Metals — Open Access Journal

Microstructure control is of vital importance in tailoring physical properties of metallic materials. Despite the enormous efforts devoted to the study of microstructure evolution during recrystallization, most previous research has been conducted under non-simple conditions, either applying complex deforming boundary conditions or employing specimens with sophisticated crystalline structure. These complexities hinder comprehensive understanding of the fundamental aspects in texture evolution and make it even harder to penetrate the already intricate recrystallization behaviors. The present study aims at a detailed evaluation of widely used phenomenological model in reproducing experimentally observed deformation characteristics under simple crystalline structure and deformation condition, as well as the prediction of nucleation sites during static recrystallization. In situ electron back-scattering diffusion (EBSD) observations were performed to record texture change during static recrystallization of single crystal pure iron specimens after tensile deformation. CP-FEM (crystal plasticity finite element method) method was employed to simulate deformed texture. Deformation heterogeneity characterized by kernel average misorientation maps derived from EBSD data and numerical calculations were compared. The former data shows deformation heterogeneity sensitive to localized microstrain while the later delivers an effective meso-scale deformation distribution. Observed approximate nucleation sites have shown a qualitative coincidence with highly distorted regions in numerical calculations. Full article

This study demonstrates the feasibility of a novel casting process called tailored additive casting (TAC). The TAC process involves injecting the melt several times to fabricate a single component, with a few seconds of holding between successive injections. Using TAC, we can successfully produce commercial-grade automotive steering knuckles with a tensile strength of 383 ± 3 MPa and an elongation percentage of 10.7 ± 1.1%, from Al 6061 alloys. To produce steering knuckles with sufficient mechanical strength, the composition of an Al 6061 alloy is optimized with the addition of Zr, Zn, and Cu as minor elements. These minor elements influence the thermal properties of the melt and alloy, such as their thermal stress, strain rate, shrinkage volume, and porosity. Optimal conditions for heat treatment before and after forging further improve the mechanical strength of the steering knuckles produced by TAC followed by forging. Full article

Mg‒Zn‒Ca metallic glasses are regarded as promising biodegradable materials. Previous studies on this alloy system have mostly focused on the composition regions with a large critical size (D_c) for the formation of metallic glasses, while this paper investigates the composition regions with a small D_c, which has been overlooked by researchers for a long time. The effects of the addition of Ag, Nd, and Yb elements on the microstructure and mechanical properties of Mg‒Zn‒Ca metallic glasses were studied. It was found that the Mg‒Zn‒Ca metallic glass exhibits a single and uniform amorphous structure with a compressive strength of 590 MPa. After the addition of a small amount of Ag into the alloy, the amorphous matrix is retained and new precipitate phases that lead to the decrease of the compressive strength are formed. The addition of the rare earth elements Nd and Yb changes the microstructure from a single amorphous matrix to a large number of quasicrystal phases, which results in an increase in compressive strength. The compressive strength of the Mg‒Zn‒Ca‒Yb alloy increases to 606.2 MPa due to the formation of multi-layered swirling solidified structure and a large number of small quasicrystals with high microhardness. Moreover, this study can be considered as a useful supplement to the existing studies on the Mg‒Zn‒Ca alloy system; it also provides new ideas for designing the microstructure and spatial structure of quasicrystal containing alloys with high performances. Full article

For cost-intensive products like automobiles, clients often with to personalize their product; this forces the industry to create a large diversity of combinable parts. Additionally, the life cycles of many components become shorter. For highly-stressable parts, which are commonly manufactured by forging, the short changeover cycles result in expensive products, as the costs of tools must be offset by the sale of only a few parts. To reduce the tool cost, new, flexible processes have to be established in tool manufacturing. Laser-based additive manufacturing is noted for its high flexibility; notably, Laser Metal Deposition (LMD) is gaining increasing relevance in research, as it is already used for coating and repairing forming tools; this technology makes it possible to add material onto free-formed surfaces. Therefore, investigations are being conducted to qualify this process to produce forging tools. Due to the thermal processes which are required during additive manufacturing, the microstructure of the material differs from that of wrought material. This, in turn, affects the strategy of post heat treatment in order that the required mechanical properties for tools be attained. Within this manuscript, the influence of additive manufacturing on performance characteristics of hot work tool steel X37CrMoV5-1 (1.2343) is analyzed. To investigate the behavior of additive manufactured material during the process chain of tool manufacturing, properties for different states of a heat treatment are characterized by hardness and strength. It was shown that the strength of the additive manufactured material could be increased compared to wrought material by using a tailored heat treatment. The effects that cause this behavior are investigated by comparing the microstructure at different states of heat treatment. Full article

Background: Creep-fatigue phenomena are complex and difficult to model in ways that are useful from an engineering design perspective. Existing empirical-based models can be difficult to apply in practice, have poor accuracy, and lack economy. Need: There is a need to improve on the ability to predict creep-fatigue life, and do so in a way that is applicable to engineering design.Method: The present work modified the unified creep-fatigue model of Liu and Pons by introducing the parameters of temperature and cyclic time into the exponent component. The relationships between them were extracted by investigating creep behavior, and then a reference condition was introduced. Outcomes: The modified formulation was successfully validated on the materials of 63Sn37Pb solder and stainless steel 316. It was also compared against several other models. The results indicate that the explicit model presents better ability to predict fatigue life for both the creep fatigue and pure fatigue situations. Originality: The explicit model has the following beneficial attributes: Integration—it provides one formulation that covers the full range of conditions from pure fatigue, to creep fatigue, then to pure creep; Unified—it accommodates multiple temperatures, multiple cyclic times, and multiple metallic materials; Natural origin—it provides some physical basis for the structure of the formulation, in its consistency with diffusion-creep behavior, the plastic zone around the crack tip, and fatigue capacity; Economy—although two more coefficients were introduced into the explicit model, the economy is not significantly impacted; Applicability—the explicit model is applicable to engineering design for both manual engineering calculations and finite element analysis. The overall contribution is that the explicit model provides improved ability to predict fatigue life for both the creep-fatigue and pure-fatigue conditions for engineering design. Full article

Modern steel plants produce today a large portfolio of various steel grades, many for end-uses demanding high quality. In order to utilize the maximum productivity of the continuous-casting machine, it is sometimes necessary to cast steel grades with different chemical compositions in one sequence. It is important, therefore, to know the possibilities of a specific continuous-casting machine to make the Intermix connections as short as possible. Any interference with established procedures may, however, have a negative impact on the cleanliness of the cast steel. Using physical and numerical simulation tools, it was found that reducing the steel level in the tundish during the exchange of ladles makes it possible to shorten the transition zone. However, when the steel level is reduced, the flow of steel is impaired, which can have a negative effect on the cleanliness of the cast steel and, in extreme cases, may even lead to entrapment of slag in the mold. The cleanliness of cast steel was evaluated using one of the most advanced tools for automatic steel cleanliness evaluation, AZtecFeature (Oxford Instruments, Abingdon, UK), which enables determination of the type, size, distribution, and shape, as well as the chemical composition, of individual types of non-metal inclusions. Full article

High purity Zirconium (Zr) materials are essential in many components of nuclear reactors, especially fuel cladding tubes. Due to the matrix influence, determination of impurities in the Zr materials requires separation from the Zr matrix. Among extraction methods, solvent extraction is common and suitable for large-scale production. In this study, extraction capability of Zr(IV) by 2-ethylhexyl phosphonic acid mono 2-ethylhexyl ester (PC88A) was examined by FT-IR and UV of ZrO(NO₃)₂ salt, PC88A-toluene solvent, and Zr-PC88A-toluene complex. ZrO₂ (obtained from Institute for Technology of Radioactive and Rare Elements—ITRRE), after being separated from the Zr matrix, was determined for impurities using internal standard (indium, In) by 50% of PC88A dissolved in toluene. Separation of impurities from the Zr matrix underwent two stages. First, one cycle of extraction of the Zr matrix and impurities in 3 M HNO₃ using 50% PC88A/toluene was conducted. Second, impurities were scrubbed by 4 M HNO₃ in two cycles. Results revealed that approximately 74% of Zr(IV) was separated to the organic phase and 26% remained in the aqueous phase. Determination of impurities after separation from the Zr matrix by ICP-MS using internal standard in revealed that the recovery of impurities achieved 95–100%. With the mentioned amount of Zr, the effect of the Zr matrix on the determination of elements by ICP-MS is negligible. Levels of impurities have relative standard deviations (RSD) of less than 6.9% and recovery of 88.6–98.8%. Therefore, the determination of impurities has high reliability and accuracy. The back-extraction of Zr(IV) in organic phase by 1 M H₂SO₄ has stripped about 99.5% of the Zr matrix back to the aqueous phase. Following this, NH₃ was added to the solution containing Zr after back-extraction to form Zr(OH)₄ which was then desiccated to produce ZrO₂. X-ray Diffraction (XRD), Scanning and Transmission Electron Microscopy (SEM and TEM) images showed that the new ZrO₂ product has spherical nanostructure with diameters of less than 25 nm, which is suitable for applications for the treatment of colorants, metal ions in wastewater sources and manufacture of anti-corrosion steel. In addition, the energy dispersive X-ray (EDX) of the new ZrO₂ product showed that it has high purity. Full article

In this paper, TiAlN-coated cemented carbide tools with chip groove were used to machine titanium alloy Ti-6Al-0.6Cr-0.4Fe-0.4Si-0.01B under dry conditions in order to investigate the machining performance of this cutting tool. Wear mechanisms of TiAlN-coated cemented carbide tools with chip groove were studied and compared to the uncoated cemented carbide tools (K20) with a scanning electron microscope (SEM) and energy dispersive spectrometer (EDS). The effects of the cutting parameters (cutting speed, feed rate and depth of cut) on tool life and workpiece surface roughness of TiAlN-coated cemented carbide tools with chip groove were studied with a 3D super-depth-of-field instrument and a surface profile instrument, respectively. The results showed that the TiAlN-coated cemented carbide tools with chip groove were more suitable for machining TC7. The adhesive wear, diffusion wear, crater wear, and stripping occurred during machining, and the large built-up edge formed on the rake face. The optimal cutting parameters of TiAlN-coated cemented carbide tools were acquired. The surface roughness Ra decreased with the increase of the cutting speed, while it increased with the increase of the feed rate. Full article

Sr-modification of A356 alloys has distinct shortages due to the volatilization and oxidation during remelting and pouring, which often reduce the modification efficiency and mechanical properties of the alloys. To avoid the adverse effects and enhance the comprehensive properties, the effects of heavy rare earth element holmium (Ho) modification on the microstructure and properties of the alloy were investigated. Ho addition inhibited the intrinsic orientation growth of (111)_Al planes and stimulated the growth of the (200)_Al planes for α-Al crystals. The addition of 0.2 wt.% Ho produced the best refinement effect for α-Al grains; 0.3 wt.% of Ho addition yielded the most distinct modification effect for eutectic Si phases, which was further improved by a T6 treatment. The extra addition of 0.4 wt.% Ho resulted in the complete loss of the refinement and modification effects and in the abnormal growth of the α-Al crystals. Ho additions produced Al₃Ho phases containing Fe elements, which were distributed on the boundaries of the α-Al dendrites. The corrosion-proof performance was enhanced by Ho addition and the T6 treatment; the tensile strength and elongation achieved the highest value upon 0.2 wt.% of Ho addition and the T6 treatment. Moreover, the hardness was also enhanced by Ho additions in both states. Full article

In order to improve the mechanical properties and phase transition temperature, the influence of Gd doping on the microstructure, phase transition temperature and mechanical properties of Co₃₅Ni₃₂Al₃₃ alloy was investigated. The results show that the γ+β phase was observed in the microstructure of the sample with less Gd doping and the γ phase+martensite was found with more Gd content. The phase transition temperature apparently increases with Gd doping and the phase transition temperature goes over room temperature when the Gd is 3 at.% or more. With increasing Gd doping, more γ phase appears in the sample which results in decrease in hardness. The compressive strength decreases from 2274 to 1630 MPa and the ductility increase from 4.2 to 12.9% with increasing Gd content. Full article

This paper deals with the roller chain commonly used for transmission of mechanical power on many kinds of industrial machinery, including conveyors, cars, motorcycles, bicycles, and so forth. It consists of a series of four components called a pin, a bush, a plate, and a roller, which are driven by a sprocket. To clarify the fatigue damage, in this paper, the finite element method (FEM) is applied to those components under three different types of states, that is, the press-fitting state, the static tensile state, and the sprocket-engaging state. By comparing those states, the stress amplitude and the average stress of each component are calculated and plotted on the fatigue limit diagram. The effect of the plastic zone on the fatigue strength is also discussed. The results show that the fatigue crack initiation may start around the middle inner surface of the bush. As am example, the FEM results show that the fatigue crack of the inner plate may start from a certain point at the hole edge. The results agree with the actual fractured position in roller chains used in industry. Full article

The H13-mod steel optimized by composition and heat treatment has reached the performance index of the shield machine hob. The hot deformation behavior of the H13-mod steel was investigated by compression tests in the temperature range from 900 to 1150 °C and the strain rate range from 0.01 to 10 s⁻¹. The true stress-strain curve showed that the rising stress at the beginning of deformation was mainly caused by work hardening. After the peak stress was attained, the curve drop and the flow softening phenomenon became more obvious at low strain rates. The flow behavior of the H13-mod steel was predicted by a strain-compensated Arrhenius-type constitutive equation. The relationship between the material constant in the Arrhenius-type constitutive equation and the true strain was established by a sixth-order polynomial. The correlation coefficient between the experimental value and the predicted value reached 0.987, which indicated that the constitutive equation can accurately estimate the flow stress during the deformation process. A good linear correlation was achieved between the peak stress (strain), critical stress (strain) and the Zener‒Hollomon parameters. The processing maps of the H13-mod steel under different strains were established. The instability region was mainly concentrated in the high-strain-rate region; however, the microstructure did not show any evidence of instability at high temperatures and high strain rates. Combined with the microstructure and electron backscattered diffraction (EBSD) test results under different deformations, the optimum hot working parameters were concluded to be 998–1026 °C and 0.01–0.02 s⁻¹ and 1140–1150 °C and 0.01–0.057 s⁻¹. Full article

This paper examines possible industrial applications of high manganese steel and the feasibility of its inoculation with a new ferroalloy, vanadium nitride. The abrasive and impact-abrasion surface wear experienced by castings has a classical pattern: microcutting—i.e., the deformation twinning of surface layers. Ferrovanadium nitride enhances the surface resistance of castings both as a cast and as thermally treated. A fine grain structure is formed in the surface layers, specifically layers in direct contact with abrasive particles. The deformation twins that are present at the solid solution grain boundaries tend to change their orientation and characteristics. The impact-abrasion wear also leads to hardened layer formation at the working surface due to deformation twinning. The carbides (nitrides) present in the surface wear do not produce any significant impact on the process of deformation twinning. As the wear line extends deeper into the casting surface, the carbides and nitrides are ripped out and cavities occur in the wearing zone. The wear is controlled by the solidification rate. Thus, at lower rates a hardened layer is formed, which accommodates adjacent areas with differing twin characteristics, such as orientation and spacing. Full article

The article presents the results of the investigation of changes in the chemical and mineralogical composition of slag during steel production in a blown oxygen converter. This process was monitored using the slag samples that were collected during the period when oxygen blowing into an oxygen converter was interrupted. The slag samples were collected after 150 s (2.5 min), then after 5, 8, 11, and 24 min of oxygen blowing, and in minute 27 when oxygen blowing was terminated. The sampling was carried out within five consecutive melting processes. The article presents and documents the changes in the contents of CaO, CaO (free), Fe (total), FeO, SiO₂, and in the basicity of the slag during oxygen blowing. It also provides the characteristics of individual structural components formed during oxygen blowing and a detailed description of the lime assimilation process, including the formation of the final structure of the slag, consisting of dicalcium silicate (2CaO·SiO₂), tricalcium silicate (3CaO·SiO₂), RO-phase, and calcium ferrites (2CaO·Fe₂O₃). The results of the investigation of the changes in the chemical composition of the slag during oxygen blowing in an oxygen converter were compared with the changes in the structural composition of the slag. Full article

Nickel-based superalloys are widely used in the aeronautical industry, especially in components requiring excellent corrosion resistance, enhanced thermal fatigue properties, and thermal stability. Haynes 282 is a nickel-based superalloy that was developed to improve the low weldability, formability, and creep strength of other γ’-strengthened Ni superalloys. Despite the industrial interest in Haynes 282, there is a lack of research that is focused on this alloy. Moreover, it is difficult to find studies dealing with the machinability of Haynes 282. Although Haynes 282 is considered an alloy with improved formability when compared with other nickel alloys, its machining performance should be analyzed. High pressure and temperature localized in the cutting zone, the abrasion generated by the hard carbides included in the material, and the tendency toward adhesion during machining are phenomena that generate extreme thermomechanical loading on the tool during the cutting process. Excessive wear results in reduced tool life, leading to frequent tool change, low productivity, and a high consumption of energy; consequentially, there are increased costs. With regard to tool materials, cemented carbide tools are widely used in different applications, and carbide is a recommended cutting material for turning Haynes 282, for both finishing and roughing operations. This work focuses on the finishing turning of Haynes 282 using coated carbide tools with conventional coolant. Machining forces, surface roughness, tool wear, and tool life were quantified for different cutting speeds and feeds. Full article

The metallurgical performances in a mold cavity were investigated using a conventional bilateral-port nozzle or a swirling flow nozzle (SFN) plus with in-mold electromagnetic stirring (M-EMS) for bloom continuous casting (CC) process. To this end, a coupled model of electromagnetism, flow, and heat transfer was developed. Meanwhile, corresponding plant trials were conducted to evaluate the influence of a melt feeding mode on the internal quality of an as-cast bloom in Shaoguan Steel, China. Under the case of the SFN plus with M-EMS, a novel opposite stirring mode in the bloom CC mold cavity can be observed. A swirling flow in the anti-clockwise direction generated by the SFN, and the other swirling flow in the clockwise direction induced by the M-EMS were formed in regions with distances ranging from 0 m to 0.11 m and 0.218 m to 1.4 m from the meniscus, respectively. As compared to the case of the bilateral-port nozzle plus with M-EMS, the opposite stirring mode in the mold cavity can promote the melt superheat dissipation, improve the casting soundness and the componential homogeneity, inhibit the mold level fluctuation, and also be beneficial to prevent slag erosion for the nozzle external wall at the meniscus. Here, the fluctuation range of carbon segregation along the casting direction is reduced from 0.16 to 0.06, and the magnitude of mold level fluctuation is reduced from 5.6 mm to 2.3 mm under the adoption of SFN plus with M-EMS, respectively. Full article

Equal-channel angular pressing (ECAP) was performed on a Mg (6 wt %) Zn alloy at temperatures from 160 to 240 °C and the microstructures and mechanical properties were studied using optical microscopy, X-ray diffraction, scanning electron microscopy, transmission electron microscopy, and an electronic universal testing machine. The results showed that ECAP was effective for grain refinement and a bi-modal grain structure formed at low temperatures, which was stable during ECAP from 160 to 200 °C. MgZn₂ phase and Mg₄Zn₇ phase were generated during the ECAP process. The mechanical properties remarkably increased after two repetitions of ECAP. However, the strengths could not be further improved by increasing the plastic deformation, but decreased when ECAP was performed between 200 and 240 °C. The mechanical properties of the ECAP Mg-6Zn alloy was determined by a combination of grain refinement strengthening, precipitation hardening, and texture softening. Full article

Metallic taper junctions of modular total hip replacement implants are analysed for corrosion damage using visual scoring based on different granularity levels that span from analysing the taper holistically to dividing the taper into several distinct zones. This study aims to objectively explore the spatial distribution and the severity of corrosion damage onto the surface of metallic stem tapers. An ordinal logistic regression model was developed to find the odds of receiving a higher score at eight distinct zones of 137 retrieved stem tapers. A method to find the order of damage severity across the eight zones is introduced based on an overall test of statistical significance. The findings show that corrosion at the stem tapers occurred more commonly in the distal region in comparison with the proximal region. Also, the medial distal zone was found to possess the most severe corrosion damage among all the studied eight zones. Full article