An Investigation into Sheet-Inconel 718 Forming with Flexible and Metal Tools-Simulation and Experiment.

The article presents the results of numerical simulations and experimental tests of plastic forming sheets made from the difficult-to-deform nickel alloy Inconel 718 with a thickness of 1 mm, using punches made from elastomeric materials with hardness 50-90 Shore A and steel dies. Elastomeric stamps were created in the form of five layers with a diameter of 160 mm. The influence of the hardness of the elastomeric punches on the geometry of the elements obtained was determined. The dies were made from 90MnCrV8 steel with a hardness of over 60 HRC. Their task was to obtain the expected shape of the element while generating various stress states in specific areas of the semi-finished product. The research was carried out using an original device whose operating principle was based on the Guerin method. The shape and dimensions of the elements made from Inconel 718 nickel alloy were determined by optical 3D scanning. The geometry of the drawpiece showed a significant impact of the hardness of the layered elastomer matrices on the degree of shape reproduction. The results obtained from numerical modeling were confirmed by the results of experimental tests. It has been shown that the hardness of the elastomeric material used for punches for plastic forming Inconel 718 nickel alloy sheets should be adapted to the shape of the drawpiece. It was also found that one of the important aspects of plastic forming sheets using the Guerin method is the tendency to obtain a diversified shape of the final elements.

Effects of Built Direction and Deformation Temperature on the Grain Refinement of 3D Printed AlSi10Mg Alloy Processed by Equal Channel Angular Pressing (ECAP).

In this work, we used an AlSi10Mg alloy produced by selective laser melting (SLM) to study the effects of build direction and deformation temperature on the grain refinement process. Two different build orientations of 0° and 90° and deformation temperatures of 150 °C and 200 °C were selected to study this effect. Light microscopy, electron backscatter diffraction and transmission electron microscopy were used to investigate the microtexture and microstructural evolution of the laser powder bed fusion (LPBF) billets. Grain boundary maps showed that the proportion of low-angle grain boundaries (LAGBs) dominated in every analysed sample. It was also found that different thermal histories caused by the change in build direction resulted in microstructures with different grain sizes. In addition, EBSD maps revealed heterogeneous microstructures comprising equiaxed fine-grained zones with ≈0.6 µm grain size and coarse-grained zones with ≈10 µm grain size. From the detailed microstructural observations, it was found that the formation of a heterogeneous microstructure is closely related to the increased fraction of melt pool borders. The results presented in this article confirm that the build direction has a significant influence on the microstructure evolution during the ECAP process.

Revealing the strengthening contribution of stacking faults, dislocations and grain boundaries in severely deformed LPBF AlSi10Mg alloy.

In this study, microstructural features direct metal laser melted (DMLM) aluminium-silicon-magnesium (AlSi10Mg) are investigated using advanced transmission electron microscopy (TEM) and high-resolution TEM (HRTEM). The focus is on post-processing by ECAP (Equal Channel Angular Pressing) and its effects on grain refinement, stacking fault formation and dislocation accumulation. In addition, the strength enhancing role of stacking faults is for the first time quantified. The results show that ECAP can increase the yield strength from 294 to 396 MPa, while the elongation increases from 2.4% to 6%. These results show that ECAP processing offers a new approach for producing AlSi10Mg products with improved strength and ductility.

Effect of Multi-Variant Thermal Treatment on Microstructure Evolution and Mechanical Properties of AlSi10Mg Processed by Direct Metal Laser Sintering and Casting.

This article presents a study on the influence of temperature and time of multi-variant heat treatment on the structure and properties of materials produced in direct metal laser sintering (DMLS) and casting technology. The materials were manufactured in the form of cuboidal elements with a cross-section of 1.5 mm × 15 mm and a length of 60 mm. The samples prepared in this way had a similar volume, but due to the production technology the metal crystallization took place at different rates and directions. In the cast, the direction of heat transfer was toward the mold, and the DMLS was directed locally layer by layer. The small thickness of the cast material allowed reaching conditions similar to the DMLS cooling process. Both DMLS and cast samples show similar mechanical properties (hardness) achieved after long ageing time, i.e., 16 h at 170 °C. The maximum hardness was observed for 8 h. In the DMLS samples, in contrast to cast samples, no lamellar precipitates of silicon were observed, which indicates their better resistance to cracking.

Hot Deformation Behavior of Non-Alloyed Carbon Steels.

The hot deformation behavior of selected non-alloyed carbon steels was investigated by isothermal continuous uniaxial compression tests. Based on the analysis of experimentally determined flow stress curves, material constants suitable for predicting peak flow stress σp, peak strain εp and critical strain εcrDRX necessary to induce dynamic recrystallization and the corresponding critical flow stresses σcrDRX were determined. The validity of the predicted critical strains εcrDRX was then experimentally verified. Fine dynamically recrystallized grains, which formed at the boundaries of the original austenitic grains, were detected in the microstructure of additionally deformed specimens from low-carbon investigated steels. Furthermore, equations describing with perfect accuracy a simple linear dependence of the critical strain εcrDRX on peak strain εp were derived for all investigated steels. The determined hot deformation activation energy Q decreased with increasing carbon content (also with increasing carbon equivalent value) in all investigated steels. A logarithmic equation described this dependency with reasonable accuracy. Individual flow stress curves of the investigated steels were mathematically described using the Cingara and McQueen model, while the predicted flow stresses showed excellent accuracy, especially in the strains ranging from 0 to εp.

Analysis of the Microstructure Development of Nb-Microalloyed Steel during Rolling on a Heavy-Section Mill.

It is not realistic to optimize the roll pass design of profile rolling mills, which typically roll hundreds of profiles, using physical modelling or operational rolling. The use of reliable models of microstructure evolution is preferable here. Based on the mathematical equations describing the microstructure evolution during hot rolling, a modified microstructure evolution model was presented that better accounts for the influence of strain-induced precipitation (SIP) on the kinetics of static recrystallization. The time required for half of the structure to soften, t0.5, by static recrystallization was calculated separately for both situations in which strain-induced precipitation occurred or did not occur. On this basis, the resulting model was more sensitive to the description of grain coarsening in the high-rolling-temperature region, which is a consequence of the rapid progress of static recrystallization and the larger interpass times during rolling on cross-country and continuous mills. The modified model was verified using a plain strain compression test (PSCT) simulation of rolling a 100-mm-diameter round bar performed on the Hydrawedge II hot deformation simulator (HDS-20). Four variants of simulations were performed, differing in the rolling temperature in the last four passes. For comparison with the outputs of the modified model, an analysis of the austenite grain size after rolling was performed using optical metallography. For indirect comparison with the model outputs, the SIP initiation time was determined based on the NbX precipitate size distribution obtained by TEM. Using the PSCT and the outputs from the modified microstructure evolution model, it was found that during conventional rolling, strain-induced precipitation occurs after the last pass and thus does not affect the austenite grain size. By lowering the rolling temperature, it was possible to reduce the grain size by up to 56 µm, while increasing the mean flow stress by a maximum of 74%. The resulting grain size for all four modes was consistent with the operating results.

Full-Field Temperature Measurement of Stainless Steel Specimens Subjected to Uniaxial Tensile Loading at Various Strain Rates.

This article presents a study on the effect of strain rate, specimen orientation, and plastic strain on the value and distribution of the temperature of dog-bone 1 mm-thick specimens during their deformation in uniaxial tensile tests. Full-field image correlation and infrared thermography techniques were used. A titanium-stabilised austenitic 321 stainless steel was used as test materials. The dog-bone specimens used for uniaxial tensile tests were cut along the sheet metal rolling direction and three strain rates were considered: 4 × 10-3 s-1, 8 × 10-3 s-1 and 16 × 10-3 s-1. It was found that increasing the strain rate resulted in the intensification of heat generation. High-quality regression models (Ra > 0.9) developed for the austenitic 321 steel revealed that sample orientation does not play a significant role in the heat generation when the sample is plastically deformed. It was found that at the moment of formation of a necking at the highest strain rate, the maximum sample temperature increased more than four times compared to the initial temperature. A synergistic effect of the strain hardening exponent and yield stress revealed that heat is generated more rapidly towards small values of strain hardening exponent and yield stress.

Correlation among the Power Dissipation Efficiency, Flow Stress Course, and Activation Energy Evolution in Cr-Mo Low-Alloyed Steel.

In the presented research, conventional hot processing maps superimposed over the flow stress maps or activation energy maps are utilized to study a correlation among the efficiency of power dissipation, flow stress, and activation energy evolution in the case of Cr-Mo low-alloyed steel. All maps have been assembled on the basis of two flow curve datasets. The experimental one is the result of series of uniaxial hot compression tests. The predicted one has been calculated on the basis of the subsequent approximation procedure via a well-adapted artificial neural network. It was found that both flow stress and activation energy evolution are capable of expressing changes in the studied steel caused by the hot compression deformation. A direct association with the course of power dissipation efficiency is then evident in the case of both. The connection of the presence of instability districts to the activation energy evolution, flow stress course, and power dissipation efficiency was discussed further. Based on the obtained findings it can be stated that the activation energy processing maps represent another tool for the finding of appropriate forming conditions and can be utilized as a support feature for the conventionally-used processing maps to extend their informative ability.

Effects of Austenitization Temperature and Pre-Deformation on CCT Diagrams of 23MnNiCrMo5-3 Steel.

The combined effect of deformation temperature and strain value on the continuous cooling transformation (CCT) diagram of low-alloy steel with 0.23% C, 1.17% Mn, 0.79% Ni, 0.44% Cr, and 0.22% Mo was studied. The deformation temperature (identical to the austenitization temperature) was in the range suitable for the wire rolling mill. The applied compressive deformation corresponded to the true strain values in an unusually wide range. Based on the dilatometric tests and metallographic analyses, a total of five different CCT diagrams were constructed. Pre-deformation corresponding to the true strain of 0.35 or even 1.0 had no clear effect on the austenite decomposition kinetics at the austenitization temperature of 880 °C. During the long-lasting cooling, recrystallization and probably coarsening of the new austenitic grains occurred, which almost eliminated the influence of pre-deformation on the temperatures of the diffusion-controlled phase transformations. Decreasing the deformation temperature to 830 °C led to the significant acceleration of the austenite → ferrite and austenite → pearlite transformations due to the applied strain of 1.0 only in the region of the cooling rate between 3 and 35 °C·s-1. The kinetics of the bainitic or martensitic transformation remained practically unaffected by the pre-deformation. The acceleration of the diffusion-controlled phase transformations resulted from the formation of an austenitic microstructure with a mean grain size of about 4 µm. As the analysis of the stress-strain curves showed, the grain refinement was carried out by dynamic and metadynamic recrystallization. At low cooling rates, the effect of plastic deformation on the kinetics of phase transformations was indistinct.

Strengthening of AA5754 Aluminum Alloy by DRECE Process Followed by Annealing Response Investigation.

In this study, a dual rolls equal channel extrusion (DRECE) process has been applied for improving the mechanical properties of the 5754 alloy. Supplementary experiments involving metallography, electron backscattered diffraction (EBSD), and XRD tests were carried out to evaluate the effect of the DRECE process. XRD analysis showed that the maximum dislocation density was achieved after six DRECE passes, which were accompanied by the formation that is typical for low-strain structures. The increasing dislocation density, as well as grain refinement throughout DRECE deformation, resulted in an increase in the mechanical properties. Annealing of the as-deformed sample resulted in grain growth and strength reduction.