Thermal diffusion chromium plating of structural carbon steel 20 by high frequency currents

To increase the service life of the gear teeth made of steel 20, operating under high shock loads, their main surfaces were subjected to high-temperature diffusion metallization, namely, chromium plating with high-frequency currents. As a result of diffusion metallization, the surface hardness increased 5.1–5.4 times – from 156–159 HV to 800–866 HV, and the strength level 3.3 times – from 250 to 820 mAh. Optimal parameters for the diffusion metallization: current I = 0.25–0.3 kA, power Pe = 8–10 kW, hardening τ = 8–10 min. By the method of scanning electron microscopy, it was found that after diffusion saturation of the surface of the gear teeth with chromium, the steel has a homogeneous structure with clearly pronounced transition layers, the average thickness of the diffusion layer was 0.06 mm. Energy dispersive analysis showed that after diffusion metallization with chromium powder, the basic composition of the steel remained constant, only the qualitative ratio of the components changed. X-ray phase analysis revealed the presence of an αFe-phase with the incorporation of Cr on the surface of the sample.

Calculation of the Cutting Forces and Torque when Milling with End Mills

This paper presents a computational sequence for calculating the components of the cutting force and torque when milling with carbide end mills. The calculation algorithm includes the transition from the tangential and radial components of the force to the force components in the machine coordinate system. On the helical cutting edge, two parts are highlighted: one on the cylindrical (peripheral) surface and the other one on the arc of the rounded tip of the tooth. These parts of the cutting edge are divided into sections where the calculation is performed, followed by summation of the force components along the axes of the machine co-ordinate system and the moment relative to the axis of the cutter. An analysis of the components of the force and torque depending on the depth of cutting, feed, number of teeth of the cutter, blade wear and radius of the tip rounding is performed. The ratio of forces and moments for various milling conditions of structural carbon steel and aluminum alloys is shown. The developed algorithm is applied in a computational program that can be used to perform operational calculations of forces and torque for various milling conditions. The calculated parameters can be used as technological limiters in optimization problems, as well as for strength calculations of tools, milling equipment, and the selection of components of milling machine drives.

Correlation of Barreling Effect with Boundary Friction Coefficient during Upsetting of Various Materials Workpieces under Processing Conditions

The necessity of taking into account the barreling effect at the design of die cavities, and open die and closed die forging processes on the basis of pre-forming of billets by upsetting is shown. The division of ideas about the indices of “bulk” and “linear” barreling (barrel shape), which is determined by the ratio of the bulk and linear dimensions of the workpiece after upsetting by flat dies, was made. The functional relation (correlation) between these indices and the friction coefficient on the boundary surface between flat dies and the upsetted workpiece has been determined. The qualitative and quantitative effect of workpiece dimensions (diameter-to-height ratio), strain range, temperature (conditions of cold and hot processing) and type of forming material (structural carbon steel, some of Cu-grades and Al-grades) on the barreling effect and friction coefficient during upsetting was found. The developed method makes it possible to predict a change in the friction coefficient during the upsetting of various material workpiece under given conditions of forming and to monitor their effect to the final shape.

Behavioral Analysis of Hydrogen in Metals under the Effect of H2S Corrosion Using a Layer-stripping Micro-hardness Technique

In order to study the distribution behavior of hydrogen in metals under the condition of H2S corrosion, a layer-stripping micro-hardness test was designed to analyze the hydrogen distribution along the depth of hydrogen-charged 45 high-quality structural carbon steel at three different hydrogen sulfide concentrations and four corrosion periods in this study. The results show that there is a terminal solid solubility of hydrogen in the metal for hydrogen sulfide solutions over various concentrations and corrosion periods. A hydrogen-saturated layer is produced by hydrogen diffusing through the metal from an unsaturated state to a fully saturated state. The hydrogen-saturated layer is not affected by the concentration of the corrosion, but its thickness increases as the corrosion period increases. In this way, we established a new hydrogen diffusion model in metals.

Identification of the Flow Properties of a 0.54% Carbon Steel during Continuous Cooling

The determinination of material properties is an essential step in the simulation of manufacturing processes. For hot deformation processes, consistently assessed Carreau fluid constitutive model derived in prior works by Schmicker et al. might be used, in which the flow stress is described as a function of the current temperature and the current strain rate. The following paper aims to extend the prior mentioned model by making a distinction, whether the material is being heated or cooled, enhancing the model capabilities to predict deformations within the cooling process. The experimental identifaction of the material parameters is demonstrated for a structural carbon steel with 0.54% carbon content. An approach to derive the flow properties during cooling from the same samples used at heating is presented, which massively reduces the experimental effort in future applications.

On the possibility of influence of micromycetes on corrosion behaviour of carbon steel

It is determined that in the oil field regions of the Perm Territory, water and soil samples contain micromycetes of various kinds. Penicillium, Aspergillus, Trichoderma were identified and identified. The effect of micromycetes on steel corrosion was investigated using the fungus resistance method. It was established that the presence of Penicillium, Aspergillus, Trichoderma causes significant corrosion damage to structural carbon steel quality grade St20. The nature of corrosion damage was determined by optical microscopy. It was shown that the areas affected by micromycetes have an uneven nature of corrosion damage with individual point and ulcerative lesions of the St20 surface. The change in the intensity of the growth of micromycetes of various kinds on steel from the time of exposure was established.

Fatigue Strength and Damage Mechanisms of Laser Welded Structural Carbon Steel Sheets

Laser welding is one of advanced and promising joining technologies of metallic materials, characteristic by numerous advantages in comparison with conventional welding processes. The technology still can be considered as fairly new and so, investigations are needed to reach optimum properties of welds in specific application cases, depending on welding parameters. Certification welding procedures usually require to demonstrate sufficient microstructure, mechanical, impact loading and other characteristics, but not fatigue resistance, which is essential for welded dynamically loaded structures. The paper contains results of fatigue resistance investigation of laser welded 10 mm thick sheets of a carbon structural S 355 steel. High cycle fatigue tests were performed after optimizing laser welding parameters. Resulting endurance limit of the welds and heat affected zone was higher than that of basic material. However, high scatter of results and different damage mechanisms were shown for different load amplitudes. The results are discussed on the basis of fractographical analyses, which provided some quite interesting details about crack initiation mechanisms.