Application of a New Alloy and Post Processing Procedures for Laser Cladding Repairs on Hypereutectoid Rail Components
Abstract
:1. Introduction
2. Materials and Methods
2.1. Laser Cladding
2.2. Cladding Materials and Sample Preparation
2.3. Heat Treatment Processes
2.4. Residual Stress Measurement
3. Results
3.1. Microstructure
3.2. Residual Stress
3.2.1. Residual Stress of the Untempered 415SS Laser Clad Rail
3.2.2. Residual Stresses of 415SS Laser Clad Rail Plates with 350 °C Tempering and Grinding
3.2.3. Residual Stress of the 540 °C 415SS Laser Clad Rail with Surface Grinding
3.3. Influence of Tempering on Microstructural Hardness
3.4. Identification of Microstructural Changes from Neutron Diffraction Data
4. Discussion
4.1. Influence of Tempering on the Residual Stress in the Cladding Layer
4.2. Influence of Tempering on the Residual Stress State in the HAZ
4.3. Influence of Surface Grinding on the Residual Stress State in Cladding and HAZ
4.4. Comparison of Residual Stress and Hardness Results with Other Studies
5. Conclusions
- In the untempered state, internal stress within the 415SS deposition is compressive in both the transverse and longitudinal directions due to the martensitic microstructure within the cladding layer. The compressive stress is balanced by tensile stress in the HAZ below the cladding–substrate interface produced by thermal inputs and solid-state phase transformations.
- Tempering at 350 °C after cladding maintains the beneficial compressive surface stresses and generates a higher compensating tensile stress in the transverse direction of the HAZ. Grinding after this heat treatment locally relieves the surface stress, with both 0.5 mm and 1.4 mm grinding depths retaining the compressive stress state in the 415SS depositions.
- A post-cladding heat treatment of reheating and holding at 540 °C for 2 h achieves a significant reduction of 76% in tensile stresses in the HAZ when compared to the untempered rail. Removal of 0.5 mm due to grinding also retains the desirable compressive cladding state which may improve the wear and RCF resistance.
- The location of the fusion boundary and significant microstructural changes after cladding and tempering can be identified through correlation of the stress profiles to the FWHM, strain, and intensity data. Therefore, non-destructive neutron diffraction measurements can be used to obtain both residual stress and microstructural information from a metal joint.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Alloy | Fe | Cr | C | Mn | Si | Ni | Cu | Mo | V | Nb | Al | S | P | Ti |
---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
415SS | Bal | 12.4 | 0.13 | 0.85 | 0.48 | 0.21 | 0.04 | 0.03 | 0.01 | <0.01 | <0.01 | 0.01 | 0.02 | <0.01 |
Rail | Bal | 0.20 | 0.93 | 0.95 | 0.28 | <0.01 | - | <0.01 | <0.01 | <0.01 | <0.01 | 0.014 | - | - |
Sample | Cladding | Tempering Process | Surface Grinding |
---|---|---|---|
Rail (600 mm section with 400 mm cladding) | 415SS single layer | untempered | No grinding |
Plate (60 × 50 × 11 mm3) | 415SS single layer | 350 °C and slow cooling | No grinding |
Plate (60 × 50 × 11 mm3) | 415SS single layer | 350 °C and slow cooling | 0.5 mm removed |
Plate (60 × 50 × 11 mm3) | 415SS single layer | 350 °C and slow cooling | 1.4 mm removed |
Plate (60 × 50 × 11 mm3) | 415SS single layer | 540 °C for 2 h, air cooling | 0.5 mm removed |
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Kendall, O.; Fasihi, P.; Abrahams, R.; Paradowska, A.; Reid, M.; Lai, Q.; Qiu, C.; Mutton, P.; Soodi, M.; Yan, W. Application of a New Alloy and Post Processing Procedures for Laser Cladding Repairs on Hypereutectoid Rail Components. Materials 2022, 15, 5447. https://doi.org/10.3390/ma15155447
Kendall O, Fasihi P, Abrahams R, Paradowska A, Reid M, Lai Q, Qiu C, Mutton P, Soodi M, Yan W. Application of a New Alloy and Post Processing Procedures for Laser Cladding Repairs on Hypereutectoid Rail Components. Materials. 2022; 15(15):5447. https://doi.org/10.3390/ma15155447
Chicago/Turabian StyleKendall, Olivia, Panahsadat Fasihi, Ralph Abrahams, Anna Paradowska, Mark Reid, Quan Lai, Cong Qiu, Peter Mutton, Mehdi Soodi, and Wenyi Yan. 2022. "Application of a New Alloy and Post Processing Procedures for Laser Cladding Repairs on Hypereutectoid Rail Components" Materials 15, no. 15: 5447. https://doi.org/10.3390/ma15155447