Influence of Semi-Random and Regular Shot Peening on Selected Surface Layer Properties of Aluminum Alloy

This paper attempts to compare regular shot peening (RSP) and semi-random shot peening (SRSP). A characteristic of the first method is that the peening elements hit the treated surface in sequence, with a regular distance maintained between the dimples. The other method (SRSP) is a controlled modification of the shot-peening process, which is random by nature. The shot-peening method used in this study differs from conventional shot peening (shot blasting and vibratory shot peening) in that it allows controlled and repeatable determination of the configuration and distribution of impacts exerted by the peening element on the workpiece surface, which makes the process more repeatable and easier to model. Specimens of EN-AW 7075 aluminum alloy were used for testing. The following variables were used in the experiments: ball diameter, impact energy, and distance between the dimples. Microhardness distribution in the surface layer, 2D surface roughness, and surface topography were analyzed. FEM simulations of the residual stress distribution in the surface layer were performed. It has been found that regular shot peening results in reduced surface roughness, while semi-random shot peening leads to higher surface layer hardening.

Influence of Welding Speed on Microstructure and Mechanical Properties of 5251 Aluminum Alloy Joints Fabricated by Self-Reacting Friction Stir Welding

In the present study, 8 mm-thick 5251 aluminum alloy was self-reacting friction stir welded (SRFSW) employing an optimized friction stir tool to analyze the effect of welding speed from 150 to 450 mm/min on the microstructure and mechanical properties at a constant rotation speed of 400 rpm. The results indicated that high-quality surface finish and defect-free joints were successfully obtained under suitable process parameters. The microhardness distribution profiles on the transverse section of joint exhibited a typical “W” pattern. The lowest hardness values located at the heat-affected zone (HAZ) and the width of the softened region decreased with increasing welding speed. The tensile strength significantly decreased due to the void defect, which showed mixed fracture characteristics induced by the decreasing welding speed. The average tensile strength and elongation achieved by the SRFSW process were 242.61 MPa and 8.3% with optimal welding conditions, and the fracture surface exhibited a typical toughness fracture mode.

Investigation of microstructural and mechanical properties of AA1050-AZ91D dissimilar friction stir welding

Joining of aluminium and magnesium alloys frequently pose significant challenges to the extent where joining may seem impossible, due to differences in the physical, metallurgical, and chemical properties of the materials. Friction stir welding is a solid-state welding technique which uses a non-consumable tool to join metals. This study examines the dissimilar friction stir welding of 3 mm thick AA1050 and AZ91D alloy sheets. Successful defect-free joints were achieved at rotational speeds of 400 rpm and 600 rpm, and a constant traverse speed of 50 mm/min. The metallurgical investigations used to characterize the microstructure of the welds are optical microscopy (OM), scanning electron microscope (SEM) and X-ray diffraction (XRD). The microstructures of the samples show distinct morphology attributed to their different rotational speeds. However, Al3Mg2 intermetallics (IMCs) phase was detected in the white bands present in both weld samples. The IMCs were formed through solid-state diffusion. The mechanical properties characterizations includes the microhardness profiles and tensile testing. The variation in the rotational speeds do not have a significant effect on the microhardness distribution of the weld samples. The tensile strength of the dissimilar weld improved substantially with the presence of an interpenetration feature (IPF).

Mitigating Inhomogeneity and Tailoring the Microstructure of Selective Laser Melted Titanium Orthorhombic Alloy by Heat Treatment, Hot Isostatic Pressing, and Multiple Laser Exposures

Titanium orthorhombic alloys based on intermetallic Ti2AlNb-phase are attractive materials for lightweight high-temperature applications. However, conventional manufacturing of Ti2AlNb-based alloys is costly and labor-consuming. Additive Manufacturing is an attractive way of producing parts from Ti2AlNb-based alloys. High-temperature substrate preheating during Selective Laser Melting is required to obtain crack-free intermetallic alloys. Due to the nature of substrate preheating, the temperature profile along the build height might be uneven leading to inhomogeneous microstructure and defects. The microstructural homogeneity of the alloy along the build direction was evaluated. The feasibility of mitigating the microstructural inhomogeneity was investigated by fabricating Ti2AlNb-alloy samples with graded microstructure and subjecting them to annealing. Hot isostatic pressing allowed us to achieve a homogeneous microstructure, eliminate residual micro defects, and improve mechanical properties with tensile strength reaching 1027 MPa and 860 MPa at room temperature and 650 °C, correspondingly. Annealing of the microstructurally graded alloy at 1050 °C allowed us to obtain a homogeneous B2 + O microstructure with a uniform microhardness distribution. The results of the study showed that the microstructural inhomogeneity of the titanium orthorhombic alloy obtained by SLM can be mitigated by annealing or hot isostatic pressing. Additionally, it was shown that by applying multiple-laser exposure for processing each layer it is possible to locally tailor the phase volume and morphology and achieve microstructure and properties similar to the Ti2AlNb-alloy obtained at higher preheating temperatures.

Effect of Surface Integrity on Hot Fatigue Life of Ti2AlNb Intermetallic Alloy

The effect of surface integrity on the hot fatigue performance of Ti2AlNb alloy was investigated. A turning process was used to prepare the standard specimens for hot fatigue tests. The surface integrity characterization and axial fatigue tests were performed. The results show that the influence of surface roughness on the hot fatigue performance of the Ti2AlNb alloy is a secondary factor. The compressive residual stress and enhanced microhardness in the surface layer has a significant effect on the hot fatigue life and they are dominant in the hot fatigue behavior of the Ti2AlNb alloy. Through the investigation on the characteristics of the fatigue fractures, the fatigue propagation process was significantly suppressed because of the strong residual compressive stress and microhardness distribution on the surface layer of the Ti2AlNb specimen.

Relationship between Processing Parameters, Product Dimensions, and Wave Strain Hardening

This article considers the influence of the size of processed workpieces during their strain hardening based on the impact of deformation waves on the processed surface. For the first time, the specificity of the hardened layer formation by wave strain hardening (WSH) makes it possible to draw attention to the fact that, with equal volumes of hardened samples and processing modes, different diagrams of microhardness distribution in the surface layer are observed. The aim of this work is to establish the relationship between processing parameters, workpiece dimensions, and the WSH nature for the first time. The experiments are carried out on a specially designed bench. It is established that WSH occurs not only from the front side (along which the processing was performed), but also from the back side, while leaving the original material hardness in the middle of the sample. The results obtained form a basis for the further development of WSH technology.

Dissimilar friction stir lap welding of AA2198 and AA7075 sheets: forces, microstructure and mechanical properties

This paper investigates the dissimilar friction stir lap welding of AA2198 and AA7075 sheets. The influence of processing parameters, namely welding speed and tool rotational speed on joint features, microstructure, and mechanical properties were studied by implementing a full factorial design of experiments. Axial and transversal forces were continuously measured during the welding process using a sensed fixture aiming at the correlation of processing parameters, forces, and quality of the achieved joints. Obtained outcomes showed hook formation for all the combination of parameters and the existence of a very narrow processing window in which it is possible to avoid the formation of internal defects, such as grooves and tunnels. The influence of the weld bead morphology on the lap shear strength was elucidated proving that the strength is ruled by the hook morphology. The microstructure of the joints was studied and discussed considering also the microhardness distribution. Graphical abstract

Process Parameters Study on Structure and Properties of Zr-Based Bulk Metallic Glasses

The effects of different process parameters on the microstructure and mechanical properties of Zr-based bulk metallic glass were studied by using four factors and four levels of orthogonal experiment. Through the observation and analysis of the X-ray diffraction pattern, room temperature compressibility, microhardness distribution and transmission electron micrograph of the [Zr0.72-x(Cu0.59Ni0.41)0.28+x]88-yAl12+y (atomic percent) amorphous alloy with different process parameters, the results show that the compressive strength of the amorphous alloys with composition of [Zr0.73(Cu0.59Ni0.41)0.27]88Al12 and [Zr0.73(Cu0.59Ni0.41)0.27]87Al13 amorphous alloy under the corresponding processing parameters has reached 2411MPa and 1993MPa, and the plastic strain of the alloys is 33.8% and 19.3%. At the same time, through orthogonal analysis, in the four process parameters, the superheat temperature of the melt during the preparation of the alloy mainly affects the compressive strength of the alloy, while the cooling rate of the melt during the preparation of the alloy has a great influence on the plastic properties of the alloy.

CHANGES IN THE MICROSTRUCTURE AND MICROHARDNESS OF 65G STEEL AFTER THERMAL HARDENING AND SURFACING WITH A LOW-CARBON ELECTRODE

When reinforcing the surfaces of the working bodies of tillage tools, they are surfaced with electrodes with a low-carbon rod. The surface in contact with the soil is not subjected to heat treatment. Recently, thermal hardening of local parts has been used. (Research purpose) The research purpose is in studying the transformation of the microstructure of 65G heat-strengthened steel deposited by an electrode with a low-carbon rod, as well as the specifics of the microhardness distribution in this section. (Materials and methods) Investigated in the cross- section of the structure of the deposited area by the standard method, consisting in the preparation of microsections, etching and directly microanalysis. (Results and discussion) The transformation of the microstructure of heat-strengthened steel 65G deposited by an electrode with a low-carbon rod is complex due to the specificity and versatility of the phase transformations that occur during its formation. The microhardness distribution plot in the cross-section of the surfacing area has a complex configuration, determined by the variety of structural components, the presence of deformation processes during crystallization and solidification, and the presence of preliminary thermal hardening of the base metal. (Conclusions) Increased values of the hardness of individual areas contribute to an increase in the abrasive wear resistance of the part. The presence of the fusion zone ensures the resistance of the deposited area to cracking. The zone of thermal influence has four clearly distinguishable areas: the drop in microhardness; the stable values according to the Vickers method; the near-shock zone; the fusion zone. The microhardness of the weld surface of the cushion is 410 Vickers or 42 Rockwell, which creates conditions for increasing the wear resistance of the surface friction. The use of electrodes with a low-carbon rod is advisable when conducting surfacing reinforcement of heat-strengthened steels.

Consolidation of Titanium Powder by Electrical Resistance Sintering: Practice and Simulation

In this work, a commercially pure titanium powder has been consolidated using the Electrical Resistance Sintering (ERS) process. This technique consists in the consolidation of a powder mass by the simultaneous application of pressure (80 MPa, in this work) and heating caused by the passage of a high intensity (3.5-6.0 kA, in this case) and low voltage current (lower than 10 V), during short dwelling times (0.8-1.6 s, in this work). The resulting compacts have been mechanically characterised by measuring their microhardness distribution. The results obtained are compared with the corresponding values of compacts prepared with the same powders following the conventional P/M route of cold pressing and furnace sintering. The results of some simulations are provided to give information about the temperatures reached inside the compacts during the electrical consolidation process.