Search Results (1,220)

The perforated backup plate of KARL KROYER MP 2C120 diaphragm pumps, used in the starch processing food industry, exhibits recurrent in-service fractures whose quantitative explanation and redesign solution have not been previously addressed in the literature. To solve this problem, an integrated analytical model is developed that combines, in a calibrable expression, small-magnitude spherical curvature, regular square-pattern perforation, and stepped peripheral clamping, calibrated against finite element numerical simulation and applied to the screening of eighteen geometrically feasible configurations. The chemical composition of the installed material was verified by portable optical emission spectrometry (PMI), identifying it as austenitic stainless steel AISI 301/1.4310 X10CrNi18-8, with nominal annealed yield strength ${\sigma }_y=195$ MPa according to EN 10088-2. The calibration quantifies an overestimation of $22.6\%$ for the simply supported edge model and an underestimation of $51.7\%$ for the clamped edge model; the dimensionless parameter ${\eta }_{\mathrm{BC}}=0.695$ describes the effective degradation of clamping due to the reduced stiffness of the perforated belt adjacent to the edge and supports the use of the simply supported model as a conservative screening bound. The currently installed configuration operates with a safety factor $F{S}_{\mathrm{op}}=0.89$ with respect to yield strength, quantitatively explaining the observed fractures. Within the standard manufacturable space, the configuration $d=5$ mm, $p=7.5$ mm ($\eta =0.333$) minimizes the maximum equivalent stress predicted by the conservative screening model; this selection corresponds to the configuration with the maximal ligament efficiency and is preserved under the single-point calibration, which acts as a single global positive scale factor. The screening is verified by a direct finite element campaign performed on the complete $d=5$ mm family (configurations 1, 2 and 3) with the experimentally verified material properties. The verification confirms the predicted ranking and the peripheral location of the critical region, but shows that the smooth cross-center field is essentially invariant across configurations ($187.3$, $195.0$ and $186.0$ MPa), so the linear-scaling estimate previously used to anchor absolute margins is not supported; the benefit of the redesign accrues at the governing hole-edge concentration, which decreases from $338.2$ to $261.5$ MPa ($22.7\%$ reduction) yet remains above the yield strength of the annealed material. Geometric modification alone is therefore insufficient, and industrial adoption requires combining configuration 3 with material substitution to a cold-worked hardened state (C700: $FS=1.91$ on the governing peak) or a duplex alloy ($FS=1.76$), together with periodic non-destructive inspection. The central contribution of this work is the parameter ${\eta }_{\mathrm{BC}}$ as a quantitative descriptor of effective clamping degradation and the proposal of an industrially feasible redesign, integrated with complementary mitigation strategies, for KARL KROYER MP 2C120 pumps and geometrically equivalent equipment. Full article

The microstructural evolution and strain-hardening mechanisms of a serviced 304 stainless steel during tensile deformation are investigated using quasi in situ EBSD measurements. This steel exhibits a high ultimate tensile strength of about 652 MPa alongside an exceptional fracture elongation of 83.4%. Its strain hardening behavior can be divided into three distinct stages. Deformation induces heterogeneous lattice rotation, which is dominated by the preferential activation of slip systems with the top two Schmid factors. With increasing strain, the deformation mechanism evolves sequentially from dislocation slip to mechanical twinning and then strain-induced martensite transformation. Mechanical twins act as the preferential nucleation sites for strain-induced martensite. In the latter two deformation stages, mechanical twinning serves as the primary driver of strain hardening, while strain-induced martensite merely contributes auxiliary hardening due to its limited volume fraction. This work elucidates the full-chain deformation mechanism of serviced 304 stainless steel. It provides experimental fundamentals for evaluating the residual ductility and failure risk of serviced austenitic stainless steel components. Full article

With contemporary advancements in additive manufacturing (AM), it has become possible to obtain hull structures for spacecraft made of relatively cheap materials. The possibility of substituting super-austenitic stainless steel Avesta SMO 254 X1NiCrMoCuN20-18-7 (EN 10088) for that already used in the Starship SpaceX 304 L-Modified is focused on achieving better thermal stability and durability in extreme conditions. The Directed Energy Deposition Arc (DED-Arc) method for AM has enabled the production of high-strength-to-weight ratios. The aim is to engage low-cost material with treatment optimization to provide greater corrosion resistance and high yield and tensile strength. For the DED-Arc, a filler wire was selected for the welding source, Fronius TPS 400i. A simulation via the RoboDK Robot Development Kit for the FANUC ARC Mate 100ID10L is provided. Additional shot pining/vibration treatment is proposed for the finished structure, which can be a substitute for the cold-worked initial metal. A comparison is made for stainless steel that has already been tested for space travel. Regimes for the manufacturing process are proposed, with representative samples of Avesta SMO 254 obtained and tested using microhardness measurements, microcracking detection, porosity measurements, interface zone assessment, and microstructural analysis. The DED-Arc process can be applied to large-space shell manufacturing. A comparison is made with a focus on the mechanical and corrosion advantages. For Avesta SMO 254, microhardness measurements ranged from 235 to 246 HV1 and increased after treatment. The controlled parameters provided a maximum heat input of 0.7 KJ/mm, no defects, and a fine microstructure. The successful use of stainless steel with AM increases the potential for multiple space missions. The advanced method shows high quality, allows cost savings and provides extended service life. Full article

Laser-welded stainless steel joints usually suffer from strain localization and premature failure in the weld metal (WM) due to microstructural heterogeneity introduced during welding. In this work, surface mechanical rolling treatment (SMRT) was applied to laser-welded 304 stainless steel plates to enhance the mechanical performance of the welded joints. Laser welding introduced multiple heterogeneous features in the WM, including local Ni compositional fluctuations, nanoscale oxide particles and heterogeneous grain structures. Among them, the local fluctuation of Ni concentration is considered to play a dominant role by locally modifying the stability of γ-austenite and promoting strain-induced martensitic transformation during SMRT. As a result, the WM exhibited more severe grain refinement and a stronger gradient nanostructure than base metal (BM) under identical processing conditions. The near-surface hardness of the WM reached ~500 Hv, which was noticeably higher than that of the BM. Uniaxial tensile tests revealed that the yield strength increased from ~350 MPa to ~700 MPa, while the ultimate tensile strength reached ~1000 MPa with ~40% elongation. More importantly, the fracture location shifted from the WM to the BM after SMRT. The enhanced martensitic transformation and gradient nanostructure effectively suppressed strain localization and improved the mechanical reliability of the welded joint. Full article

This study examines the influence of powder characteristics and laser powder bed fusion (LPBF) processing parameters on the microstructure and mechanical performance of ASTM F139 stainless steel fabricated from powders supplied by two manufacturers. Feedstock powders were characterized with respect to chemical composition, particle size distribution, morphology, density, and flowability. Cubic and tensile specimens were produced using different combinations of laser power, scan speed, hatch spacing, and scanning strategy. The fabricated components were evaluated by density and porosity measurements, surface roughness analysis, optical and electron microscopy, hardness testing, and tensile characterization in both horizontal and vertical build orientations. Powder flowability and packing density were found to strongly influence consolidation behaviour, with improved flow characteristics promoting higher densification and reduced porosity. Scanning strategy also affected defect formation, and a 67° interlayer rotation produced lower porosity than the conventional 0°/90° pattern. An optimal processing window was identified at a laser power of 212 W, scan speed of 1600 mm s⁻¹, hatch spacing of 0.07 mm, and layer thickness of 30 μm, yielding components with ~1% porosity, surface roughness below 15 μm, and a density of 7.65 g cm⁻³ (>95% of the theoretical density). Under these conditions, horizontally built specimens exhibited an ultimate tensile strength of 612 ± 43 MPa and a yield strength of 544 ± 37 MPa, exceeding the corresponding values obtained for vertically built specimens. Microstructural characterization revealed a refined cellular austenitic structure associated with epitaxial grain growth during solidification, while fractographic analysis indicated predominantly ductile failure through microvoid coalescence. The results establish clear process–structure–property relationships in LPBF-fabricated ASTM F139 stainless steel and demonstrate that the combined optimization of powder quality, scan strategy, and energy input enables the production of near-full-density components. Full article

The optimization and the engineering development of additive manufacturing (AM) products both require accurate, non-destructive techniques to extract their mechanical performances. The Instrumented Indentation Test (IIT) has such a potential, although it currently lacks standard procedures that are suitable for analyzing materials which are affected by internal residual stress (RS). Additionally, nanoindentation testing suffers from the presence of indentation size effects (ISE), which hamper the possibility of correlating the measured mechanical performance at different indentation depths or peak loads using the standard indentation hardness (H_IT) and modulus (E_IT). This paper presents a novel IIT methodology that is based on new indentation parameters, namely the loading stiffness rate (LSR) and the rate-derived hardness (H_R), which are then used to assign the desired mechanical performances of an L-PBF 316L austenitic stainless-steel alloy obtained via multiload/multiscale IIT strategy. The mean values of LSR, H_R, H_IT, and E_IT on the macroscale were 57.3 ± 1.4 GPa, 2.33 ± 0.059 GPa, 2.41 ± 0.13 GPa, and 201 ± 7.8 GPa, respectively, whereas on the nanoscale they were 56.1 ± 5.1 GPa, 2.30 ± 0.21 GPa, 3.00 ± 0.36 GPa, and 219 ± 24 GPa, respectively. Unlike the standard H_IT, the new indentation parameters of the nano- and macro-IITs are within the standard deviation, proving their ISE-free property. The obtained E_IT was slightly higher than the reference Young’s modulus (~190 GPa) of the 316L stainless steel. The loading secant stiffness versus depth plot can be used to assess the susceptibility of RS to relax during indentation, which is an important performance factor for the engineering design of AM components. The successful correlation that has been found between electron backscatter diffraction (EBSD) analysis (in terms of crystal anisotropy, grain size, and dislocation density) and nanoindentation testing at three subregions of the core zone of the investigated deposit confirms the validity of the proposed methodology. The proposed methodology is a step towards the full determination of the three Ps, that is, process, properties, and performance of advanced AM products. Full article

In the present work, four grades of austenitic stainless steels, namely AISI 321, AISI 316Ti, AISI 309, and AISI 310S, are investigated in terms of electrochemical hydrogenation effect on their room-temperature impact toughness. All the materials were studied in their as-received (AR), i.e., industrially manufactured, material condition. LOM and SEM microstructural analyses combined with phase XRD and EBSD phase analyses revealed in all steels the polygonal-grain austenitic matrix and varying minor amounts of elongated δ-ferrite grains. Moreover, the metastable AISI 321 and AISI 316Ti steels exhibited noticeable occurrence (16% and 10%, respectively) of the BCC-structured phases (i.e., the strain-induced α′-martensite and non-equilibrium δ-ferrite) and little occurrence of primary TiN nitrides (below 1%). The AISI 321 and AISI 316Ti steels exhibited average amounts of 2.95% and 6.32% of δ-ferrite, respectively. The stable AISI 309 steel exhibited the occurrence of intergranular (Cr,Fe)₂₃(C,N)₆ precipitates (below 3%), indicative of prolonged (slow) cooling from the warm working temperature during the material manufacturing. The individual steel grades exhibited variable values of hardness and impact toughness depending strongly on their solid solution alloying and the amounts of individual minor phases in their microstructures. The AISI 316Ti steel exhibited the highest average hardness (273 HV) and lowest impact toughness (160 J/cm²) due to Mo-alloying and having the highest amount of δ-ferrite. The AISI 310S steel showed the highest impact toughness (210 J/cm²) and the second highest hardness (245 HV) thanks to having the most stable austenitic microstructure with the highest Ni- and Cr-alloying. The AISI 321 and AISI 309 steels show similarly low hardness (195 HV vs. 196 HV) and medium values of impact toughness (202 J/cm² vs. 193 J/cm²). More importantly, all the steels under investigation exhibited detectable hydrogen-induced toughening effects, indicated by the negative HEI values. The metastable steels showed the lowest toughening effects (HEI: −2.0% and −3.8% for AISI 321 and AISI 316Ti, respectively), likely due to the adverse effect of α′-martensite. In contrast, the stable steels exhibited much higher toughening (HEI: −5.2% and −7.6% for AISI 309 and AISI 310S, respectively). Microstructural observations indicated that such toughening behavior might be related to the hydrogen-enhanced deformation banding and hydrogen-enhanced deformation twinning mechanisms, dividing the grains into smaller deformation zones, increasing the overall dissipation of deformation energy and consequently the materials’ impact toughness. Full article

This study aims to investigate the effects of heterogeneous microstructure and strain rate on the microstructural evolution and mechanical properties of ultrafine-grained (UFG) austenitic stainless steel during elevated-temperature tension. In this research, 17Cr-10Ni austenitic stainless steel was rolled to a 60% reduction in thickness at room temperature and 200 °C, followed by annealing at 1000 °C and 500 °C, respectively. The microstructural evolution of the annealed samples and high-temperature tensile specimens was characterized using optical microscopy, transmission electron microscopy, scanning electron microscopy equipped with electron backscatter diffraction, and X-ray diffraction. Results show that at room temperature, the heterogeneous twinned UFG (TW-UFG) sample, influenced by hetero-deformation-induced stress strengthening, maintains good ductility while exhibiting higher strength than the uniform UFG sample. During tensile deformation at 600 °C, grain refinement still contributes to strengthening, and the dominant deformation mechanism in the uniform UFG sample is dislocation dynamic recovery, whereas in the TW-UFG sample is detwinning combined with dynamic dislocation recovery. At low strain rates (10⁻⁴ s⁻¹), sufficient dynamic recovery and detwinning in the TW-UFG sample delay plastic instability and improve elongation. Full article

Hot cracking in welding is a very complex phenomenon. It can happen in the weld metal zone during solidification but also in the heat-affected zone (HAZ). Hot cracking defects are material decohesion that occur at high temperatures along grain boundaries when the strain and strain rate exceed a certain level. The cracks can be internal or open to the surface in the weld bead. During a welding operation, different types of hot cracks can appear, such as hot cracking due to solidification, hot cracking due to liquation, hot cracking due to loss of ductility. The main factors favoring hot solidification cracking include the presence of residual elements and impurities, leading to the formation of a low-melting eutectic; the solidification mode; and mechanical restraints. This review paper gives an introduction to solidification cracking in stainless-steel welds, the weldability of the austenite grades, and the causes of solidification cracking occurrence. The main methods with which to detect and inspect cracks are investigated. Particular focus is placed on TIG (tungsten inert gas), also known as Gas Tungsten Arc Welding (GTAW). A review of the literature reveals that considerable progress has been made in terms of the improvement in the properties of the weld joint through the application of mitigation means and strategies. The effort made by researchers in understanding solidification cracking phenomena has been key to enhancing cracking resistance and ensuring the integrity of structures. Full article

This study investigates the effect of low-temperature pulsed DC plasma nitriding on the surface properties of AISI 304 stainless steel for homogenizer valve-seat components. Plasma nitriding was performed in an ammonia atmosphere at 400, 440 and 480 °C for 8 h. The treatment led to the formation of expanded austenite at 400 °C, while higher temperatures promoted the formation of Fe-N and CrN-containing phases. The thickness of the modified layer increased from approximately 36 μm at 400 °C to 65 μm at 480 °C. Surface microhardness increased from 203 HV0.1 for the untreated steel to 652.6, 806.0 and 961.8 HV0.1 after nitriding at 400, 440 and 480 °C, respectively. The wear rate decreased markedly, reaching 1.92 × 10⁻⁵ mm³/(N·m) for DCPN480 compared with 30.65 × 10⁻⁵ mm³/(N·m) for the untreated sample. Among the nitrided samples, DCPN440 showed the most favorable corrosion behavior in 3.5 wt.% NaCl solution, indicating a balance between surface hardening and preservation of corrosion resistance. Numerical modeling confirmed that the strengthened surface layer can withstand equivalent homogenizer valve-seat loading without local plastic deformation. The results demonstrate that pulsed DC plasma nitriding can significantly improve the hardness and wear resistance of AISI 304 stainless steel while maintaining acceptable corrosion performance under optimized treatment conditions. Full article

Pitting corrosion is particularly dangerous due to its localised nature, which can render materials unusable and cause catastrophic failures. It is important to characterise the material in regard to pitting corrosion resistance in order to improve material selection according to the conditions of the exposed environment. Electrochemical tests were carried out to assess pitting corrosion in austenitic stainless steel EN 1.4301. This study identifies the optimal experimental conditions to ensure reliability and reproducibility in electrochemical tests. The results demonstrate the influence of these parameters in evaluating the resistance of stainless steels to pitting corrosion. To ensure the reproducibility of the breakdown potential (Eb), deaeration was standardised using an N₂ flow rate of 0.6–0.8 L/min for 20 min. Furthermore, mechanical agitation at 280 rpm was established as a necessary condition to homogenise the electrolyte and effectively renew the metal/solution interface. Finally, the water flow rate was set at a critical value of 7 mL/h, statistically identified as the most decisive parameter (p < 0.05). This optimisation mitigates crevice corrosion, ensuring that damage nucleation occurs exclusively via a pitting mechanism. Full article

Although hydrogen embrittlement mechanisms focus predominantly on the plastic deformation regime, the fundamental effect of interstitial hydrogen on the elastic regime remains elusive. The elastic behavior due to hydrogen is critical because lattice alterations drive microstructural instabilities and macro-failure. This work aims to determine the hydrogen-affected single-crystal elastic constants and anisotropy of 304L stainless steel and link them to dislocation-mediated embrittlement mechanisms. Using in situ neutron diffraction and the Kröner model, this study derived, for the first time, the single-crystal elastic constants ($C_{\mathrm{i}\mathrm{j}}$) of 304L austenitic stainless steel. Hydrogen charging expanded the lattice constant by ~0.7% (from 3.558 $\mathrm{\AA }$ to 3.583 $\mathrm{\AA }$) and selectively increased $C_{11}$ and $C_{12}$ while leaving $C_{44}$ nearly unchanged. Consequently, while bulk polycrystalline Young’s and shear moduli remained invariant, Zener’s anisotropy and Poisson’s ratios increased. Hydrogen reduced the shear modulus of the {111}<110> slip system by ~8.3% and the Peierls–Nabarro stress by approximately 38%. The experimental derivation of single-crystal elastic moduli proved that lattice-scale modifications selectively enhanced volumetric stiffness while lowering the slip-direction shear modulus. Coupled with hydrogen-induced lattice expansion, these findings validate the theoretical volumetric and modulus components of the hydrogen-enhanced localized plasticity mechanism, thereby elucidating its fundamental origin. Full article

Three-year atmospheric field-exposure tests were conducted on 304 austenitic stainless steel at the Great Wall and Zhongshan Stations in Antarctica to evaluate its corrosion behavior under severe polar conditions. The exposed specimens were dominated by localized corrosion with pronounced pitting characteristics at both sites. Corrosion was more severe at Zhongshan Station, and the mean corrosion rates at Great Wall and Zhongshan Stations were 1.428 and 1.643 μm y⁻¹, respectively. The mean/maximum pit depths were 4.16/5.51 μm at Great Wall Station and 5.85/8.24 μm at Zhongshan Station. Raman spectroscopy, X-ray photoelectron spectroscopy (XPS), grazing-incidence X-ray diffraction (GIXRD), and focused ion beam-transmission electron microscopy (FIB-TEM) showed that the corrosion products consisted mainly of β-FeOOH, α-FeOOH, and γ-Fe₂O₃, and the Antarctic exposure substantially altered the thickness, structure, and electrochemical response of the passive film. Compared with the unexposed specimen, the exposed specimens exhibited markedly lower charge-transfer resistance and higher donor density, indicating degradation of the protective passive film. Combined with the site-specific environmental features, the lower temperature, more intense freeze–thaw cycling, freezing-induced concentration of electrolytes, and stronger irradiation at Zhongshan Station are inferred to promote Cl⁻ enrichment in localized surface liquid films and destabilization of the passive film, thereby accelerating pit initiation and growth. These findings provide a mechanistic basis for material selection and corrosion-protection design for 304 stainless steel in polar engineering environments. Full article

To improve the efficiency of TIG (Tungsten Inert Gas) welding, our team developed a novel fast-frequency pulsed twin-TIG welding power source and matched welding procedures to overcome the drawbacks of conventional high-efficiency TIG welding. After parameter optimization, stable, high-efficiency and high-quality welding of 316L stainless steel can be realized. Compared with traditional DC TIG welding, the mechanical properties of joints are greatly improved: the weld grain size is refined by 38% under moderate current, while tensile strength, elongation and microhardness rise by 13.6%, 26% and 10% respectively, which achieves simultaneous improvement in strength and ductility. Numerical simulations were carried out to analyze the evolution of molten pool temperature field and velocity vector flow field. The simulation results are highly consistent with experimental data, which verifies the reliability of the model and lays a foundation for the study of molten pool behavior. Combined with molten pool flow characteristics and weld microstructure, the evolution mechanism of microstructure and texture as well as grain refinement in this welding process is revealed. Full article

High-temperature structural components are susceptible to creep deformation, which can ultimately lead to failure. In this work, an AI-based framework was developed capable of predicting the creep time of 316 austenitic stainless steel. Here, creep time refers to both the time to reach specific strain levels and the time to rupture. However, the scope of the present work is limited to rupture-time prediction, while the application of the framework to strain-level prediction will be reported in future work. The dataset consisted of creep strain curves from four heats, including both rupture and non-rupture curves. Random Forest (RF), Gradient Boosting (GB), Extreme Gradient Boosting (XGB), Support Vector Regressor (SVR), Gaussian Process Regressor (GPR), and Neural Network (NN) were employed. The effects of square-root and cube-root transformations on data distribution and model learning behaviour were analysed using model learning curves. An Optuna (version 4.3.0)-based hyperparameter tuning strategy was employed. The cube-root transformation improved the learning performance of SVR, GPR, and NN, whereas RF, GB, and XGB remained unaffected. Learning curves revealed mild overfitting for RF, GB, and XGB, and very minimal overfitting for SVR, GPR, and NN. NN achieved the best predictive performance (${\mathrm{R}}^2=0.92,\mathrm{R}\mathrm{M}\mathrm{S}\mathrm{E}=0.195$, deviation factor of 1.57). The findings demonstrated that the combined useof creep strain curves, data transformation, learning curve guided model selection, and rigorous hyperparameter tuning can improve the prediction accuracy under a limited dataset. Full article