X-ray CT Analysis of the Cross-Section of a 3D-Printed Deformed Layer

In this study, we experimentally analyzed the deformation shape of stacked layers developed using three-dimensional (3D) printing technology. The nozzle traveling speed was changed to 80, 90, 100, and 110 mm/s when printing the layers to analyze its effect on layer deformation. Furthermore, the cross-sectional area and the number of layers were analyzed by printing five layers with overall dimensions of 1000 (w) × 2200 (l) × 50 (h) mm (each layer was 10 mm high) using Vernier calipers. Moreover, we analyzed the interface and cross-sectional area of layers that are difficult to confirm visually using X-ray computed tomography (X-ray CT) analysis. As a result of measuring the deformation at the center of the layer, it was confirmed that the deformation was greater for lower nozzle traveling speeds. Consequently, the X-ray CT analysis verified that the layer had the same cross-sectional area irrespective of the layer printing order at the same nozzle travel speed, even if the layer was deformed.

Abrasive Wear of High-Carbon Low-Alloyed Austenite Steel: Microhardness, Microstructure and X-ray Characteristics of Worn Surface

A high-carbon, high-silicon steel (1.21 wt% C, 2.56 wt% Mn, 1.59 wt% Si) was subjected to quenching from 900 and 1000 °C, resulting in microstructures containing 60 and 94% of retained austenite, respectively. Subsequent abrasive wear tests of quenched samples were performed using two-body abrasion and three-body abrasion testing machines. Investigations on worn surface and subsurface were carried out using SEM, XRD, and microhardness measurement. It was found that the highest microhardness of worn surface (about 1400 HV0.05) was achieved on samples quenched from 900 °C after three-body abrasion. Microhardness of samples after two-body abrasion was noticeably smaller. with a maximum of about 1200 HV0.05. This difference correlates with microstructure investigations along with XRD results. Three-body abrasion has produced a significantly deeper deformed layer; corresponding diffractograms show bigger values of the full width at half maximum parameter (FWHM) for both α and γ alone standing peaks. The obtained results are discussed in the light of possible differences in abrasive wear conditions and differing stability of retained austenite after quenching from different temperatures. It is shown that a structure of metastable austenite may be used as a detector for wear conditions, as the sensitivity of such austenite to phase transformation strongly depends on wear conditions, and even small changes in the latter lead to significant differences in the properties of the worn surface.

Experimental and Numerical Analysis of the Depth of the Strengthened Layer on Shafts Resulting from Roller Burnishing with Roller Braking Moment

The article presents the results of investigations into the depth of the plastically deformed surface layer in the roller burnishing process. The investigation was carried out in order to obtain information on the dependence relationship between the depth of plastic deformation, the pressure on the roller and the braking torque. The research was carried out according to the original method developed by the authors, in which the depth of plastic deformation is increased by applying a braking torque to the burnishing roller. In this method, it is possible to significantly increase (up to 20%) the depth of plastic deformation of the surface layer. The tests were carried out on a specially designed device on which the braking torque can be set and the force of the rolling resistance of the roller during burnishing can be measured. The tests were carried out on specimens made of C45 heat-treatable carbon steel. The dependence of the depth of the plastically deformed surface layer was determined for a given pressure force and variable braking moments. The depth of the plastically deformed layer was measured on the deformed end face of the ring-shaped samples. The microhardness in the sample cross-section and the evolution of the microstructure were both analysed.

Softening Behaviors of Severely Deformed Zn Alloy Studied by the Nanoindentation

Zamak 3 alloy treatment by sliding-friction treatment (SFT) was investigated by nanoindentation to explore the influence of microstructure and strain rate on nanoscale deformation at room temperature. The results show that obvious material softening occurs in the ultrafine-grained (UFG) Zn alloy and strain-hardening happens in the twinning-deformed layer, respectively. It can be concluded that almost constant values of V in the UFG Zn alloy contribute to the dislocations moving along the grain boundary (GB) not cross the grain interior. In the twinning-deformed layer, the highly frequent dislocation–twinning boundary (TB) interactions are responsible for subsequent inverse Cottrell–Stokes at lower stress, which is quite different from dislocation–dislocation reaction inside the grain in their coarse-grained (CG) counterpart.

Nanocrystallisation of Nickel Free High Nitrogen Austenitic Stainless Steel through Ultrasonic Shot Peening

Ultrasonic Shot Peening (USP) - a novel route of surface modification was employed on biomedical grade Nickel free high nitrogen stainless steel (18Cr-21Mn-0.65N-balance Fe) to obtain a surface nanostructure without changing its chemical composition and microstructural phase transformation. Hardened steel shots of diameter 2 mm and 3mm were repeatedly impacted on the specimen surface at a constant frequency of 20KHz for 2 and 8 minutes duration. Coarse surface grains of size 36±6µm transformed into nanocrystalline grains of size 13-18 nm. The deformed layer resulted by USP treatment increased with increase in shot diameter and duration of USP. The microstructure was characterized by using optical microscope, SEM, XRD and TEM technique. The hardness and roughness of the treated surface was also found to be strongly dependent on the USP process parameters.

Preliminary Results on Finishing of WC-Co Coating by Magnetorheological Finishing Process

Thermal spray coating has the ability to enhance the lifetime of engineering components by reinforcing the surface properties. The surface roughness of the as-sprayed coatings needs to be suitably finished for its end use. The nanofinished WC-Co coatings are widely used in aerospace and automobile industries. In this present investigation, surface grinding followed by the magnetorheological finishing (MRF) processes is employed for finishing of WC-Co coating. Boron carbide (B4C) powder is used as the abrasive particles in the MRF process. MRF spot finishing technique is performed on the ground coating. The plastically deformed layer from the ground surface is removed completely by the gentle mechanical abrasion of MR fluid ribbon. The surface roughness and volume of material removed are measured over the finishing time. It is perceived that the surface roughness of the finishing spot is increased after a threshold machining time. This is attributed to the aging of MR fluid and the mechanical abrasion of wear debris. The experiment is also performed with the assistance of Murakami’s reagent to perform etching and finishing, simultaneously. A comparatively higher finishing rate is observed in this case.

Experimental Assessment of the Depth of the Deformed Layer in the Roller Burnishing Process

This paper presents the methods of experimental determining the depth of the plastically deformed top layer in the roller burnishing process. Precise determination of the depth of the plastically deformed layer is difficult due to slight deformation at the boundary of the plastic and elastic zone, the lack of visible changes in the microstructure, and minimal changes in microhardness. The article shows the method of original measurement method that consists in determining the thickness of the deformed layer using rings. The method involves the profilographometric measurements of the disconnected rings (samples) which are flat-faced in the package on the mandrel. The rings material deforms plastically in the surface layer causing wrapping of the end face of the ring in the direction of the rolling tool movement. After dismantling the ring pack, measurements were made on the face of each ring along radial directions, and the thickness of the deformed layer was observed on the microscope. The method was verified by microhardness measurements in the cross-section and cross-section of the ring. The results of deformation depth measurements were verified by finite-element-based numerical simulation.