Development of Ti PVD Films to Limit the Carburization of Metal Powders during SPS Process

Spark plasma sintering technique is used for the fabrication of dense materials with a fine-grained microstructure. In this process, a powder is placed into a graphite mold and a uniaxial pressure is applied by two graphite punches. A graphite foil is inserted between the punches and the powder and between the mold and the powder to ensure good electrical, physical and thermal contact. One of the major drawbacks during sintering of metal powders is the carburization of the powder in contact with the graphite foils. In this study, a PVD coating of titanium was applied on the graphite foils in contact with the metal powder (pure iron). The results are promising, as the investigations show that the application of a Ti PVD film of 1.5 and 1.1 µm thickness is effective to completely avoid the carburization of iron powder. Carbon diffuses inside the PVD film during sintering. In parallel, iron diffusion was revealed inside the Ti coating of 1.5 µm thickness. On the other hand, a Ti PVD film of 0.5 µm thickness provides a protection against carbon diffusion just on the sides in contact with the mold, proving that the coating thickness represents an important parameter to consider.

Comparison of the Hardness-Toughness Relationship of Medium-Mn Steels after Q&T and Q&P Treatments*

In contrast to quenching and tempering (Q&T), with quenching to room temperature, quenching and partitioning (Q&P) usually applies quenching to a temperature between Ms and room temperature. To stabilize a sufficient amount of retained austenite (RA), carbon diffusion from martensite into austenite and a prevention of cementite formation takes place during the successive partitioning step. Larger amount of RA, and its transformation into martensite during plastic deformation, provides Q&P treated steels with an enhanced combination of strength and ductility. In this investigation, the effect of different Q&T and Q&P treatments on the hardness-toughness relationship was determined. These results are compared with the RA contents and mechanical properties provided by tensile testing. The obtained results clearly demonstrate that the optimum parameters for strength and ductility do not match with the best combinations of hardness and toughness. Furthermore, the stability of the RA plays an important role in the understanding of toughness properties of the investigated Q&P steels.

Dynamic restructuring of supported metal nanoparticles and its implications for structure insensitive catalysis

Some fundamental concepts of catalysis are not fully explained but are of paramount importance for the development of improved catalysts. An example is the concept of structure insensitive reactions, where surface-normalized activity does not change with catalyst metal particle size. Here we explore this concept and its relation to surface reconstruction on a set of silica-supported Ni metal nanoparticles (mean particle sizes 1–6 nm) by spectroscopically discerning a structure sensitive (CO2 hydrogenation) from a structure insensitive (ethene hydrogenation) reaction. Using state-of-the-art techniques, inter alia in-situ STEM, and quick-X-ray absorption spectroscopy with sub-second time resolution, we have observed particle-size-dependent effects like restructuring which increases with increasing particle size, and faster restructuring for larger particle sizes during ethene hydrogenation while for CO2 no such restructuring effects were observed. Furthermore, a degree of restructuring is irreversible, and we also show that the rate of carbon diffusion on, and into nanoparticles increases with particle size. We finally show that these particle size-dependent effects induced by ethene hydrogenation, can make a structure sensitive reaction (CO2 hydrogenation), structure insensitive. We thus postulate that structure insensitive reactions are actually apparently structure insensitive, which changes our fundamental understanding of the empirical observation of structure insensitivity.

Dissimilar Rotary Friction Welding of Inconel 718 to F22 Using Inconel 625 Interlayer

Dissimilar metal joining has always been a challenging task because of the metallurgical incompatibility and difference in melting points of alloys being joined. Diffusion and mixing of alloying elements from dissimilar base metals at the weld often cause unwanted metallurgical changes resulting in unsuccessful welds or underperformance of the weldment. Solid-state dissimilar friction welds of Inconel 718 and F22 were prepared in this study with an Inconel 625 interlayer to address the carbon enrichment of Inconel 718 during the welding. Defect-free rotary friction welds were produced in this study. Microstructural and mechanical properties investigation of the weldments and base metals was carried out, and results were analysed. Intermixing zone was observed at the weld interface due to the softening of the metal at the interface and rotatory motion during the welding. The high temperatures and the plastic deformation of the intermixing zone and thermo-mechanically affected zone (TMAZ) resulted in the grain refinement of the weld region. The highest hardness was observed at the Inconel 718/F22 weld interface due to the plastic strain and the carbon diffusion. The tensile specimens failed in the F22 base metal for the weld prepared with and without the Inconel 625 interlayer. Inconel 718/F22 welds exhibited lower toughness values compared to the Inconel 718/F22 welds prepared with Inconel 625 interlayer.

Influence of welding parameters on decarburization in heat affected zone of dissimilar weldments after post weld heat treatment

Purpose: This paper aims to assess an influence of thermal welding parameters on microstructural evolution in the weld adjacent zone of P91 steel, overlayed by austenitic consumables, after post weld heat treatment. Design/methodology/approach: Analysis of the width of decarburized layer on microphotographs of overlayed specimens after tempering 750°C, 7 and 18 hours. Specimens were made by using different heat input and preheating temperature parameters. Findings: It is shown that with increase of the heat input energy, the width of the resulting decarbonized layer decreases linearly; the effect of heating temperature on the layer width is parabolic with a minimum at a temperature of ~195°C. Research limitations/implications: Future research may include comparison of the creep rupture strength of the weldments, made with different welding parameters, to assess the influence of kinetics of decarburization and variation of the parameters on creep rupture strength. Practical implications: Results permit to achieve minimization of rate of carbon diffusion in the weld adjacent zone of the HAZ by means of variation of welded parameters. Originality/value: Experimentally was confirmed a role of high-diffusivity paths (grain boundaries) on carbon diffusion in the HAZ of dissimilar weldments; found correlation between welding parameters and the rate of the diffusion during high temperature exposure.

Numerical Modeling of Phase Transformations in Dual-Phase Steels Using Level Set and SSRVE Approaches

Development of a reliable model of phase transformations in steels presents significant challenges, not only metallurgical but also connected to numerical solutions and implementation. The model proposed in this paper is dedicated to austenitic transformation during heating and ferritic transformation during cooling. The goal was to find a solution which allows for the decreasing of computing time without noticeable decreasing the accuracy and reliability of the model. Proceedings to achieve this goal were twofold. Statistically Similar Representative Volume Element was used as a representation of the microstructure. It allowed for the reducing of the complexity of the computational domain. For the purpose of the model, carbon diffusion was assumed to be the main driving force for both transformations. A coupled finite element–level set method was used to describe growth of a new phase. The model was verified and validated by comparing the results with the experimental data. Numerical tests of the model were performed for the industrial intercritical annealing process.

Numerical Simulation of Full Carburizing Process of an Automotive Gear

The objective of the paper is to present material and numerical models needed to simulate with accuracy the full carburizing process of an automotive gear. The rough dimensions of the gear studied are 120mm in diameter and 45mm in height. From a numerical standpoint, as the carburizing affects only a thin layer under the surface, the mesh discretization must be adapted. Consequently, anisotropic mesh is used to describe accurately this zone. The temporal discretization must be also adapted to follow carbon diffusion and thermal evolution. The material models represent metallurgical phenomena during the complete carburizing process. The initial heating of the part induces phases transformation due to austenization. Subsequently, while holding at carburizing temperature, boundary conditions are applied to diffuse carbon into the part. While carbon content increases next to the surface, austenitic metallurgical grain growth is also modelled. A final cooling sets the properties of the carburized part. The model takes into account the phase changes using phase transformation diagrams locally adapted to chemical compositions and grain sizes. Simulation is used to predict the in-use properties of the gear at the end of the carburizing process as well as important results such as assessment of distortion and residual stresses. Thermal stresses, volume variation due to phase changes, and transformation plasticity all contribute to establish the final mechanical properties of the part. During the complete process, the material is modelled with an elasto-viscoplastic behavior and mixing methods are used to consider the relative contribution of each phase.