Characterization of Cobalt-Based Stellite 6 Alloy Coating Fabricated by Laser-Engineered Net Shaping (LENS)

The results of microstructure and mechanical properties evaluation of a Stellite 6 (Co-6) alloy deposited on X22CrMoV12-1 substrate by the laser-engineered net shaping (LENSTM) technology are presented in this paper. The Stellite 6 alloy is widely used in industry due to its excellent wear resistance at elevated temperatures and corrosive environments. Specific properties of this alloy are useful in many applications, e.g., as protective coatings in steam turbine components. In this area, the main problems are related to the fabrication of coatings on complex-shaped parts, the low metallurgical quality of obtained coatings, and its insufficient adhesion to a substrate. The results of recently performed investigations proved that the LENS technology is one of the most effective manufacturing techniques of the Co-6 alloy coatings (especially deposited on complex-shaped turbine parts). The microstructural and phase analyses of obtained Stellite 6 coatings were carried out by light microscopy techniques and X-ray diffraction analysis. A chemical homogeneity of Co-6 based layers and a fluctuation of chemical composition in coating–substrate zone after the laser deposition were analyzed using an energy dispersive X-ray spectrometer coupled with scanning electron microscopy. The room temperature strength and ductility of the LENS processed layers were determined in static bending tests.

Evaluation of the structural stability of welded joints in welding

Brittle (intergranular) destruction of the heat-affected zone metal (local failure) of welded joints of power equipment during welding and heat treatment (tempering) was an unexpected and serious problem. Its solution based on the development of progressive technological solutions is an urgent task of modern power engineering. The article considers an applied method of fluctuation analysis for assessing the stability of the structure and the probability of local destruction (LD) of the metal of the heat-affected zone (HAZ) of thick-walled welded structures of power equipment made of low-alloy steel 15Kh2NMFA. A computational - experimental method for calculating the range of optimal values of heat input is stated. The LD mechanism is stated and its connection with the technology and thermal conditions of welding and the structural stability of the HAZ metal is established. It was found that the growth of austenite grains of the HAZ metal stimulates the tendency to LD, if a dendrid-type carbide phase is precipitated at grain boundaries during welding. By optimizing the heat input during welding, it is possible to control the structural and chemical homogeneity of the HAZ metal and the associated tendency to form LD.

A Scale-up Study on Chemical Segregation and the Effects on Tensile Properties in Two Medium Mn Steel Castings

Two ingots weighing 400 g and 5 kg with nominal compositions of Fe–8Mn–4Al–2Si–0.5C–0.07V–0.05Sn were produced to investigate the effect of processing variables on microstructure development. The larger casting has a cooling rate more representative of commercial production and provides an understanding of the potential challenges arising from casting-related segregation during efforts to scale up medium Mn steels, while the smaller casting has a high cooling rate and different segregation pattern. Sections from both ingots were homogenized at 1250 $$^{\circ} $$ ∘ C for various times to study the degree of chemical homogeneity and $$\delta $$ δ -ferrite dissolution. Within 2 hours, the Mn segregation range (max–min) decreased from 8.0 to 1.7 wt pct in the 400 g ingot and from 6.2 to 1.5 wt pct in the 5 kg ingot. Some $$\delta $$ δ -ferrite also remained untransformed after 2 hours in both ingots but with the 5 kg ingot showing nearly three times more than the 400 g ingot. Micress modeling was carried out, and good agreement was seen between predicted and measured segregation levels and distribution. After thermomechanical processing, it was found that the coarse untransformed $$\delta $$ δ -ferrite in the 5 kg ingot turned into coarse $$\delta $$ δ -ferrite stringers in the finished product, resulting in a slight decrease in yield strength. Nevertheless, rolled strips from both ingots showed $$>900$$ > 900 MPa yield strength, $$>1100$$ > 1100 MPa tensile strength, and $$>40$$ > 40 pct elongation with $$<10$$ < 10 pct difference in strength and no change in ductility when compared to a fully homogenized sample.

Tailoring a Refractory High Entropy Alloy by Powder Metallurgy Process Optimization

This paper reports the microstructural evolution and mechanical properties of a low-density Al0.3NbTa0.8Ti1.5V0.2Zr refractory high-entropy alloy (RHEA) prepared by means of a combination of mechanical alloying and spark plasma sintering (SPS). Prior to sintering, the morphology, chemical homogeneity and crystal structures of the powders were thoroughly investigated by varying the milling times to find optimal conditions for densification. The sintered bulk RHEAs were produced with diverse feedstock powder conditions. The microstructural development of the materials was analyzed in terms of phase composition and constitution, chemical homogeneity, and crystallographic properties. Hardness and elastic constants also were measured. The calculation of phase diagrams (CALPHAD) was performed to predict the phase changes in the alloy, and the results were compared with the experiments. Milling time seems to play a significant role in the contamination level of the sintered materials. Even though a protective atmosphere was used in the entire manufacturing process, carbide formation was detected in the sintered bulks as early as after 3 h of powder milling. Oxides were observed after 30 h due to wear of the high-carbon steel milling media and SPS consolidation. Ten hours of milling seems sufficient for achieving an optimal equilibrium between microstructural homogeneity and refinement, high hardness and minimal contamination.

Spatial variability of air pollutants in a megacity characterized by mobile measurements: Chemical homogeneity under haze conditions

Characterization of the spatial distributions of air pollutants on an intracity scale is important for understanding localized sources, secondary formation, and human exposure. In this study, we conducted in situ mobile measurements for the chemical composition of fine particles, volatile organic compounds (VOCs), oxygenated VOCs (OVOCs), and common gas pollutants in winter in the megacity of Beijing. The spatial variations of these gaseous and particulate pollutants under different pollution conditions are investigated. During the less-polluted periods, a large spatial variability exists in the inorganic composition of fine particles, suggesting a wide range of particle neutralization in Beijing. Significant spatial variations are also observed in the composition of organic aerosol (OA), which is mainly driven by local emissions of primary OA from vehicle and cooking exhaust. The spatial variations of VOCs and OVOCs vary by species. In general, hydrocarbon compounds show a large spatial variability driven by traffic emissions, while secondary OVOCs are more spatially homogeneous in concentration. Other gas pollutants show relatively low spatial variabilities, although hot spots of concentration frequently appear which are plausibly caused by high-emitting plumes as well as fast on-road ozone titration. During the haze periods, the spatial variabilities of air pollutants are largely reduced because of the contribution of regional transport. Hydrocarbons and less-oxygenated OVOCs show good positive spatial-temporal correlations in concentration. More-oxygenated OVOCs show good positive correlations among themselves and moderate negative correlations with hydrocarbons, less-oxygenated OVOCs, and particulate components. The results highlight the potential role of chemical homogeneity on the SOA production in the megacity under haze conditions. On the other hand, the spatial heterogeneity of air pollution calls a future need of using fine-resolution models to evaluate human exposure and pollution control strategies.

Detection of Segregation in a High Carbon Steel by Non-Destructive Techniques

In high carbon steel manufacture, segregation is a common problem that compromises the quality and performance of cast products. When they are rolled or forged, hard metallurgical phases can develop, promoting material embrittlement. To detect the segregation presence, traditionally, it is analyzed by macro-attack (according to the ASTM 381 standard). However, this methodology is limited to the subjective interpretation of the quality inspector, and also it is dangerous. Non-destructive means represent an agile alternative for quality control because they are sensitive to the chemical composition and microstructure of the steel. Through conventional ultrasound technique, an increase in attenuation coefficient was detected in the area of greater segregation and lower values in regions with greater chemical homogeneity. On the other hand, the longitudinal wave velocity was lower in the segregated region and higher in the zone with less segregation. Furthermore, by some mathematical relationships and wave speeds, Poisson’s ratio Young’s and shear modulus were obtained, which are related to the ease of rolling in steel. Finally, Eddy currents and impedance plane determined that the segregation region has a lower phase angle, and therefore, a higher electrical conductivity concerning the zones of less segregation.

Comparison of the Processability and Influence on the Microstructure of Different Starting Powder Blends for Laser Powder Bed Fusion of a Fe3.5Si1.5C Alloy

This paper examines different blends of starting materials for alloy development in the laser powder bed fusion (LPBF) process. By using blends of individual elemental, ferroalloy and carbide powders instead of a pre-alloyed gas-atomized starting powder, elaborate gas-atomization processes for the production of individual starting powders with varying alloy compositions can be omitted. In this work the model alloy Fe3.5Si1.5C is produced by LPBF from different blends of pure elemental, binary and ternary powders. Three powder blends were processed. The base material for all powder blends is a commercial gas-atomized Fe powder. In the first blend this Fe powder is admixed with SiC, in the second with the ternary raw alloy FeSiC and in the third with FeSi and FeC. After characterizing the powder properties and performing LPBF parameter studies for each powder blend, the microstructures and the mechanical properties of the LPBF-manufactured samples were analyzed. Therefore, investigations were carried out by scanning electron microscopy, wave length dispersive x-ray spectroscopy and micro hardness testing. It was shown that the admixed SiC dissolves completely during LPBF. But the obtained microstructure consisting of bainite, martensite, ferrite and retained austenite is inhomogeneous. The use of the lower melting ferroalloys FeSi and FeC as well as the ternary ferroalloy FeSiC leads to an increased chemical homogeneity after LPBF-processing. However, the particle size of the used components plays a decisive role for the dissolution behavior in LPBF.