Search Results (1,546)

Carburizing is a cost-effective surface hardening process that significantly enhances the strength of components and is widely used in critical parts such as main transmission gears and cams. However, research on mathematical models for characterizing the strength of carburized layers remains underdeveloped, limiting the accurate assessment of the service strength of carburized workpieces. To address this issue, this study focuses on 20CrNiMo steel and proposes a novel composite strength method for the quantitative prediction of the tensile strength of carburized specimens. By establishing a continuous mapping function between microhardness measurements and tensile strength distribution, and developing an equivalent strength mathematical model for non-uniform carburized gradient structures, the proposed method successfully predicts the strength of specimens under different carburizing depths. This approach represents a departure from the conventional Voigt-based paradigm, which relies on layered discretization of the carburized zone for approximate estimation, leading to significant improvements in both predictive efficiency and accuracy. Based on experimental data, the proposed method achieves a reduction in prediction errors of over 41.8% compared to traditional multilayer methods. In summary, this study not only provides a reliable and efficient computational tool for the quantitative characterization of carburized steels, but also demonstrates strong potential for application in the strength assessment and design optimization of critical engineering components. Full article

In this study, sheets of experimental high-carbon low-density steels (LDSs) with a thickness of 1.7 mm were processed in a combined tool designed for press-hardening. Press hardening, also known as hot stamping or hot press forming, is a manufacturing process used to create car body parts with exceptional mechanical properties and safety standards. These components often require tailored properties, meaning different mechanical characteristics in various parts of the component. LDSs have a lower specific density than conventional steels, so their use would be particularly suitable in automotive applications. Combined tools achieve distinct mechanical properties within a single part through thermomechanical processing. Simultaneous forming and heat treatment create tailored zones of high strength and ductility within the sheet metal. The hardened zone provides crashworthiness, while the more ductile zone absorbs kinetic energy and converts it into deformation energy. Hot stamping enables forming complex geometries from high-strength sheets with limited cold formability, a capability that can also be exploited for the aluminium-alloyed LDS under investigation in this work. Three different high-carbon LDSs with differences in chemical composition were subjected to this experiment, and the hardness, microstructure, and mechanical properties of the two areas of each sheet were evaluated. The aim is to determine their suitability for processing by press hardening and to try to achieve tailored properties (i.e., differences in ductility and strength across one part) as in a typical representative of 22MnB5 boron steel, where a strength limit of 1500 MPa at 5% ductility is achieved in the cooled part and 600 MPa at 15% in the heated part. Tailored properties were also achieved in the investigated LDS, but with only relatively small differences between the two tool areas. The omega profiles were produced by press hardening without visible defects, and it was possible to process the steels without any difficulties. Full article

This study investigated the electrolytic-plasma hardening (EPH) of cast 20GL steel, used for railway spring beams. The main objective was to analyze the spectral characteristics of the cathodic discharge and establish correlations between the plasma parameters, processing regimes, and resulting surface properties. Optical emission spectroscopy revealed that the plasma at 260 V exhibited a high-energy state with an electron density of ~5.3 × 10¹⁶ cm⁻³ and an electron temperature of 10,031 K. Using these parameters, the heat flux from the plasma to the steel surface was estimated at ~1.5 × 10⁷ W/m², confirming that the discharge provides sufficient energy for surface austenitization. Microstructural analysis demonstrated that the electrolyte flow rate, which determines the cooling rate, is the key parameter controlling phase transformations. At low flow rates, ferrite–pearlite and bainitic structures formed, while a fully martensitic structure and maximum hardness (1046 HV) were achieved at 10 L/min. Tribological tests confirmed the superior wear resistance of the martensitic layers, showing a friction coefficient of 0.454 and a wear volume 3.4 times lower than in the as-cast state. These findings verify that EPH offers an energy-efficient, low-cost method for improving the surface performance and service life of 20GL steel components in heavy-duty railway applications. Full article

The objective of this study was to investigate electron beam hardening (EBH) technology and compare its performance with laser beam hardening (LBH) in the context of manufacturing components such as gears, which increasingly employ submicron bainitic steels. Given the stringent demands for durability and fatigue resistance of gear teeth, identifying an optimal surface hardening method is essential for extending service life. Comprehensive analyses, including light and electron microscopy, hardness testing, tribocorrosion testing, and X-ray diffraction for phase composition, were conducted. The EBH-treated layer exhibited a slightly higher hardness (by 26 HV) compared to the LBH-treated layer (average 654 HV), while the base material measured 393 HV. The EBH process produced a uniform hardness distribution with a subsurface zone of reduced hardness. In contrast, LBH resulted in a surface oxide layer absent in EBH due to its vacuum environment. Both techniques reduced the residual austenite content in the surface layer from 22.5% to approximately 1.3%–1.4%. Notably, EBH achieved comparable hardening effects with nearly half the energy input of LBH, demonstrating superior energy efficiency and industrial feasibility. Application of the developed EBH process to an actual gear component confirmed its practical potential for modern gear manufacturing. Full article

Comprehensive studies of hydrogen embrittlement in high-strength austenitic alloys under cryogenic conditions are scarce, leaving the combined effect of hydrogen charging and extreme temperatures largely unexplored. Given the demands of cryogenic applications such as hydrogen storage and transport, understanding material behavior under these conditions is crucial. Here, we present the first systematic study of hydrogen’s effect at liquid helium temperature (4.2 K) on the mechanical properties of precipitation hardened austenitic alloys, specifically the nickel-based Alloy 718 and austenitic stainless steel A286. Both materials were subjected to pressurized hydrogen charging at 473 K followed by slow strain rate tensile testing at room temperature and at 4.2 K. Hydrogen charging caused significant ductility loss at room temperature in both alloys. In contrast, testing at 4.2 K resulted in increased strength and no evidence of hydrogen embrittlement. Notably, materials pre-charged with hydrogen and tested at 4.2 K exhibited higher stress drop amplitudes and increased strain accumulation during serration events, suggesting persistent hydrogen–dislocation interactions and possible enhanced dislocation pinning by obstacles such as Lomer–Cottrell locks. These results indicate that while hydrogen influences plasticity mechanisms at cryogenic temperatures, embrittlement is suppressed, providing new insight into the safe development of austenitic alloys in cryogenic hydrogen environments. Full article

This study investigates the influence of current density distribution on the hardening behavior of 20GL cast steel during electrolytic plasma processing (EPP). Experimental and numerical methods were combined to establish the relationship between discharge dynamics, heat flux, microstructural transformation. Electrolytic plasma hardening was carried out at cathodic voltages of 150 V and 250 V in a 20% Na₂CO₃ solution. The transient evolution of current density was analyzed using a 3D COMSOL Multiphysics model incorporating a vapor–gas shell (VGS) represented as a distributed impedance layer with realistic conductivity and permittivity. High-speed video confirmed that microdischarges preferentially initiate at sample corners, where modeling also predicts local current concentration and heat flux up to 12 MW/m². Experimental current density values (3–4 × 10⁴ A/m²) showed good agreement with the simulations. Microhardness tests revealed that increasing voltage from 150 V to 250 V increases the thickness of the hardened layer (from ~250 µm to ~600 µm) and raises surface hardness (up to 750 HV), while polarization tests showed a 40% reduction in corrosion rate. The results highlight that current density distribution governs the non-uniformity of thermal effects and surface strengthening during EPP, emphasizing the importance of electrode alignment and VGS stability for uniform hardening. Full article

The accurate detection and quantification of martensitic transformation in steel during quenching are essential for controlling the resulting material properties. Numerous studies have investigated this phenomenon using Acoustic Emission (AE) techniques, owing to the significant energy release associated with the transformation. However, no model based on acoustic emission currently exists that can estimate the martensite volume formed during induction hardening. In this work, a novel model is proposed to estimate the transformed martensite volume in induction hardening treatment, focused on the material, geometry, and AE settings used. By integrating acoustic emission data with conventional Vickers hardness measurements, the model parameters can be calibrated. Induction quenching experiments were carried out on cylindrical 42CrMo4 (AISI 4140) steel bars equipped with acoustic emission sensors to capture transformation-related events during heat treatment. The martensite volume after quenching was estimated from hardness values. Model calibration using the experimental acoustic emission data and martensite volume demonstrated strong agreement between predictions and experimental observations. The proposed model offers the potential for in-process monitoring of induction quenching, thereby reducing reliance on conventional characterization techniques. Full article

Steel energy dissipation devices are integral to seismic design, as they help reduce structural deformations during strong earthquakes by absorbing and dissipating energy through large inelastic deformations. This research provides new insights into the cyclic behavior and constitutive modeling of carbon steel SS275, a domestically manufactured material in Korea specifically used for seismic energy dissipation applications. To characterize its mechanical response, monotonic and strain-controlled cyclic loading tests are conducted on nine machined coupons. The cyclic tests are performed under constant strain amplitudes ranging from ±0.5% to ±3.0%. Experimental strain–life data obtained at these amplitudes are used to determine the Coffin–Manson parameters, while the cyclic stress–strain relationship is defined using the Ramberg–Osgood equation. Furthermore, material parameters for the Chaboche nonlinear hardening model are extracted from the experimental results and validated through finite element simulations of coupon tests in ABAQUS, ensuring close agreement with the measured cyclic response. Following the coupon-level analysis, a member-scale test is performed on a buckling-restrained brace (BRB) fabricated from SS275 steel. The calibrated Chaboche parameters are then applied in numerical simulations of the BRB, and the results are compared with experimental data to assess the model’s predictive capability for seismic performance. Full article

The increasing demand for enhanced wear resistance and mechanical integrity in tooling applications has driven the development of advanced surface engineering strategies for high-alloy steels. Böhler K390 MICROCLEAN, a powder-metallurgical V–Cr–Mo–W cold work tool steel with high vanadium content, features a composite metal matrix–carbide microstructure, consisting of uniformly distributed coarse vanadium carbides and finer carbides (M₇C₃, M₆C/MC) embedded in a ferritic matrix. This study investigated the effects of non-melting laser surface treatment (LST) applied to both as-received and bulk heat-treated K390 specimens. Microstructural characterization using SEM, EBSD, XRD, and EDX revealed the formation of a hardened surface layer comprising a structureless mixture of ultrafine-grained martensite and retained austenite, localized around vanadium carbides. Lattice parameter analysis and Williamson–Hall evaluation demonstrated increased carbon content, lattice distortion, and crystallite size reduction, contributing to high dislocation density (6.4 × 10¹⁴ to 2.6 × 10¹⁵ m⁻²) and enhanced hardness. Microhardness was increased by up to 160% compared to the initial state (reaching 835–887 HV₂₀), and dry-sliding testing showed up to 3.94 times reduced volume loss and decreased friction coefficients. Wear occurred via the formation and delamination of thin oxide tribo-layers, which enhanced the wear behavior. The combined approach of bulk heat treatment followed by LST produced a graded microstructure with superior mechanical stability, offering clear advantages for extending tool life under severe contact loads in stamping and forming operations. Full article

The effect of tempering temperature and tempering time on the density of hydrogen traps, hydrogen diffusivity, and microhardness in a vanadium-modified AISI 4140 martensitic steel was determined. Tempering parameters were selected to activate the second, third, and fourth tempering stages. These conditions were intended to promote specific microstructural transformations. Permeability tests were performed using the electrochemical method developed by Devanathan and Stachurski, and microhardness was measured before and after these tests. It was observed that hydrogen diffusivity is inversely proportional to microhardness, while the density of hydrogen traps is directly proportional to microhardness. The lowest hydrogen diffusivity, the highest trap density, and the highest microhardness were obtained in the as-quenched condition and the tempering at 286 °C for 0.25 h. In contrast, tempering at a temperature corresponding to the fourth tempering stage increases hydrogen diffusivity and decreases the density of hydrogen traps and microhardness. However, as the tempering time or temperature increases, the opposite occurs, which is attributed to the formation of alloy carbides. Finally, hydrogen has a softening effect for tempering temperatures corresponding to the fourth tempering stage, tempering times of 0.25 h, and in the as-quenched condition. However, with increasing tempering time, hydrogen has a hardening effect. Full article

This study focuses on improving the wear resistance of cutting tools and extending their service life under intense mechanical, thermal, and radiation loads in nuclear power plant environments. This research investigates the potential of electrospark alloying (ESA) using W–Zr–B system electrodes obtained from disks synthesised by spark plasma sintering (SPS). The novelty of this work lies in the use of SPS-synthesised W–Zr–B ceramics, which are promising for nuclear applications due to their high thermal stability, radiation resistance and neutron absorption, as ESA electrodes. This work also establishes the relationship between discharge energy, coating microstructure and performance. The alloying electrode material exhibited a heterogeneous microstructure containing WB₂, ZrB₂, and minor zirconium oxides, with high hardness (26.6 ± 1.8 GPa) and density (8.88 g/cm³, porosity < 10%). ESA coatings formed on HS6-5-2 steel showed a hardened layer up to 30 µm thick and microhardness up to 1492 HV, nearly twice that of the substrate (~850 HV). Elemental analysis revealed enrichment of the surface with W, Zr, and B, which gradually decreased toward the substrate, confirming diffusion bonding. XRD analysis revealed a multiphase structure comprising WB₂, ZrB₂, WB₄, and BCC/FCC solid solutions, indicating the formation of complex boride phases during the ESA process. Tribological tests demonstrated significantly enhanced wear resistance of ESA coatings. The results confirm the efficiency of ESA as a simple, low-cost, and energy-efficient method for local strengthening and restoration of cutting tools. Full article

Crystal grain size control in steel is critical for achieving mechanical properties. This study investigates the effectiveness of microalloying with titanium, niobium, zirconium, and yttrium to inhibit grain growth with the pinning effect. The comparison of selected microalloying elements in the exact same conditions is crucial for understanding their effect and is novel. Hot-rolled samples were annealed across a wide range of temperatures (1050 to 1200 °C) for up to eight hours. Microstructural analysis confirmed the presence of stable precipitates and non-metallic inclusions such as Nb(C,N), Ti(C,N), ZrO₂, and Y₂O₃ acting as obstacles to grain boundary migration. All microalloying elements significantly outperformed the reference steel, but their effectiveness was highly dependent on the annealing temperature. Titanium was the most effective inhibitor at lower temperatures (1050 °C), while zirconium maintained control up to 1150 °C. Critically, at the highest temperature of 1200 °C, only the yttrium-alloyed steel retained a fine-grain structure, demonstrating superior thermal stability. Niobium, conversely, only showed a minimal effect at 1050 °C, though this grade also exhibited the highest hardness (up to 165 HB) due to precipitation hardening. The kinetics of grain growth were successfully modeled using the Arrhenius-type Sellars–Whiteman equation, accurately describing the behavior for up to four hours of annealing. The findings provide critical insight for selecting optimal microalloying strategies based on maximum operating temperature. Full article

Forging plays a crucial role in various industries, including aerospace, automotive, oil and gas, and defense. We investigated the effect of post-processing forging on microstructural and mechanical properties of 316L stainless steel forging preforms fabricated by laser powder bed fusion. The as-built samples were subjected to hot forging in order to refine the microstructure and enhance mechanical performance. Detailed characterization was performed using Electron Backscatter Diffraction, Scanning Electron Microscopy, Energy Dispersive Spectroscopy, Tensile testing, and Hardness Testing. Substantial grain refinement (up to 97%) was observed, in addition to a reduction in porosity. The forging process effectively transformed the columnar grain morphology into equiaxed grains, increased yield and ultimate tensile strengths of 560 MPa and 740 MPa, representing 27% and 32% improvements, respectively, with a corresponding decrease in elongation to 32% from 47%. The horizontally built samples achieved the highest yield strength of 605 MPa but slightly lower UTS 710 MPa, representing 32% and 5% increment and decrease in ductility to 28% from 37.5%. These trends reflect the combined effects of work hardening and grain refinement, which enhance strength at the expense of ductility. Full article

The application of the instrumented indentation method with a Berkovich indenter (triangular pyramid) is considered for the determination of microhardness and radiation hardening of ion-irradiated steels. The main difficulties arising in the assessment of the microhardness of a thin irradiated layer are identified. They are connected with the indentation depth effect on microhardness even for homogeneous materials when the indentation diagram is used. A method of microhardness determination is proposed that is based on direct measurement of the indent projection area, taking into account the formed pile-ups. The proposed method allows one practically to exclude the influence of the indentation depth on the microhardness of homogeneous material at least over the depth range from 0.2 to 4 μm and to obtain an adequate assessment of the radiation hardening for a thin irradiated layer with a depth of about 2 μm. Moreover, a formula is proposed for taking into account the influence of pile-ups on the microhardness determined from the indentation diagram using the Oliver–Pharr method. The proposed method and the formula are verified for austenitic and ferritic-martensitic steels. Full article

In this study, shot blasting was employed to enhance the wear resistance and impact toughness of SCMnH11 high-manganese steel. The steel was first fabricated via vacuum casting, followed by forging and water-toughening treatment. Subsequently, the steel was cut to the required dimensions using wire electrical discharge machining before the final shot blasting was performed. The influence of shot blasting duration on the microstructure and mechanical properties was investigated. Shot blasting introduced compressive residual stress and dislocations, resulting in the formation of numerous low-angle grain boundaries. As the shot blasting time increased, the surface grains were progressively refined. The surface hardness increased rapidly from an initial value of approximately 250 HV, reaching a maximum of 643 HV. After 60 min of shot blasting, the thickness of the surface hardened layer reached 600 µm; however, the surface hardness exhibited a trend of first increasing and then decreasing. In contrast, the wear resistance showed the opposite trend. Additionally, the dominant surface wear mechanism transitioned from adhesive wear in the heat-treated sample to abrasive wear in the shot-blasted samples. Compared to the heat-treated sample, the impact toughness of the samples subjected to 5 min and 60 min shot blasting was significantly enhanced. Correspondingly, the fracture mechanism shifted from predominantly ductile fracture to a mixed mode of ductile and cleavage fracture. In summary, shot blasting can effectively enhance the wear resistance and impact resistance of SCMnH11 steel. However, the selection of shot blasting duration is critical. Appropriate parameters can balance work hardening, compressive stress, and surface microcracks, thereby enabling the material to achieve an optimal combination of wear resistance and impact resistance. Full article