Search Results (207)

This study introduces a time-efficient rotating bending fatigue testing system featuring 11 dual-end spindles, enabling simultaneous testing of 22 specimens. Designed for high-throughput fatigue life (S–N curve) assessment, the system theoretically allows over 93% reduction in total test duration, with 87.5% savings demonstrated in validation experiments using AISI 304 stainless steel. The PLC-based architecture provides autonomous operation, real-time failure detection, and automatic cycle logging. ER16 collet holders are easily replaceable within one minute, and all the components are selected from widely available industrial-grade parts to ensure ease of maintenance. The modular design facilitates straightforward adaptation to different station counts. The validation results confirmed an endurance limit of 421 MPa, which is consistent with the established literature and within ±5% deviation. Fractographic analysis revealed distinct crack initiation and propagation zones, supporting the observed fatigue behavior. This high-throughput methodology significantly improves testing efficiency and statistical reliability, offering a practical solution for accelerated fatigue life evaluation in structural, automotive, and aerospace applications. Full article

In today’s industrial applications, cutting fluids have attained prime importance due to their all-round features, including increase of tool life by lubrication of the tool at the tool–workpiece interface. This study compares the effects of mango seed oil and pongamia oil on cutting force and surface morphology during the turning of AISI 304 steel. The design of experiments was applied using Taguchi’s method with an L9 array of experiments. During the experiment, it was discovered that mango seed and pongamia-based cutting fluid exhibited the lowest contact angles of 22.1° and 24.4°, respectively, at a 97:3 volumetric concentration of deionized water and eco-friendly oil. The use of mango seed oil as a cutting fluid with MQL (Minimum Quantity Lubrication) resulted in the lowest surface roughness of 0.809 µm, compared to 0.921 µm with pongamia-based cutting fluid. The cutting force was reduced by a maximum of 28.68% using mango seed-based cutting fluid, compared to pongamia-based cutting fluid. ANOVA analysis revealed that feed rate had the maximum influence on the optimization of output parameters for mango seed cutting fluid. For pongamia-based cutting fluid, feed rate had the maximum influence on cutting force, while the depth of cut had the strongest influence on surface roughness. Full article

The formation mechanism of black streak defects in hot-rolled steel sheets was investigated to address the influence of the process parameters on the surface quality during the production of 304 stainless steels. Macro-/microstructural characterization revealed that the defect regions contained necessary mold slag components (Ca, Si, Al, Mg, Na, K) which originated from the initial stage of solidification in the mold region of the continuous casting process, indicating obvious slag entrapment during continuous casting. On this basis, a three-dimensional coupled finite-element model for the molten steel flow–thermal characteristics was established to evaluate the effects of typical casting parameters using the determination of the critical slag entrapment velocity as the criterion. Numerical simulations demonstrated that the maximum surface velocity improved from 0.29 m/s to 0.37 m/s with a casting speed increasing from 1.0 m/min to 1.2 m/min, which intensified the meniscus turbulence. However, the increase in the port angle and the depth of the submerged entry nozzle (SEN) effectively reduced the maximum surface velocity to 0.238 m/s and 0.243 m/s, respectively, with a simultaneous improvement in the slag–steel interface temperature. Through MATLAB (version 2023b)-based reverse optimization combined with critical velocity analysis, the optimal mold slag properties were determined to be 2800 kg/m³ for the density, 4.756 × 10⁻⁶ m²/s for the kinematic viscosity, and 0.01 N/m for the interfacial tension. This systematic approach provides theoretical guidance for process optimization and slag design enhancement in industrial production. Full article

This study investigates the influence of plastic deformation and temperature on the formation of mechanically induced martensite and the associated changes in hardness in AISI 304 austenitic stainless steel. Cold rolling was performed at three temperatures (20 °C, 0 °C, and −196 °C) and various degrees of deformation (10–70%). Microstructural changes, including the formation of ε and α′ martensite, were characterized using X-ray diffraction (XRD) and electron backscatter diffraction (EBSD). The results confirm that martensitic transformation proceeds via the γ → ε → α′ sequence, with transformation rates and martensite fractions increasing at lower temperatures and higher strains. The stacking fault energy of 25.9 mJ/m² favors this transformation pathway. Transformation rates of α′ martensite fractions significantly increased at lower temperatures and higher strains, 91.8% α′ martensite was observed at just 30% deformation at −196 °C. Hardness measurements revealed a strong correlation with martensite content: strain hardening dominated at lower deformations, while martensite formation became the primary hardening mechanism at higher deformations, especially at cryogenic temperatures. The highest hardness (551 HV) was observed in samples deformed to 70% at −196 °C. The findings provide insights into optimizing the mechanical properties of AISI 304 stainless steel through controlled deformation and temperature conditions. Full article

The erosion resistance of materials against solid particles is a very important property, especially in the transportation of powders or in aeronautics (dust inside jet engines). There is a strong need to introduce new materials that have higher solid particle erosion resistance than state-of-the-art materials. Thus, in the present work, the solid erosion particles of high entropy alloys (HEAs) based on the Al0.7CoCrFeNi matrix were studied compared to the state-of-the-art stainless steel AISI 304. Furthermore, the effect of the addition of Ti to HEAs on hardness and erosion resistance was investigated. Current research included the development of the chemical composition of a new kind of HEA designed on the basis of thermodynamical calculations performed in CALPHAD, its manufacturing, full characterization involving microstructural and phase analyses, hardness measurements, solid particle erosion tests, and finally, the elucidation of erosion mechanisms. It was found that HEAs showed higher hardness as well as erosion resistance than AISI 304. Moreover, it was found that the increase in Ti content in an HEA resulted in an increase in the hardness and resistance to the erosion of the studied HEA. As the main reason for this phenomenon, the stabilization of the β-BCC phase, suppression of the α-FCC phase, and the appearance of the Ni₃Ti phase in the studied HEA were claimed. Full article

Nickel-based coatings have been demonstrated to effectively enhance the surface performance of stainless-steel components. The present study investigates the deposition efficiency and quality of Colmonoy 227-F nickel alloy coatings on AISI 304 stainless steel using direct energy deposition (DED). The work focuses on the relationships between process parameters, microstructural features, and mechanical properties. A total of sixteen process parameter combinations were studied, varying laser power and scanning speed to establish optimal deposition conditions and to evaluate coating morphology, surface topology, dilution behavior, and mechanical performance. The surface geometry was analyzed using three-dimensional digital confocal microscopy. New material distribution (MD) indices were developed to quantify spatial uniformity and integrity of single coating scan tracks (CSTs) across the XY, XZ, and YZ planes. The optimal process was identified around 900 W laser power, balancing deposition efficiency and structural integrity. Scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) reveal a gradual compositional transition between coating and substrate. The results of the microhardness test demonstrate a consistent gradient in mechanical properties, extending from the coating to the substrate. Coatings were found to achieve a hardness level of up to 600 HK. These findings establish a new benchmark for evaluating DED high-performance coatings and offer a scalable methodology for optimizing additive manufacturing processes in surface engineering applications. Full article

The production of AISI 304 stainless steel (a corrosion-resistant alloy prone to solidification defects from high alloy content) particularly benefits from twin-roll strip casting—a short-process green technology enabling sub-rapid solidification (the maximum cooling rate exceeds 1000 °C/s) control for high-performance steels. However, the internal phenomena within its molten pool remain exceptionally challenging to monitor. This study developed a multiscale numerical model to simulate coupled fluid flow, heat transfer, and solidification in AISI 304 stainless steel twin-roll strip casting. A quarter-symmetry 3D model captured macroscopic transport phenomena, while a slice model resolved mesoscopic solidification structure. Laboratory experiments had verified that the deviation between the predicted temperature field and the measured average value (1384.3 °C) was less than 5%, and the error between the solidification structure simulation and the electron backscatter diffraction (EBSD) data was within 5%. The flow field and flow trajectory showed obvious recirculation zones: the center area was mainly composed of large recirculation zones, and many small recirculation zones appeared at the edges. Parameter studies showed that, compared with the high superheat (110 °C), the low superheat (30 °C) increased the total solid fraction by 63% (from 8.3% to 13.6%) and increased the distance between the kiss point and the bottom of the molten pool by 154% (from 6.2 to 15.8 mm). The location of the kiss point is a key industrial indicator for assessing solidification integrity and the risk of strip fracture. In terms of mesoscopic solidification structure, low superheat promoted the formation of coarse columnar crystals (equiaxed crystals accounted for 8.9%), while high superheat promoted the formation of equiaxed nucleation (26.5%). The model can be used to assist in the setting of process parameters and process optimization for twin-roll strip casting. Full article

In the present study, an approach for determining the different states of ball burnishing (BB) operations aimed at forming regular reliefs’ patterns on planar surfaces is introduced. The methodology involves acquiring multi-axis accelerometer data from CNC-driven milling machine to capture the dynamics of the BB tool and workpiece, mounted on the machine table. Following data acquisition from an AISI 304 stainless steel workpiece, which is subjected to BB treatments at different toolpaths and feed rates, the recorded signals are preprocessed through noise reduction techniques, DC component removal, and outlier correction. The refined data are then transformed using a root mean square (RMS) operation to simplify further analysis. A Gaussian Mixture Model (GMM) is subsequently employed to decompose the compressed RMS signal into distinct components corresponding to various operational states during BB. The experimental trials at feed rates of 500 and 1000 mm/min reveal that increased feed rates enhance the distinguishability of these states, thus leading to an augmented number of statistically significant components. The results obtained from the proposed GMM based algorithm applied on compressed RMS accelerations signals is compared with two other methods, i.e., Short-Time Fourier Transforms and Continuous Wavelet Transform. The results from the comparison show that the proposed GMM method has the advantage of segmenting three to five different states of the BB-process from nonstationary accelerations signals measured, while the other tested methods are capable only to distinguish the state of work of the deforming tool and state of its rapid (re-)positioning between the areas of working, when there is no contact between the BB-tool and workpiece. Full article

This study explores the feasibility of manufacturing martensitic stainless steel turbine blades via a directed energy deposition (DED) process using a powder precursor. Five different blade geometries were fabricated using AISI 431 L martensitic stainless steel deposited onto an AISI 304 L austenitic stainless steel substrate. The produced components were characterized in terms of microstructure, surface roughness, porosity, hardness, and residual stresses in both the as-processed condition and after heat treatment at 260 and 593 °C. Optical and scanning electron microscopy (SEM) analyses revealed a predominantly martensitic microstructure with well-defined grain boundaries. Heat treatment influenced the phase distribution and grain size, but did not have a significant impact on the surface roughness or modulus of elasticity. Tomographic assessments confirmed the absence of aligned or coalesced pores, which are critical sites for crack initiation. Residual stress analysis indicated the presence of compressive stresses in all blade geometries, which were effectively relieved by heat treatment. In addition, salt spray corrosion tests demonstrated that the corrosion resistance of the manufactured blades was similar to that of the base material. These findings suggest that DED is a viable technique for producing and repairing turbine blades, providing structural integrity and mechanical properties suitable for high-performance applications. Full article

This work presents a novel, compact (six pieces), low-cost (<$500 USD), and easy-to-manufacture metallography mounting device. The device is designed to produce high-quality polymer encapsulated samples that rival those obtained from commercial equipment ($5000–$10,000 USD). Utilizing the House of Quality (HoQ) framework within Quality Function Deployment (QFD), the device prioritizes critical customer requirements, including safety (validated via finite element method, FEM), affordability, and compatibility with standard hydraulic presses. FEM analysis under 29 MPa pressure revealed a maximum Von Mises stress of 80 MPa, well below the AISI 304 stainless steel yield strength of 170 MPa, yielding a static safety factor of 2.1. Fatigue analysis under cyclic loading (mean stress ${\sigma }_m$ = 40 MPa, amplitude stress ${\sigma }_a$ = 40 MPa) using the Modified Goodman Criterion demonstrated a fatigue safety factor of 3.75, ensuring infinite cycle durability. The device was validated at 140 °C (413.15 K) with a 5-min dwell time, encapsulating samples in a cylindrical configuration (31.75 mm diameter) using a 200 W heating band. Benchmarking confirmed performance parity with commercial systems in edge retention and surface uniformity, while reducing manufacturing complexity (vs. conventional 100-piece systems). This solution democratizes access to metallography, particularly in resource-constrained settings, fostering education and industrial innovation. Full article

This work studied the effect of self-protective paste nitriding (SPN) and ion plasma nitriding (IPN) on the surface chemistry, microstructure, and nanohardness of AISI 304 and 316L stainless steels, with both treated at 440 °C for 5 h. Surface modifications analyzed using SEM and nanoindentation revealed distinct outcomes. SPN induced an oxynitriding effect due to the oxidation properties of the pastes, forming Fe₃O₄ and Fe_xC phases, while IPN produced an expanded austenite layer. Both methods enhanced surface nanohardness, but SPN showed superior results. For 316L SS, SPN increased nanohardness by 367.81% (6.83 GPa) compared to a 133.5% increase (3.41 GPa) with IPN. For 304 SS, SPN improved nanohardness by 26% (2.23 GPa), whereas IPN reduced it by 48% (0.92 GPa). These findings highlight SPN’s potential as an effective anti-wear treatment, particularly for 316L SS. The SPN process utilized a eutectic mixture of sodium cyanate and sodium carbonate, while IPN employed a N₂:H₂ (1:1) gas mixture. SEM analyses confirmed the formation of γ-Fe(N) phases, indicating dispersed iron nitrides (FeN, Fe₃N, Fe₄N). SPN’s simultaneous oxidation and nitrocarburization led to an oxide layer above the nitride diffusion layer, enhancing mechanical properties through iron oxides (Fe₃O₄) and carbides (Fe_xC). Comparative analysis showed that AISI 316L exhibited better performance than AISI 304, underscoring SPN’s effectiveness for surface modification. Full article

This work investigates the effect of the addition of tungsten carbide (WC) particles as reinforcements to Ni (Inconel 625) versus Co (Stellite 6) alloys during deposition by laser cladding to form wear-resistant metal matrix composite (MMC) coatings. While the related literature often associates the presence of WC with the enhanced wear performance of MMC coatings, this work shows that such an effect is not universal as it may critically depend on the metallic matrix employed. Thus, to demonstrate whether the reinforcement and matrix act synergically in such a scenario or not, MMC coatings formed by Inconel 625 and Stellite 6, both with WC content ranging from 10% to 40%, were deposited under the same laser cladding setup on AISI 304 stainless steel substrates, being WC-free samples produced together for comparison basis. As expected, the hardness levels increased with more WC presence in both matrices, but the wear resistance was specifically evaluated by means of the metal wheel abrasion test (ASTM B611). The results revealed that the use of WC as a reinforcement indeed affects the matrix materials differently; for Stellite 6, the wear resistance increased with up to 20% of WC (in contrast to the hardness indication), whereas for Inconel 625, the wear resistance progressively decreased with more WC content. It was observed via scanning electron microscopy (SEM) that the WC particles within the Inconel 625 alloy tended to intensive cracking, being in this way more prone to detach from the matrix and hence representing a weakening factor for the effectiveness of the coatings produced. Thus, it is concluded that the addition of WC particles, as potential reinforcements for MMC coatings, is not always effective (synergic with the matrix) in providing wear resistance, hence, opposing the prevailing consensus. This outcome and its reasons will certainly help with insights into proper design of MMC coatings, starting with the importance of matrix material selection. Full article

This research reports on numerical simulations of the multi-pass laser forming process aimed at obtaining cylindrical surfaces from planar AISI 304 stainless-steel sheets. The effect of laser power, scanning speed, and distance between irradiation lines on the thermomechanical material response is assessed, with particular emphasis on the final curvature radius, maximum temperature, and final plastic deformation. To this end, a coupled thermomechanical finite element formulation is applied to the analysis of different experimental tests reported in the literature. The predictive capabilities of this model are demonstrated in the analysis of bent parts exhibiting a wide range of curvature radii, whose values were found in this work to inversely correlate with the total line energy input to the workpiece. In such situations, it was found that both the thermal response and the effective plastic strain values obtained in each test correlate directly with the line energy value. Furthermore, the distance between irradiation lines was identified as a key parameter in the formation of cylindrical surfaces, as it significantly influences the displacement and induced deformation. However, no significant impact of this parameter on the effective plastic strain was observed. Full article

This article focuses on the microstructural evolution and mechanical property changes of AISI 304 austenitic stainless steel corrugated pipes after aging treatment and solution treatment. The influence of different heat treatment processes on the microstructural evolution, second phase precipitation behavior, mechanical properties, and corrosion resistance of corrugated pipes was analyzed through metallographic microscopy (OM), scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), fatigue testing, hardness testing, and corrosion resistance experiments. The results showed that after aging treatment at 600 °C, carbides precipitated at the grain boundaries and twin boundaries of the corrugated tube, leading to corrosion behavior. The average microhardness value was 266.08 HV, and the work hardening problem of the corrugated tube was not improved. After solution treatment at 1050 °C, a single-phase austenite structure was obtained in the corrugated tube, and the carbides at the grain boundaries were completely dissolved. The average microhardness value was 66.02 HV, significantly improving the work hardening problem of the corrugated tube. Simultaneously, excellent comprehensive fatigue performance and intergranular corrosion resistance were exhibited. The solid solution treatment process is more suitable for the manufacturing of corrugated pipes that require high formability and corrosion resistance, while the aging treatment requires strict temperature control to avoid the sensitization temperature zone. This study provides a theoretical basis for optimizing the heat treatment process of AISI 304 austenitic stainless steel corrugated pipes. Full article

The cutting force exerted on steel bars plays a crucial role in determining tunneling parameters for shield tunneling, especially when cutters are used to cut through existing pile foundations. This research focuses on the cutting force during the initial phase of the cutting process. Using 2D finite element analysis, this study examines the early stage of orthogonal cutting with negative rake angle cutters, exploring the formation of a slip plane mode. By combining slip line theory with the shear band model, a computational model is developed to calculate the cutting force for negative rake angle cutters when cutting a circular steel bar cross-section at various depths. In addition, with the incorporation of the Johnson–Cook model, this study models cutting forces under various conditions, taking into account factors such as material strength, strain rate sensitivity, and temperature effects. The steels studied include AISI 1040, AISI 4340, and AISI 304, which are commonly used in construction, with attention given to how their mechanical properties, such as strength and hardness, affect the cutting forces. While this study acknowledges the steels’ manufacturing conditions, the primary focus remains on the cutting process and its impact on force predictions. The model’s calculated horizontal cutting force is compared to numerical simulations, showing a maximum absolute error of 33.85% and an average error of 14.23%. The vertical cutting force calculations are less accurate, with a maximum error of 64.2% and an average error of 14.06%. The analysis further reveals that chip accumulation significantly impacts the horizontal cutting force, while the variation in average stress along the slip line has a smaller effect. This study also examines how factors like material properties, initial temperature, low friction coefficients, and steel bar radius contribute to the model’s accuracy and reliability. Full article