The Influence of the Soaking Temperature Rotary Forging and Solution Heat Treatment on the Structural and Mechanical Behavior in Ni-Rich NiTi Alloy

The structural and thermophysical characteristics of an Ni-rich NiTi alloy rod produced on a laboratory scale was studied. The soak temperature of the solution heat-treatment steps above 850 °C taking advantage of the precipitate dissolution to provide a matrix homogenization, but it takes many hours (24 to 48) when used without thermomechanical steps. Therefore, the suitable reheating to apply between the forging process steps is very important, because the product’s structural characteristics are dependent on the thermomechanical processing history, and the time required to expose the material to high temperatures during the processing is reduced. The structural characteristics were investigated after solution heat treatment at 900 °C and 950 °C for 120 min, and these heat treatments were compared with as-forged sample structural characteristics (one hot deformation step after 800 °C for a 30 min reheat stage). The phase-transformation temperatures were analyzed through differential scanning calorimetry (DSC), and the structural characterization was performed through synchrotron radiation-based X-ray diffraction (SR-XRD) at room temperature. It was observed that the solution heat treatment at 950 °C/120 min presents a lower martensitic reversion finish temperature (Af); the matrix was fully austenitic; and it had a hardness of about 226 HV. Thus, this condition is the most suitable for the reheating stages between the hot forging-process steps to be applied to this alloy to produce materials that can display a superelasticity effect, for applications such as crack sensors or orthodontic archwires.

The influence of aging treatment on the microstructural and mechanical behavior by ultra-micro hardness tester in Ni-rich NiTi alloy

The present study aims to assess the superelasticity behavior in Ni-rich NiTi alloy wire produced by rotary forging process. The thermomechanical process involved four steps of hot working at 800ºC, two steps of cold working with solution heat treatment at 800ºC between them, and subsequently a solution heat treatment (950ºC during 2 hours) followed by aging treatment at 350, 400 and 450 ºC during 30 minutes. X-ray diffraction (XRD) and instrumented ultra-micro hardness testers evaluated the present phase at each aged sample and were compared with their mechanical behavior. The results put in evidence the work-hardening effect on a forged condition associated with the final step of cold rotary forging. The solution treatment promotes stress relaxation and precipitate dissolution. The sample heat-treated shows the presence of the precipitated (Ni4Ti3) and R phase. The presence of these precipitates is beneficial because precipitation-hardening increases the yield strength of austenite, which in turn contributes to better functional stability.

Numerical Model Simulation of the Double-Roll Rotary Forging of Large Diameter Thin-Walled Disk

Double-roll rotary forging is an emerging plastic forming technology based on rotary forging. Owing to the advantages of being labor-saving, a small eccentric load, low noise and vibration, good uniformity, high surface quality, and material saving, it is very promising for the fabrication of large diameter thin-walled disks. To date, little relevant research on the double-roll rotary forging technology of large diameter thin-walled metal disks has been reported, and the deformation characteristic and the influence of three key parameters on the double-roll rotary forging process remain uninvestigated. Herein, a reasonable 3D rigid-plastic numerical model of the double-roll rotary forging of a disk workpiece is established under the Deform software environment. Based on the valid 3D numerical model, the deformation mechanism, and the effective laws of three key parameters (feed rate v of the lower die, rotational speed n of the upper die, and the initial temperature T of the disk workpiece) on the metal flow and force and power parameters in the double-roll rotary forging process have been explored. The research results provide valuable guidelines for a better understanding of double-roll rotary forging for the fabrication of large diameter thin-walled disks.

Forming Characteristics and Mechanism of Double-roll Rotary forging for Large Diameter and Thin-walled Metal Discs

Double-roll rotary forging is an emerging plastic forming technology based on rotary forging. Owing to the advantages of labor saving, small eccentric load, low noise and vibration, good uniformity, high surface quality and material saving, it is very promising for fabrication of large-diameter thin-walled disc. To date, few relevant research on the double-roll rotary forging technology of large-diameter thin-walled metal discs has been reported, and the forming mechanisms and process of disc workpieces remains uninvestigated. Herein, a 3D rigid-plastic finite element model (FEM) is established to simulate the fabrication process of large-diameter thin-walled disc, four geometric features appear in the forming process: “mushroom” shape, “upper drum” shape, “drum shape” shape and “lower drum” shape. Equivalent stress, equivalent strain and temperature field of these four geometric shapes are analyzed, and the forming mechanism of these four geometric shapes is revealed. The reliability and accuracy of FEM are verified through experiments and the four geometric shape features occur in the process are consistent with the simulation. The research results provide valuable guidelines for better understanding of double-roll rotary forging for the fabrication of large-diameter thin-walled discs.

Microstructure and deformation mechanism of TA2 titanium deformed by rotary forging

Rotary forging was conducted for TA2 titanium samples with initial forming temperatures ranging from room temperature to 923 K. The microstructure of the samples was examined by using electron back-scattered diffraction and X-ray diffraction. The results indicate that rotary forging remarkably enhanced the formability of TA2 titanium and took a notable grain refinement effect over the whole temperature range. The theoretical calculation results indicate that enough working heat was generated during the early deformation stage to raise the temperature of the sample to above the dynamic recrystallization temperature. The deformation of titanium during rotary forging can be roughly divided into two stages as dislocation slip stage and the dynamic recrystallization stage.

Research on forming technology of rotary forging with double symmetry rolls of large diameter : thickness ratio discs

Rotary forging with double symmetry rolls (DSRs) is a new metal plastic forming technology developed on the basis of conventional rotary forging with a single roll, which uses a pair of symmetrical cone rolls to realize continuous local pressure plastic deformation of the workpiece. Large-diameter, thin discs are a key component in nuclear power, aerospace, deep-sea exploration, and other fields. At present, the forming process of large-diameter discs mainly includes welding and multiple local upsetting, but these processes exhibit many defects and can not meet the requirements of industry. In this paper, a large diameter : thickness ratio disc is integrally formed by rotary forging with DSRs. Using theoretical calculation and finite element simulation methods, the stable rolling conditions and calculation formulas of force and power parameters of rotary forging with DSRs of a large diameter : thickness ratio disc are derived. Based on the reliable three-dimensional rigid-plastic finite element model, the plastic deformation characteristics of rotary forging with DSRs of discs are studied, the reliability of the stable rolling conditions and the calculation formulas of force and power parameters are verified, and the defects and causes of unstable rolling conditions are analysed. An experiment was carried out on a rotary forging press developed with double symmetry rolls, and the experimental results are in good agreement with simulation results, which demonstrated that rotary forging with DSRs is a reliable technology for forming large diameter : thickness ratio discs. The results of this research are helpful to promote the further development of rotary forging with DSRs.