Search Results (264)

This study employed a Gleeble-3800TM thermal simulator to conduct thermal cycle experiments on the coarse-grained heat-affected zone (CGHAZ) of Nb-Ti-La microalloyed steel under welding heat inputs of 50, 80, 100, and 120 kJ/cm. A systematic analysis was carried out to investigate the influence of heat input on the microstructure and impact toughness of the CGHAZ. The results indicate that the microstructure of the CGHAZ across different heat inputs consists of acicular ferrite (AF), granular bainite ferrite (GBF), polygonal ferrite (PF), as well as hard phases such as M/A constituents and degenerated pearlite (DP). With increasing heat input, the content of GBF decreases monotonically, while the content of PF increases monotonically, and the amount of hard phases rises continuously. In contrast, the content of AF initially increases and then decreases, reaching its peak at 100 kJ/cm. The microstructural changes induced by higher heat input lead to increased inhomogeneity in the local microstrain, thereby causing a monotonic reduction in crack initiation energy. Regarding crack propagation energy, the optimal performance is achieved at 100 kJ/cm due to the formation of a high proportion of AF, which heterogeneously nucleates on La-rich inclusions. This structure provides a high density of high-angle grain boundaries that effectively hinder crack propagation. Consequently, under the combined influence of crack initiation and propagation behaviors, the CGHAZ exhibits the best impact toughness at a heat input of 100 kJ/cm. Full article

Hypo-peritectic steels are susceptible to interfacial cracking during thin-slab continuous casting, in which non-metallic inclusions play a critical role. This study systematically investigates the effects of inclusion type and morphology on interface cracking behavior in the steel matrix, with the aim of improving billet shell quality. Hot tensile experiments were conducted using a Gleeble 3800 thermal simulator, and a finite element–based cohesive zone model was developed to simulate inclusion-induced crack nucleation and propagation. The results demonstrate that inclusions markedly influence interfacial stress distribution and damage evolution. The maximum interfacial stresses associated with MnS, Al₂O₃, and composite inclusions are 20.7, 23.4, and 30.5 MPa, respectively. Owing to severe stress concentration at sharp corners, composite inclusions exhibit the earliest crack nucleation at an applied stress of 11.3 MPa and the highest energy dissipation. In all cases, cracks initially nucleate at the location of maximum tensile stress (α = 90°), propagate along the interface, and subsequently penetrate into the matrix, ultimately leading to failure. The strong agreement between numerical simulations and experimental results confirms that angular inclusions accelerate damage by disrupting matrix continuity. These findings provide theoretical guidance for improving hypo-peritectic steel quality through inclusion morphology control during continuous casting. Full article

Ultra-high heat input welding offers high efficiency for large-scale offshore engineering, but excessive heat input can degrade low-temperature toughness. This study investigates the microstructural evolution and impact toughness of EH36 ship steel under high heat inputs (300–500 kJ/cm) using Gleeble-3500 thermal simulation, Charpy impact tests, and multi-scale characterization (OM, SEM, EBSD). Results show that impact toughness peaks at 400 kJ/cm, with surface and core energies reaching 343.33 J and 215.18 J, respectively. The optimal toughness is attributed to the formation of acicular ferrite and a high fraction of high-angle grain boundaries (up to 48.7%), which effectively inhibit crack propagation. These findings provide a practical basis for selecting heat input to balance welding efficiency and mechanical performance in marine steel fabrication. Full article

To investigate the hot deformation characteristics of the Al–10Mg–3Zn alloy, a series of hot compression tests was carried out using a Gleeble-3500 simulator. The experimental matrix covered temperatures of 300–450 °C and strain rates from 0.001 to 10 s⁻¹. The true stress–strain curves were obtained and the hot processing map of the alloy was constructed based on the Dynamic Material Model principle. The multi-objective optimization of the extrusion process parameters was performed using the response surface method. The results showed that the flow stress of Al–10Mg–3Zn alloy increased with the increase in the strain rate and decreased with the increase in the deformation temperature, indicating that the alloy had a positive strain rate sensitivity. A strain-compensated Arrhenius constitutive model and a hot processing map of Al–10Mg–3Zn alloy were established based on the temperature-corrected data; here, the optimal temperature range and strain rate range for hot processing were specified. The optimal extrusion process parameters, determined by the response surface method, were as follows: billet temperature of 400 °C, extrusion speed of 0.20 mm/s, and ingot length of 350 mm. With this parameter combination, the simulation predicted an extrusion load of 73.29 MN, a velocity deviation of 24.96%, and a cross-sectional temperature difference of 9.48 °C for the profile. The predicted values from the response surface method were highly consistent with those from the finite element simulation. The optimized process parameters significantly reduced the extrusion load of the profile. Full article

Extrusion of AlZnMgCu alloys is associated with a very high plastic resistance of the materials at forming temperatures and significant friction resistance, particularly at the contact surface between the ingots and the container. In technological practice, this translates into high maximum extrusion forces, often close to the capacity of hydraulic presses, and the occurrence of surface cracking of extruded profiles, resulting in a reduction in metal exit speed (production process efficiency). The accuracy of mathematical material models describing changes in the plastic stress of a material as a function of deformation, depending on the forming temperature and deformation speed, plays a very important role in the numerical modelling of extrusion processes using the finite element method (FEM). Therefore, three mathematical material models of the tested aluminium alloy were analysed in this study. In order to use the results of plastometric tests determined on the Gleeble device, they were approximated with varying degrees of accuracy using the Hnsel–Spittel equation and then implemented into the material database of the QForm-Extrusion^® programme. A series of numerical FEM calculations were performed for the extrusion of Ø50 × 3 mm tubes made of 7075 aluminium alloy using chamber dies for two different billet heating temperatures, 480 °C and 510 °C, and for three different material models. The metal flow was analysed in terms of geometric stability and dimensional deviations in the wall thickness of the extruded tube and its surface quality, as well as the maximum force in the extrusion process. Experimental studies of the industrial extrusion process of the tubes, using a press with a maximum force of 28 MN and a container diameter of 7 inches, confirmed the significant impact of the accuracy of the material model used on the results of the FEM numerical calculations. It was found that the developed material model of aluminium alloy 7075 number 1 allows for the most accurate representation of the actual conditions of deformation and quality of extruded tubes. Moreover, the material data obtained on the Gleeble simulator made it possible to determine the limit temperature of the extruded alloy, above which the material loses its cohesion and cracks appear on the surface of the extruded profiles. Full article

This article presents the results of research on the possibility of extruding oxygen-free copper pipes in bridge dies. The possibility of continuous production of a finished product of any length with a uniformly deformed wall was analysed. One of the most important elements of the work was to determine the shape of the tool (die and bridge) that would allow durable connection of the material. Numerical studies conducted using the commercial computer programme FORGE^®NxT 2.1, including analysis of the distribution of material temperature and hydrostatic pressure in the welding zone of the bridge die affecting the copper joint during the manufacture of tubular profiles, confirmed the validity of the research issue. The results of the numerical studies were supplemented by laboratory tests, confirming the accuracy of the selected variant of the finished product manufacturing process. The process of bonding under conditions of two-part material compression was used for physical modelling of copper welding. The tests were conducted using the Gleeble 3800 metallurgical process simulator with the PocketJaw module. Based on the analysis of the obtained results, it was found that for tubes with a wall-thickness-to-inner-diameter ratio of 0.5, it is justified to use tools with a longer sizing section and welding chamber, as well as a larger mandrel generating-line angle within the welding chamber. Full article

04Cr13Ni5Mo martensitic stainless steel is extremely sensitive to forging temperature and is prone to generating extremely large cracks, which leads to the failure of forging. Therefore, high-temperature tensile tests were performed on 04Cr13Ni5Mo martensitic stainless steel using a Gleeble-1500D thermo-mechanical simulator to investigate its damage mechanisms. The tests covered a temperature range of 950–1200 °C and strain rates of 0.001–1 s⁻¹. The high-temperature damage behavior and tissue evolution law at high temperatures were studied by means of EBSD, TEM, etc. Secondly, two high-temperature damage models of 04Cr13Ni5Mo, namely Normalized Cockcroft and Latham (NCL) and Oyane, were established by combining optimization algorithm and finite element simulation. Then, the two high-temperature damage models were integrated into the Forge^®NxT 3.2 finite element software. Simulated thermal tensile tests were conducted on 04Cr13Ni5Mo at temperatures from 950 to 1200 °C, strain rates from 0.001 to 1 s⁻¹. A comparison was made between the predicted and experimentally measured fracture displacements of the tensile specimens. The calculated correlation coefficients (R) were 0.995 and 0.991, respectively. It was determined that the NCL model has better simulation accuracy for predicting the forging cracks of 04Cr13Ni5Mo. The reliability of the finite element method for predicting forging crack defects in 04Cr13Ni5Mo forgings was established. Full article

The industrial production of high-speed steel via continuous casting has been impeded by considerable technical obstacles, due to its high carbon content and fast cooling speed, which predispose it to severe segregation and poor high-temperature plasticity; thus, industrial continuous casting of high-speed steel is virtually nonexistent. In 2022, a curved continuous casting process was successfully applied in the production of M2 high-speed steel; in our previous study, it was found that the carbides were finer and better distributed in the billets by curved continuous casting than those in the billets by ingot casting. The change in carbides in the billets is significant in subsequent processes for M2 high-speed steel produced by curved continuous casting. Therefore, it is necessary to investigate the high-temperature tensile properties of M2 high-speed steel produced by curved continuous casting. In this paper, high-temperature tensile tests were conducted using a GLEEBLE-3500 simulator (DSI, located in New York State, USA) at different temperatures and holding times with a certain strain rate to obtain the tensile strength and reduction of area, and then the morphology of carbides near the fracture surface was observed. The results showed that the tensile strength and reduction of area increased with the increase in temperature at 850 °C to 950 °C, and there existed a temperature range between 950 °C and 1120 °C with good thermoplasticity and a reduction of area from 45% to 50%. In addition, a sharp drop in thermoplasticity below 5% occurred at 1180 °C, which is due to the significant growth of carbides. The zero-strength temperature and plastic temperature were 1220 °C and 1200 °C, respectively. In addition, with the increase in holding time at 1150 °C, the reduction of area increased from 34% to 54%, and the tensile strength decreased from 92 MPa to 70 MPa and then increased to 82 MPa. The best solution for carbides in M2 high-speed steel produced by curved continuous casting occurred when the range of the P_HJ value was about 28.0 to 30.5. With the increase in P_HJ value, the shape of carbides gradually changed from fibrous to short rod-like and blocky during high-temperature diffusion. Full article

The deformation mechanism during the hot compression of PM nickel-based superalloy FGH99 and its micro-structural evolution, especially the evolution of γ’ phases, are the key factors affecting the final molding quality of aero-engine hot forged turbine disks. In this study, a new constitutive model of viscoplasticity with micro-structures as physical internal parameters were developed to simulate the hot compression behavior of FGH99 by incorporating the strengthening effect of the γ’ phase. The mechanical behavior of high-temperature (>1000 K) compressive deformation of typical superalloys under a wide strain rate (0.001~1 s⁻¹) is investigated using the Gleeble thermal-force dynamic simulation tester. The micro-structure after the hot deformation was characterized using EBSD and TEM. Work hardening as well as dynamic softening were observed in the hot compression tests. Based on the mechanical responses and micro-structural features, the model considered the coupled effects of dislocation density, DRX, and γ’ phase during hot flow. The model is programmed into a user subroutine based on the Fortran language and called in the simulation of the DEFORM-3D V6.1 software, thus realizing the multiscale predictive simulation of FGH99 alloy by combining macroscopic deformation and micro-structural evolution. The established viscoplastic constitutive model shows a peak discrepancy of 10.05% between its predicted hot flow stresses and the experimental values. For the average grain size of FGH99, predictions exhibit an error below 7.20%. These results demonstrate the high accuracy of the viscoplastic constitutive model developed in this study. Full article

In additively manufactured (AM) Ti-6Al-4V, the role of martensitic α′ in governing brittleness versus toughness remains debated, largely because complex thermal histories and other intertwined physical factors complicate interpretation. To isolate and clarify the intrinsic effect of cooling rate, we employed a Gleeble thermal simulator, which enables precisely controllable cooling rates while simultaneously achieving ultra-fast quenching comparable to AM (up to ~7000 °C/s). By varying the cooling rate only, three distinct microstructures were obtained: α/β, α_m/α′, and fully α′. Compression tests revealed that the ultra-fast-cooled fully martensitic Ti-6Al-4V attained both higher strength and larger fracture strain, with densely distributed elongated dimples indicative of ductile failure. Three-dimensional microstructures reconstructed from microscopy, analyzed using an EVP-FFT crystal plasticity model, demonstrated that refined α′ laths and abundant high-angle boundaries promote more homogeneous strain partitioning and reduce stress triaxiality, thereby delaying fracture. These results provide potential evidence that extreme-rate martensitic transformation can overcome the conventional strength–ductility trade-off in Ti-6Al-4V, offering a new paradigm for processing titanium alloys and AM components with superior performance. Full article

Isothermal hot compression tests were performed on an Al-4.8Cu-0.25Mg-0.32Mn-0.17Si alloy using a Gleeble-3500 thermomechanical simulator within the temperature range of 350–510 °C and strain rate range of 0.001–10 s⁻¹, achieving a true strain of 0.9. The constitutive equation and hot processing maps were established to predict the flow behavior of the alloy. The hot deformation mechanisms were investigated through microstructural characterization using inverse pole figure (IPF), grain boundary (GB), and grain orientation spread (GOS) analysis. The results demonstrate that both dynamic recovery (DRV) and dynamic recrystallization (DRX) occur during hot deformation. At high lnZ values (high strain rates and low deformation temperatures), discontinuous dynamic recrystallization (DDRX) dominates. Under middle lnZ conditions (low strain rate or high deformation temperature), both continuous dynamic recrystallization (CDRX) and DDRX are the primary mechanisms. Conversely, at low lnZ values (low strain rates and high temperatures), CDRX and geometric dynamic recrystallization (GDRX) become predominant. The DRX process in the Al-Cu-Mg alloy is controlled by the deformation temperature and strain rate. Full article

The aim of this study is to investigate the influence of Mo on the microstructure and mechanical properties of railway frog steel. To address the challenges of a coarse microstructure and alloy element segregation caused by the current casting method of railway frog steel, the application of thermal mechanical control process (TMCP) technology can achieve a uniform and refined microstructure and stable mechanical properties, which is progress for the development of high-manganese railway frog steel. The TMCP of four experimental steels with varying Mo contents of 0.02~1.01 wt.% was simulated using a Gleeble 3500. The mechanical properties were tested, and the microstructure of each sample was characterized. A single austenite formed in each Mo-containing steel. With the increased Mo content, the grain boundary carbides decreased due to the formation of carbides within the grains, and the austenite and twin sizes were refined. Moreover, grain boundary strengthening and dislocation strengthening increased, while solid solution strengthening and precipitation strengthening had little effect, leading to an increase in the final yield strength. The contribution of dislocation strengthening to the yield strength was 51~56%, indicating that dislocation strengthening was the most significant strengthening method in the high-manganese railway frog steel produced using the TMCP. The impact energy showed a trend of first increasing and then decreasing, and the impact energy reached the highest point when the Mo content was 0.30 wt.%. In addition, the mechanisms governing the effect of increased Si in controlling the final microstructure and mechanical properties are discussed. Full article

This paper investigates the effects of Ti and Nb addition with varying Mn content on the solidification macrostructure and microstructure in the continuous casting slab of Q355 steel using optical microscopy, scanning electron microscopy, transmission electron microscopy, and electron probe microanalysis. The evolution of central segregation and MnS inclusions during thermal simulation compress deformation has been clearly established using Gleeble-1500 thermal simulation tester. The results indicate that by reducing the Mn content and adding a small amount of Ti and Nb, it is possible to refine the grain and mitigate the center segregation of Q355 steel. Mn steel with 1.25% Mn and without Ti and Nb addition exhibits the most severe center segregation. The TiNb steel with 0.52% Mn and a small amount of Ti and Nb addition showed a marked improvement in the center segregation of the slab. The Nb steel with 0.56% Mn and 0.009% Nb shows the presence of thin film ferrite along prior grain boundaries surrounded by Widmanstätten ferrite, and the central segregation has not shown significant improvement. The thermal simulation samples of the three steel types inherit the characteristics of their respective casting structures. Full article

To address the coarse and mixed grain phenomena in ultra-large martensitic stainless steel forgings, this study investigated the hot deformation behavior of 04Cr13Ni5Mo martensitic stainless steel under deformation conditions of 950–1200 °C and strain rates of 0.001–0.1 s⁻¹ using Gleeble-1500D thermomechanical simulation tests. Based on the experimental data, the flow stress curves of the steel were obtained, and a dynamic recrystallization (DRX) kinetic model was established. The model was then integrated into finite element software for simulation to verify its reliability, providing theoretical guidance for optimizing high-temperature forging processes. The results demonstrate that dynamic recrystallization in 04Cr13Ni5Mo steel occurs more readily at temperatures above 1050 °C and strain rates below 0.1 s⁻¹. Under the selected hot compression test condition (1100 °C/0.01 s⁻¹), the simulated grain size in the central deformation zone was 48.98 μm, closely matching the experimentally measured value of 48.18 μm. This agreement confirms the reliability of finite element-based prediction and control of grain size in martensitic stainless steel forgings. Full article

To address the central cracking problem in continuous casting slabs of 38CrMoAl steel, high-temperature tensile tests were performed using a Gleeble-3800 thermal simulator to characterize the hot ductility of the steel within the temperature range of 600–1200 °C. The phase transformation behavior was computationally analyzed via the Thermo-Calc software, while the microstructure, fracture morphology, and precipitate characteristics were systematically investigated using a metallographic microscope (MM), a field-emission scanning electron microscope (FE-SEM), and transmission electron microscopy (TEM). Additionally, the effects of different holding times and cooling rates on the microstructure and precipitates of 38CrMoAl steel were also studied. The results show that the third brittle temperature region of 38CrMoAl steel is 645–1009 °C, and the fracture mechanisms can be classified into three types: (I) in the α single-phase region, the thickness of intergranular proeutectoid ferrite increases with rising temperature, leading to reduced hot ductility; (II) in the γ single-phase region, the average size of precipitates increases while the number density decreases with increasing temperature, thereby improving hot ductility; and (III) in the α + γ two-phase region, the precipitation of proeutectoid ferrite promotes crack propagation and the dense distribution of precipitates at grain boundaries causes stress concentration, further deteriorating hot ductility. Heat treatment experiments indicate that the microstructures of the specimen transformed under water cooling, air cooling, and furnace cooling conditions as follows: martensite + proeutectoid ferrite → bainite + ferrite → ferrite. The average size of precipitates first decreased, then increased, and finally decreased again with increasing holding time, while the number density exhibited the opposite trend. Therefore, when the holding time was the same, reducing the cooling rate could increase the average size of the precipitates and decrease their number density, thereby improving the hot ductility of 38CrMoAl steel. Full article