Methodology for the Study of Residual Temperature Stresses in the Butt Contour of a Welded Joint Made of Carbon and High-Alloy Structural Steels during Multi-Pass Welding

The method of investigation of residual temperature stresses in the butt contour of the welded joint "shell – plate" made of carbon and high-alloy structural steels during multi-pass welding is described. The temperature problem was solved on the basis of the obtained experimental data of temperature measurement at the reference points of the structure during the application of the rollers. A solution is proposed that takes into account several stages, each of which corresponds to a specific intermediate temperature field due to the peculiarities of welding technology. The evaluation of residual stresses was carried out on the basis of the energy theory of plasticity, taking into account the dependences of the yield strength and elastic modulus of welded metals on temperature.

Innovative Study on Microstructural Change in Duplex Stainless Steel in Corrosive Media

Duplex Stainless Steel was developed long back in 1930 and gradually finds its wide application because of its high strength, good weldability, good toughness and resistance to stress corrosion cracking. This alloy finds its application in pressure vessels, bridges, process plants and also in typically down to minus 50 degree centigrade applications. However, because of its high alloy content thermal conductivities of duplex stainless steel are low. Casting this alloy is difficult and can be industrially used after proper heat treatment. In this present study corrosion rates were measured for CD4MCu in terms of weight loss/unit area/hour and microstructures were observed in different corrosive medium with time as variable.

Determination of Adhesive and Cohesive Strength in Metal Coatings Deposited by Hypersonic Metallization

. It is known that at present, methods of thermal spraying are widely used to restore and strengthen various worn-out machine parts. As a rule, metal coatings applied by thermal spraying have lower strength characteristics than solid materials. It is believed that the strength of coatings is proportional to their adhesive and cohesive strength. The value of adhesive and cohesive strength depends on various factors, including the nature of the materials and the technology of coating. An important factor characterizing the possibility of using metal coatings in various industries is the strength of adhesion of coatings to the base metal. The paper presents the determination of the adhesive and cohesive strength of coatings from different materials, applied by the method of hypersonic metallization. The results of testing the strength of metal coatings made of ER316LSi-grade wire, nichrome (Cr20Ni80) and molybdenum wire are given in the paper. Based on the results of metallographic studies, the proportion of the participation of cohesive and adhesive components in the strength of coatings has been determined, and some features of coating destruction have been described. It has been found that the participation of the cohesive and adhesive components of the coating strength differs depending on the material used. The cohesive component prevails in the strength of coatings made of high-alloy wire of the ER316LSi-grade, at which destruction mainly occurs along the coating-base boundary. For nichrome coatings and especially for coatings made of molybdenum, the cohesive component is predominant, in which the destruction of the coating occurs not along the coating-base boundary, but between the coating layers.

Technology Innovation for the Manual Laser Cladding of High-Alloy Tool Steels

This paper presents the development and successful application of an inductive preheating system running simultaneously with the manual laser cladding process in order to enable the repair of high-alloy tool steels having a highly limited weldability. In this study, the design and optimization of a suitable inductor as well as the analysis of the welding process were carried out by means of FE-simulation in order to generate material deposition without imperfections. Parameter variation studies were conducted while parallel modifying the generator power resulting in different preheating temperatures. These examinations showed that by using appropriate process parameters and an inductive preheating temperature of 200 ∘C, crack- and pore-free deposition layers could be produced on the commercial high-alloyed PM steel Elmax. This result can be explained by FE-simulation demonstrating that the cooling rate was halved in the weld and in the heat-affected zone. In conclusion, this study shows the high potential of the developed technical innovation for the manual laser cladding of high-performance tools.

Measurement of welding fume production in welding with high-alloy electrodes

Due to their good structural properties, stainless Cr-Ni steels have a very wide application in various branches of technology. During the welding of stainless Cr-Ni steels with high-alloy coated electrodes, welding fumes of complex chemical composition are generated, which is very harmful for welders and the environment. For the purposes of this experiment, two variants of one rutile Cr-Ni commercial electrode, designated E 23 12 2 LR 12, were designed and fabricated. Higher production of welding fume particles also means greater danger to humans and the environment. In order to show the influence of the base material on the production of welding fume particles, an experiment for measuring the production of welding fume particles was performed in which two different steels were used as the base material, general structural steel S235JRG2 and stainless steel X6CrNiTi18.10.

Abrasive machining of high-alloy corrosion resistant steels by example of 12Kh18N10T

The paper focuses on research into processing of high-alloy corrosion resistant steels by the method of centreless circular grinding. The physical and mechanical properties of such steels determine certain difficulties in their grinding as compared with other materials, which necessitates a thorough investigation of this issue. The paper presents experimental data on the dependence of machined surface roughness and hardness, as well as workpiece surface average temperature and microhardness, on the machining conditions and grinding wheel characteristics.

INVESTIGATION OF THE CAUSES OF UNSATISFACTORY RESULTS OF ULTRASOUND CONTROL OF EXPERIMENTAL FORGES FROM AUSTENITE HIGH-ALLOY STEEL

The purpose of the work is to establish the main causes of defects by ultrasonic testing (UST) of experimental forgings made of high-alloyed austenitic steel 08Kh18N10T on the basis of comprehensive comparative studies of samples of defective and suitable forgings. Techniques. Chemical analysis of forgings was performed on a high-sensitivity spectrometer "SPECTROMAX" company "SPECTRO", Germany; studies of macro- and microstructure (liquation heterogeneity, grain boundary structure, non-metallic inclusions, excess phases, etc.) were carried by the methods: metallographic and electron microscopic with micro-X-ray spectral analysis; tests of forgings for durability against intergranular corrosion (IGC) were carried out by the methods of AMU, GOST 6032. Results. It was established that experimental forgings rejected by UZK, in contrast to suitable forgings, were characterized by: the presence of areas of liquation inhomogeneity of steel, including high content of δ-ferrite; local defects of the macrostructure in the form of flocs; areas with anomalous multi-grained microstructure with a grain size of –2 to 8 points according to GOST 5639; release of chromium carbides at the boundaries of austenitic grains; susceptibility to intergranular corrosion (ICC). All forgings contained non-metallic inclusions within the permissible limits according to GOST 1778, as well as titanium carbides. Scientific novelty. For the first time on the basis of complex researches it is proved that the main reason of unsatisfactory results of UZK of experimental forgings from high-alloyed austenitic steel, is the anomalous multigrain structure connected with the unstable temperature-deformation mode of forging of ingots. Practical significance. Recommendations for improving the structure and improving the quality characteristics of industrial forgings made of high-alloy austenitic steels in terms of industrial production have been developed.

RATIONAL FOR REHEATING IN THE AUTOMATED LINE FOR RING BLANKS PRODUCTION

Features and requirements to the use of reheating of ring blanks in the conditions of production on the automated line are considered. An assessment is given for a technological temperature state of ring blanks at various stages of production under conditions of the automated line. For assessment of rational for reheating at production of ring blanks, a classification of ring manufacturing technology is proposed with the production of a pressed non-core blank in an open die, with the production of a pressed profile blank in a closed die, with the production of a pressed profile blank in a stamp with reverse extrusion. The technology of ring rolling with the production of a pressed non-core blank in an open die is the most economical and does not require the use of reheating in the manufacture of rings made of medium-alloy steels. The technology of ring rolling of a profile blank obtained in a closed die does not require the use of additional heating after pressing, in the case of manufacturing rings with a simplified profile on the outer or inner diameters of the ring. In the manufacture of rings with a more complex profile on the outer and inner diameters of the ring, as well as rings made of high-alloy steels, the final decision on the need for additional heating is made depending on the temperature of the end of intensive plastic deformation for the selected steel grade of the ring. The technology of ring rolling with the production of a pressed profile blank in a die with reverse extrusion requires the use of reheating after the pressing operation before the ring rolling operation, and is recommended for the manufacture of rings from medium- and high-alloy steels with a complex profile section on the outer and inner diameters, wall thicknesses, with a ratio of wall thickness to outer diameter D within h / D = 0.011...0.016 and with a ratio of wall thickness to ring height L within h / L = 0.020...0.041. The proposed recommendations are intended for use in the development of technological support for the operation of the automated ring-rolling complex at OJSC “BELAZ”.