungsten Heavy Alloy.

Probably the most advantageous fabrication technology of tungsten heavy alloys enabling the achievement of required performance combines methods of powder metallurgy and processing by intensive plastic deformation. Since the selected processing conditions applied for each individual processing step affect the final structures and properties of the alloys, their optimization is of the utmost importance. This study deals with thorough investigations of the effects of sintering temperature, sintering time, and subsequent quenching in water on the structures and mechanical properties of a 93W6Ni1Co tungsten heavy alloy. The results showed that sintering at temperatures of or above 1525 °C leads to formation of structures featuring W agglomerates surrounded by the NiCo matrix. The sintering time has non-negligible effects on the microhardness of the sintered samples as it affects the diffusion and structure softening phenomena. Implementation of quenching to the processing technology results in excellent plasticity of the green sintered and quenched pieces of almost 20%, while maintaining the strength of more than 1000 MPa.

Correlating Microstrain and Activated Slip Systems with Mechanical Properties within Rotary Swaged WNiCo Pseudoalloy.

Due to their superb mechanical properties and high specific mass, tungsten heavy alloys are used in demanding applications, such as kinetic penetrators, gyroscope rotors, or radiation shielding. However, their structure, consisting of hard tungsten particles embedded in a soft matrix, makes the deformation processing a challenging task. This study focused on the characterization of deformation behavior during thermomechanical processing of a WNiCo tungsten heavy alloy (THA) via the method of rotary swaging at various temperatures. Emphasis is given to microstrain development and determination of the activated slip systems and dislocation density via neutron diffraction. The analyses showed that the grains of the NiCo2W matrix refined significantly after the deformation treatments. The microstrain was higher in the cold swaged sample (44.2 × 10-4). Both the samples swaged at 20 °C and 900 °C exhibited the activation of edge dislocations with <111> {110} or <110> {111} slip systems, and/or screw dislocations with <110> slip system in the NiCo2W matrix. Dislocation densities were determined and the results were correlated with the final mechanical properties of the swaged bars.

Affecting Structure Characteristics of Rotary Swaged Tungsten Heavy Alloy Via Variable Deformation Temperature.

This study focuses on numerical prediction and experimental investigation of deformation behaviour of a tungsten heavy alloy prepared via powder metallurgy and subsequent cold (20 °C) and warm (900 °C) rotary swaging. Special emphasis was placed on the prediction of the effects of the applied induction heating. As shown by the results, the predicted material behaviour was in good correlation with the real experiment. The differences in the plastic flow during cold and warm swaging imparted differences in structural development and the occurrence of residual stress. Both the swaged pieces exhibited the presence of residual stress in the peripheries of W agglomerates. However, the NiCO matrix of the warm-swaged piece also exhibited the presence of residual stress, and it also featured regions with increased W content. Testing of mechanical properties revealed the ultimate tensile strength of the swaged pieces to be approximately twice as high as of the sintered piece (860 MPa compared to 1650 MPa and 1828 MPa after warm and cold swaging, respectively).

Analysis of Deformation Behaviour and Residual Stress in Rotary Swaged Cu/Al Clad Composite Wires.

Both copper and aluminum are widely applicable throughout a variety of industrial and commercial branches, however, joining them in a composite provides the possibility of combining all their advantageous properties in one material. This study investigates uniquely sequenced copper-aluminum clad composite wires, fabricated via rotary swaging technology. The composites were processed at 20 °C and 250 °C to a diameter of 5 mm. Structural observations and the determination of residual stress within both elements of the swaged wires were performed via electron microscopy; the experimental results were correlated with numerical predictions. As shown in the results, both the applied swaging force and temperature affected the plastic flow, which had a direct influence on residual stress and texture development; the Alsheath elements exhibited ideal rolling textures, whereas the Cuwires elements featured ideal shear texture orientation. The grains within both the Alsheath elements of the 5 mm composite wire were refined down to sub-micron size. Structural restoration also had a positive influence on residual stress.