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Metals, Volume 8, Issue 2 (February 2018)

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Cover Story (view full-size image) In order to reduce rotating masses, the Presta joining process is extended to the usage of aluminum [...] Read more.
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Open AccessArticle Processing Effects on the Formability of Magnesium Alloy Sheets
Metals 2018, 8(2), 147; https://doi.org/10.3390/met8020147
Received: 31 January 2018 / Revised: 16 February 2018 / Accepted: 19 February 2018 / Published: 23 February 2018
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Abstract
As a generalized semi-finished product, the use of magnesium sheets requires addressing two major aspects of their processing: their microstructure and texture control, which are both essential for the forming behavior of such sheets during their forming to parts. Further, the processing of
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As a generalized semi-finished product, the use of magnesium sheets requires addressing two major aspects of their processing: their microstructure and texture control, which are both essential for the forming behavior of such sheets during their forming to parts. Further, the processing of such sheets is complex, and therefore expensive, and requires simplification. In this work, magnesium alloys AZ31, ZE10, and ME21 are investigated in the form of conventionally rolled sheets, as well as in the form of extruded sheets. Their microstructural and textural development are correlated to their mechanical and forming properties. During extrusion, strong textures develop that hinder stretch-forming operations, even in rare earth-containing alloys. Chemical composition and process parameters have a significant impact on the texture development, and enable the design of sheet materials with weak textures and potentially enhanced formability. Full article
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Open AccessArticle Numerical Simulation of Transient Multiphase Flow in a Five-Strand Bloom Tundish during Ladle Change
Metals 2018, 8(2), 146; https://doi.org/10.3390/met8020146
Received: 30 December 2017 / Revised: 8 February 2018 / Accepted: 13 February 2018 / Published: 23 February 2018
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Abstract
The steel-slag-air multiphase flow in a bloom tundish with five strands during the transient casting of the ladle change was simulated using the Volume of Fluid (VOF) model, and the formation mechanisms of macro-inclusions and the behavior of the steel-slag-air interface during the
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The steel-slag-air multiphase flow in a bloom tundish with five strands during the transient casting of the ladle change was simulated using the Volume of Fluid (VOF) model, and the formation mechanisms of macro-inclusions and the behavior of the steel-slag-air interface during the filling process were investigated. Water model experiments were conducted to validate the multiphase model. The results showed that the numerical results of slag entrapment behavior and the exposed area of steel are basically consistent with the experimental results. The flow of molten steel in the tundish is weak except for the region around the stopper rods at the end of the emptying process. Strong fluctuations in liquid level were formed during the filling process, showing two wave crests in front of and behind the shroud in the impact zone, which intensified with the increase in filling time and then declined gradually. Entrapment phenomena and exposure of liquid steel could not be observed before the filling stage. While the entrapped slag droplets mostly float up and can be removed within 40 s during the filling process, the remainder enters the casting zone through the baffle. The maximum exposed area of molten steel is 252 cm2 when the filling time is 4.0 s. Full article
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Open AccessArticle An Investigation on the Adiabatic Shear Bands in Depleted U-0.75 wt % Ti Alloy under Dynamic Loading
Metals 2018, 8(2), 145; https://doi.org/10.3390/met8020145
Received: 10 January 2018 / Revised: 1 February 2018 / Accepted: 14 February 2018 / Published: 22 February 2018
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Abstract
Adiabatic shear bands in uranium alloy projectiles/penetrators, during penetration, allow them to “self-sharpen,” a process that is absent in most tungsten alloy projectiles/penetrators. U-0.75 wt % Ti alloy samples have been accelerated to impact steel targets, and the distribution of adiabatic shear bands
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Adiabatic shear bands in uranium alloy projectiles/penetrators, during penetration, allow them to “self-sharpen,” a process that is absent in most tungsten alloy projectiles/penetrators. U-0.75 wt % Ti alloy samples have been accelerated to impact steel targets, and the distribution of adiabatic shear bands in residual samples has been studied in detail to understand the effect of self-sharpening on penetration. In our study, self-sharpening was evidenced by the distribution of the shear bands in the recovered sample. The shear bands formed during impact were observed to change direction when they crossed grain boundaries, which indicated that the grain boundaries had an influence on the adiabatic shear bands of U-0.75 wt % Ti. Micro-hardness test results showed that the Vickers micro-hardness in the adiabatic shear zone was 18% lower than that in the matrix. In the split-Hopkinson pressure bar (SHPB) experiment, a strain rate of around 2891 s−1 was the threshold strain rate that triggered the formation of adiabatic shear bands in the U-0.75 wt % Ti alloy. Full article
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Open AccessArticle Microstructure, Texture Evolution and Magnetic Properties of Fe-6.5 wt. % Si and Fe-6.5 wt. % Si-0.5 wt. % Cu Alloys during Rolling and Annealing Treatment
Metals 2018, 8(2), 144; https://doi.org/10.3390/met8020144
Received: 15 November 2017 / Revised: 9 February 2018 / Accepted: 13 February 2018 / Published: 22 February 2018
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Abstract
Sheets of Fe-6.5 wt. % Si and Fe-6.5 wt. % Si-0.5 wt. % Cu with the thickness of 0.3 mm have been produced by hot and warm rolling. The microstructure, texture evolution and magnetic properties of the two alloys were investigated. It was
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Sheets of Fe-6.5 wt. % Si and Fe-6.5 wt. % Si-0.5 wt. % Cu with the thickness of 0.3 mm have been produced by hot and warm rolling. The microstructure, texture evolution and magnetic properties of the two alloys were investigated. It was found that the addition of 0.5 wt. % Cu promoted the formation of shear bands during warm rolling, and enhanced the {110}<001> texture at surface layer and {111}<112> texture in the middle layer. After annealing treatment, a strong η fiber texture with a peak at {110}<001> was formed in the Fe-6.5 wt. % Si-0.5 wt. % Cu sample, while the Fe-6.5 wt. % Si sample was characterized by complex γ, η and λ fibers. The formation of dominating η fiber in the annealed Fe-6.5 wt. % Si-0.5 wt. % Cu sample is attributed to the shear bands formed in {111}<112> oriented grains. These shear bands in {111}<112> oriented grains acted as the nucleation sites of η oriented grains and promoted the growth of Goss oriented grains. The presence of strong η fiber with a peak at Goss in Fe-6.5 wt. % Si-0.5 wt. % Cu sample was the cause for the higher magnetic induction observed for this sample than for the Fe-6.5 wt. % Si sample. Full article
(This article belongs to the Special Issue Metallic Materials and Manufacturing)
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Open AccessArticle Particle-Reinforced Aluminum Matrix Composites (AMCs)—Selected Results of an Integrated Technology, User, and Market Analysis and Forecast
Metals 2018, 8(2), 143; https://doi.org/10.3390/met8020143
Received: 31 December 2017 / Revised: 2 February 2018 / Accepted: 19 February 2018 / Published: 22 February 2018
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Abstract
The research and development of new materials such as particle-reinforced aluminum matrix composites (AMCs) will only result in a successful innovation if these materials show significant advantages not only from a technological, but also from an economic point of view. Against this background,
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The research and development of new materials such as particle-reinforced aluminum matrix composites (AMCs) will only result in a successful innovation if these materials show significant advantages not only from a technological, but also from an economic point of view. Against this background, in the Collaborative Research Center SFB 692, the concept of an integrated technology, user, and market analysis and forecast has been developed as a means for assessing the technological and commercial potential of new materials in early life cycle stages. After briefly describing this concept, it is applied to AMCs and the potential field of manufacturing aircraft components. Results show not only technological advances, but also considerable economic potential—the latter one primarily resulting from the possible weight reduction being enabled by the increased yield strength of the new material. Full article
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Open AccessArticle The Properties of Arc-Sprayed Aluminum Coatings on Armor-Grade Steel
Metals 2018, 8(2), 142; https://doi.org/10.3390/met8020142
Received: 3 December 2017 / Revised: 14 February 2018 / Accepted: 17 February 2018 / Published: 22 February 2018
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Abstract
This article presents the results of an examination of the properties of arc-sprayed aluminum on alloyed armor-grade steel. Thermal arc spraying was conducted with a EuTronic Arc Spray 4 wire arc sprayer. Aluminum wire 1.6 mm in diameter was used to produce dense,
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This article presents the results of an examination of the properties of arc-sprayed aluminum on alloyed armor-grade steel. Thermal arc spraying was conducted with a EuTronic Arc Spray 4 wire arc sprayer. Aluminum wire 1.6 mm in diameter was used to produce dense, abrasion- and erosion-resistant coatings approx. 1.0 mm thick with and without nickel/5% aluminum-buffered subcoating. Aluminum coatings were characterized in accordance with ASTM G 65-00 abrasion resistance test, ASTM G 76-95 erosion resistance tests, ASTM C 633-01 adhesion strength, HV0.1 hardness tests and metallographic analyses. Results demonstrate properties of arc-sprayed aluminum and aluminum-nickel material coatings that are especially promising in industrial applications where erosion-, abrasion- and corrosion-resistant coating properties are required. Full article
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Open AccessArticle The Formation and Evolution of Shear Bands in Plane Strain Compressed Nickel-Base Superalloy
Metals 2018, 8(2), 141; https://doi.org/10.3390/met8020141
Received: 22 January 2018 / Revised: 2 February 2018 / Accepted: 9 February 2018 / Published: 18 February 2018
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Abstract
The formation and evolution of shear bands in Inconel 718 nickel-base superalloy under plane strain compression was investigated in the present work. It is found that the propagation of shear bands under plane strain compression is more intense in comparison with conventional uniaxial
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The formation and evolution of shear bands in Inconel 718 nickel-base superalloy under plane strain compression was investigated in the present work. It is found that the propagation of shear bands under plane strain compression is more intense in comparison with conventional uniaxial compression. The morphology of shear bands was identified to generally fall into two categories: in “S” shape at severe conditions (low temperatures and high strain rates) and “X” shape at mild conditions (high temperatures and low strain rates). However, uniform deformation at the mesoscale without shear bands was also obtained by compressing at 1050 °C/0.001 s−1. By using the finite element method (FEM), the formation mechanism of the shear bands in the present study was explored for the special deformation mode of plane strain compression. Furthermore, the effect of processing parameters, i.e., strain rate and temperature, on the morphology and evolution of shear bands was discussed following a phenomenological approach. The plane strain compression attempt in the present work yields important information for processing parameters optimization and failure prediction under plane strain loading conditions of the Inconel 718 superalloy. Full article
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Open AccessArticle Sensitivity Analysis of Oxide Scale Influence on General Carbon Steels during Hot Forging
Metals 2018, 8(2), 140; https://doi.org/10.3390/met8020140
Received: 8 December 2017 / Revised: 8 February 2018 / Accepted: 12 February 2018 / Published: 17 February 2018
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Abstract
Increasing product requirements have made numerical simulation into a vital tool for the time- and cost-efficient process design. In order to accurately model hot forging processes with finite, element-based numerical methods, reliable models are required, which take the material behaviour, surface phenomena of
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Increasing product requirements have made numerical simulation into a vital tool for the time- and cost-efficient process design. In order to accurately model hot forging processes with finite, element-based numerical methods, reliable models are required, which take the material behaviour, surface phenomena of die and workpiece, and machine kinematics into account. In hot forging processes, the surface properties are strongly affected by the growth of oxide scale, which influences the material flow, friction, and product quality of the finished component. The influence of different carbon contents on material behaviour is investigated by considering three different steel grades (C15, C45, and C60). For a general description of the material behaviour, an empirical approach is used to implement mathematical functions for expressing the relationship between flow stress and dominant influence variables like alloying elements, initial microstructure, and reheating mode. The deformation behaviour of oxide scale is separately modelled for each component with parameterized flow curves. The main focus of this work lies in the consideration of different materials as well as the calculation and assignment of their material properties in dependence on current process parameters by application of subroutines. The validated model is used to carry out the influence of various oxide scale parameters, like the scale thickness and the composition, on the hot forging process. Therefore, selected parameters have been varied within a numerical sensitivity analysis. The results show a strong influence of oxide scale on the friction behaviour as well as on the material flow during hot forging. Full article
(This article belongs to the Special Issue Advances in Plastic Forming of Metals)
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Open AccessArticle Effect of Nitric and Oxalic Acid Addition on Hard Anodizing of AlCu4Mg1 in Sulphuric Acid
Metals 2018, 8(2), 139; https://doi.org/10.3390/met8020139
Received: 15 December 2017 / Revised: 7 February 2018 / Accepted: 13 February 2018 / Published: 17 February 2018
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Abstract
The anodic oxidation process is an established means for the improvement of the wear and corrosion resistance of high-strength aluminum alloys. For high-strength aluminum-copper alloys of the 2000 series, both the current efficiency of the anodic oxidation process and the hardness of the
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The anodic oxidation process is an established means for the improvement of the wear and corrosion resistance of high-strength aluminum alloys. For high-strength aluminum-copper alloys of the 2000 series, both the current efficiency of the anodic oxidation process and the hardness of the oxide coatings are significantly reduced in comparison to unalloyed substrates. With regard to this challenge, recent investigations have indicated a beneficial effect of nitric acid addition to the commonly used sulphuric acid electrolytes both in terms of coating properties and process efficiency. The present work investigates the anodic oxidation of the AlCu4Mg1 alloy in a sulphuric acid electrolyte with additions of nitric acid as well as oxalic acid as a reference in a full-factorial design of experiments (DOE). The effect of the electrolyte composition on process efficiency, coating thickness and hardness is established by using response functions. A mechanism for the participation of the nitric acid additive during the oxide formation is proposed. The statistical significance of the results is assessed by an analysis of variance (ANOVA). Eventually, scratch testing is applied in order to evaluate the failure mechanisms and the abrasion resistance of the obtained conversion coatings. Full article
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Open AccessArticle The Effect of Interlayer Materials on the Joint Properties of Diffusion-Bonded Aluminium and Magnesium
Metals 2018, 8(2), 138; https://doi.org/10.3390/met8020138
Received: 15 December 2017 / Revised: 8 February 2018 / Accepted: 12 February 2018 / Published: 17 February 2018
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Abstract
Diffusion bonding is a well-known technology for a wide range of advanced joining applications, due to the possibility of bonding different materials within a defined temperature-time-contact pressure regime in solid state. For this study, aluminium alloys AA 6060, AA 6082, AA 7020, AA
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Diffusion bonding is a well-known technology for a wide range of advanced joining applications, due to the possibility of bonding different materials within a defined temperature-time-contact pressure regime in solid state. For this study, aluminium alloys AA 6060, AA 6082, AA 7020, AA 7075 and magnesium alloy AZ 31 B are used to produce dissimilar metal joints. Titanium and silver were investigated as interlayer materials. SEM and EDXS-analysis, micro-hardness measurements and tensile testing were carried out to examine the influence of the interlayers on the diffusion zone microstructures and to characterize the joint properties. The results showed that the highest joint strength of 48 N/mm2 was reached using an aluminium alloy of the 6000 series with a titanium interlayer. For both interlayer materials, intermetallic Al-Mg compounds were still formed, but the width and the level of hardness across the diffusion zone was significantly reduced compared to Al-Mg joints without interlayer. Full article
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Open AccessArticle Effects of Pre-Strain on the Aging Behavior of Al 7075 Alloy for Hot-Stamping Capability
Metals 2018, 8(2), 137; https://doi.org/10.3390/met8020137
Received: 12 January 2018 / Revised: 10 February 2018 / Accepted: 12 February 2018 / Published: 16 February 2018
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Abstract
The present study investigates the significance of pre-strain on the T6 aging behavior of an Al 7075 alloy for evaluating the applicability of hot stamping. In practice, the alloy was pre-strained up to 15% during solution heat treatment at 480 °C prior to
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The present study investigates the significance of pre-strain on the T6 aging behavior of an Al 7075 alloy for evaluating the applicability of hot stamping. In practice, the alloy was pre-strained up to 15% during solution heat treatment at 480 °C prior to quenching, and artificial aging was conducted at 120 °C. The peak aging time and precipitation behavior were compared with the alloy with pre-straining at room temperature after quenching but immediately before the artificial aging. The results showed that increasing amounts of pre-strain tend to reduce the aging time up to 50% for achieving peak hardness, which is consistent with the alloy at the T6 condition. There is a limitation for the maximum attainable amount of pre-strain of 10% for the homogeneous distribution of strain when the alloy is strained at room temperature (RT) due to the low formability. The pre-strained alloy as hot stamping exhibited lowering of the peak reaction temperatures for dissolution and formation of Guinier–Preston (GP)-Zones and precipitated with increasing amounts of pre-strain towards 15% through the differential scanning calorimetry analysis, thereby confirming the shortening of the peak aging time. The present study confirms the excellent potential of the hot-stamping process to extend the capability of an Al 7075 alloy. Full article
(This article belongs to the Special Issue Heat Treatment of Aluminum Alloys)
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Open AccessArticle Finite Element Analysis of Surface Integrity in Deep Ball-Burnishing of a Biodegradable AZ31B Mg Alloy
Metals 2018, 8(2), 136; https://doi.org/10.3390/met8020136
Received: 29 December 2017 / Revised: 3 February 2018 / Accepted: 12 February 2018 / Published: 16 February 2018
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Abstract
As an effective and affordable technique, deep ball-burnishing has been applied to induce the plastic deformation of material, thus resulting in an increased surface hardness, compressive residual stress, and finish quality. Recent research shows that the fast degradation of an Mg alloy implant
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As an effective and affordable technique, deep ball-burnishing has been applied to induce the plastic deformation of material, thus resulting in an increased surface hardness, compressive residual stress, and finish quality. Recent research shows that the fast degradation of an Mg alloy implant is a prime limiting factor for its success in in vivo human trials. This paper presents a comprehensive investigation into deep ball-burnishing of a biodegradable AZ31B Mg alloy, in order to improve the alloy’s surface integrity. A series of experiments using an in-house built burnishing tool with a 10-mm steel ball have been conducted, with a key focus of exploring the influence of the major process parameters—e.g., burnishing force (750–2650 N), feed rate (150–500 mm/min), and step-over (0.05–0.15 mm)—on hardness and finish quality. With the aim of performing a parametric sensitivity study, a three-dimensional (3D) finite element (FE) model is developed to predict the deformation mechanics, plastic flow, hardness, and residual stress. The FE model agrees with the experiment, hence validating the reliability of the model. Results show that while burnishing significantly improves surface integrity compared to the untreated surface, burnishing force and step-over are shown to be dominant. The net material movement dictates generated residual stress (tensile or compressive), often negatively affecting the surface integrity (e.g., surface cracks), which may be responsible for the onset of corrosion. An appropriate burnishing strategy must therefore be planned, in order to achieve the intended process outcome. The resulting surface properties, enhanced by the deep ball-burnishing, are expected to potentially increase the corrosion resistance of AZ31B Mg alloy implants. Full article
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Open AccessFeature PaperArticle Chemical Synthesis and Characterization of Pd/SiO2: The Effect of Chemical Reagent
Metals 2018, 8(2), 135; https://doi.org/10.3390/met8020135
Received: 28 December 2017 / Revised: 7 February 2018 / Accepted: 12 February 2018 / Published: 16 February 2018
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Abstract
The size and shape distribution of metal nanoparticles (NPs) are important parameters that need to be tuned in order to achieve desired properties of materials for practical applications. In the current work, we present the synthesis of palladium NPs supported on silica by
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The size and shape distribution of metal nanoparticles (NPs) are important parameters that need to be tuned in order to achieve desired properties of materials for practical applications. In the current work, we present the synthesis of palladium NPs supported on silica by three different methods, applying reduction by sodium borohydride, hydrazine vapors, and polyethylene glycol (PEG). The synthesized materials were characterized by X-ray diffraction, X-ray fluorescence, transmission electron microscopy, surface area and porosity measurements, and thermogravimetric analysis. Similar nanoparticle sizes with narrow size distribution centered at 8 nm were obtained after reduction by sodium borohydride and hydrazine vapors, whereas the smallest particle size of about 4.8 nm was obtained after reduction by PEG. The effect of modification of the initial palladium chloride compound by ammonium hydroxide was found to lead to the formation of larger particles with average size of 15 nm and broader size distribution. In addition, the process of the reduction of palladium by PEG at different reduction stages was monitored by UV-Vis spectroscopy. CO-stripping voltammetry showed that reduction in hydrazine and in PEG allowed the preparation of Pd NPs with high electrochemically-active surface area. Such NPs are promising materials for electrocatalysis. Full article
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Open AccessArticle Comparative Effect of Mo and Cr on Microstructure and Mechanical Properties in NbV-Microalloyed Bainitic Steels
Metals 2018, 8(2), 134; https://doi.org/10.3390/met8020134
Received: 4 January 2018 / Revised: 10 February 2018 / Accepted: 13 February 2018 / Published: 16 February 2018
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Abstract
Steel product markets require the rolled stock with further increasing mechanical properties and simultaneously decreasing price. The steel cost can be reduced via decreasing the microalloying elements contents, although this decrease may undermine the mechanical properties. Multi-element microalloying with minor additions is the
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Steel product markets require the rolled stock with further increasing mechanical properties and simultaneously decreasing price. The steel cost can be reduced via decreasing the microalloying elements contents, although this decrease may undermine the mechanical properties. Multi-element microalloying with minor additions is the route to optimise steel composition and keep the properties high. However, this requires deep understanding of mutual effects of elements on each other’s performance with respect to the development of microstructure and mechanical properties. This knowledge is insufficient at the moment. In the present work we investigate the microstructure and mechanical properties of bainitic steels microalloyed with Cr, Mo, Nb and V. Comparison of 0.2 wt. % Mo and Cr additions has shown a more pronounced effect of Mo on precipitation than on phase balance. Superior strength of the MoNbV-steel originated from the strong solid solution strengthening effect. Superior ductility of the CrNbV-steel corresponded to the more pronounced precipitation in this steel. Nature of these mechanisms is discussed. Full article
(This article belongs to the Special Issue Advances in Microalloyed Steels)
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Open AccessArticle Elastic and Plastic Behavior of the QE22 Magnesium Alloy Reinforced with Short Saffil Fibers and SiC Particles
Metals 2018, 8(2), 133; https://doi.org/10.3390/met8020133
Received: 30 December 2017 / Revised: 8 February 2018 / Accepted: 12 February 2018 / Published: 15 February 2018
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Abstract
Magnesium alloy QE22 (nominal composition 2 wt % Ag, 2 wt % mixture of rare earth elements, balance Mg) was reinforced with 5 vol % Saffil fibers and 15 vol % SiC particles. The hybrid composite was prepared via the squeeze cast technique.
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Magnesium alloy QE22 (nominal composition 2 wt % Ag, 2 wt % mixture of rare earth elements, balance Mg) was reinforced with 5 vol % Saffil fibers and 15 vol % SiC particles. The hybrid composite was prepared via the squeeze cast technique. The microstructure of the monolithic alloy and composite was analyzed using scanning electron microscopy. Elastic modulus was measured at room temperature and modeled by the Halpin–Tsai–Kardos mathematical model. The strengthening effect of fibers and particles was calculated and compared with the experimentally obtained values. The main strengthening terms were determined. Fracture surfaces were studied via scanning electron microscope. While the fracture of the matrix alloy had a mainly intercrystalline character, the failure of the hybrid composite was transcrystalline. Full article
(This article belongs to the Special Issue Metal Matrix Composites)
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