Carl Blais

Development of an integrated method for fully characterizing multiphase inclusions and its application to calcium-treated steels

Abstract An integrated technique for the full characterization of multiphase inclusions has been developed. It is based on the positioning of the beam of a scanning electron microscope along the skeleton of each phase present in the inclusions. It requires the integration of the signals generated by the scanning electron microscope, the X-ray spectrometer, and the image analyzer. This technique was used to characterize inclusions found in commercial heats of steel treated with calcium. An optimum Ca S ratio of 0.70 allows modification of the mean shape factor of MnS inclusions, which then changes from 0.25 to 0.73. The optimum calcium concentration in the sulfide phase is ≈15wt.%. An increase of this value beyond 15wt.% does not translate into any change in the shape factor of the inclusions. Finally, an empirical model for the transformation of inclusions, as a result of the calcium treatment, is proposed. It specifies that Ca-aluminates act as nucleation sites for the solidification of (Mn,Ca)S inclusions.

Characterisation of inclusions found in C–Mn steel welds containing titanium

AbstractThe main goal of the present study was to identify the chemistry of the phases on the surface of inclusions found in steel welds, to enable a better understanding of their role in the formation of acicular ferrite. Transmission electron microscopy and parallel electron energy loss spectrum imaging of specimens prepared by ultramicrotomy have been used to characterise inclusions found in C–Mn welds having different titanium concentrations. The results indicate that, for a weld containing 28 ppm titanium, which is the tough est weld studied, a phase comprising MnTi2O4 is present on the surface of the inclusions. As the concentration of titanium in the weld is increased to 120 ppm, the MnTi2O4 phase is found more towards the centre of the inclusions. It is partially enveloped by a slag of MnO . SiO2 . The presence of TiO, often cited as a phase promoting the formation of acicular ferrite, was found only in the specimen that contained 410 ppm titanium. Thermodynamic calculations using databases for ox...

Turning and drilling of parts made from sinter hardenable steel powders

Abstract The constant demand for improved mechanical properties and lower production costs of PM parts has lead to the development of sinter hardenable steel powders. These powders produce fully martensitic microstructures by appropriately controlling the cooling rate during the sintering operation. Thus, the heat treatment operation (oil quenching) that would generally be required to obtain hardened parts can be eliminated. However, machining of the relatively hard sinter hardened parts is difficult.It then becomes critical to optimise the tool selection and the machining conditions, such as surface speed and feed. This paper presents guidelines for the turning and drilling of parts made with sinter hardenable powders, as well as a discussion on the effect of manganese sulphide particles and chip formation during turning.

Characterisation of machinability of sintered steels during drilling operations

Abstract This study deals with the quantitative evaluation of the machinability of sintered steels during drilling operations. A characterisation technique using scanning electron microscopy and image analysis was developed to characterise quantitatively the amount of flank wear on drillbits. It was shown experimentally, using a drilling test bench, that the evolution of flank wear was proportional to the rate of variation of the thrust force as measured during drilling. Thus, the results show that the slope of the linear region measured on the curve of the thrust force v. the amount of material removed is a more accurate criterion to characterise the machinability of PM products than the average thrust force, which is often suggested in the literature. Furthermore, the effect of the technique used to add MnS to PM powders was investigated. Quantitative characterisation of machinability during drilling operations showed that parts made with steel powders of the type FC–0208 + 0·5 wt-%MnS machine better when the manganese sulphide particles are pre-alloyed rather than admixed. Finally, machinability of parts made with two sinter hardening powders was characterised including a pre-alloyed MnS powder. The results showed that the ‘drillability’ of this type of part is improved when they are in the presintered state rather than when they are in the green state, i.e. unsintered. Moreover, parts made with the sinter hardening powder pre-alloyed with manganese sulphide particles (MnS) showed superior machinability characteristics.

Tribo-Mechanical Properties of HVOF Deposited Fe3Al Coatings Reinforced with TiB2 Particles for Wear-Resistant Applications

This study reveals the effect of TiB2 particles on the mechanical and tribological properties of Fe3Al-TiB2 composite coatings against an alumina counterpart. The feedstock was produced by milling Fe3Al and TiB2 powders in a high energy ball mill. The high-velocity oxy-fuel (HVOF) technique was used to deposit the feedstock powder on a steel substrate. The effect of TiB2 addition on mechanical properties and dry sliding wear rates of the coatings at sliding speeds ranging from 0.04 to 0.8 m·s−1 and loads of 3, 5 and 7 N was studied. Coatings made from unreinforced Fe3Al exhibited a relatively high wear rate. The Vickers hardness, elastic modulus and wear resistance of the coatings increased with increasing TiB2 content in the Fe3Al matrix. The wear mechanisms strongly depended on the sliding speed and the presence of TiB2 particles but were less dependent on the applied load. This study reveals the effect of TiB2 particles on the mechanical and tribological properties of Fe3Al-TiB2 composite coatings against an alumina counterpart. The feedstock was produced by milling Fe3Al and TiB2 powders in a high energy ball mill. The high-velocity oxy-fuel (HVOF) technique was used to deposit the feedstock powder on a steel substrate. The effect of TiB2 addition on mechanical properties and dry sliding wear rates of the coatings at sliding speeds ranging from 0.04 to 0.8 m·s−1 and loads of 3, 5 and 7 N was studied. Coatings made from unreinforced Fe3Al exhibited a relatively high wear rate. The Vickers hardness, elastic modulus and wear resistance of the coatings increased with increasing TiB2 content in the Fe3Al matrix. The wear mechanisms strongly depended on the sliding speed and the presence of TiB2 particles but were less dependent on the applied load. This study reveals the effect of TiB2 particles on the mechanical and tribological properties of Fe3Al-TiB2 composite coatings against an alumina counterpart. The feedstock was produced by milling Fe3Al and TiB2 powders in a high energy ball mill. The high-velocity oxy-fuel (HVOF) technique was used to deposit the feedstock powder on a steel substrate. The effect of TiB2 addition on mechanical properties and dry sliding wear rates of the coatings at sliding speeds ranging from 0.04 to 0.8 m·s−1 and loads of 3, 5 and 7 N was studied. Coatings made from unreinforced Fe3Al exhibited a relatively high wear rate. The Vickers hardness, elastic modulus and wear resistance of the coatings increased with increasing TiB2 content in the Fe3Al matrix. The wear mechanisms strongly depended on the sliding speed and the presence of TiB2 particles but were less dependent on the applied load. This study reveals the effect of TiB2 particles on the mechanical and tribological properties of Fe3Al-TiB2 composite coatings against an alumina counterpart. The feedstock was produced by milling Fe3Al and TiB2 powders in a high energy ball mill. The high-velocity oxy-fuel (HVOF) technique was used to deposit the feedstock powder on a steel substrate. The effect of TiB2 addition on mechanical properties and dry sliding wear rates of the coatings at sliding speeds ranging from 0.04 to 0.8 m·s−1 and loads of 3, 5 and 7 N was studied. Coatings made from unreinforced Fe3Al exhibited a relatively high wear rate. The Vickers hardness, elastic modulus and wear resistance of the coatings increased with increasing TiB2 content in the Fe3Al matrix. The wear mechanisms strongly depended on the sliding speed and the presence of TiB2 particles but were less dependent on the applied load. This study reveals the effect of TiB2 particles on the mechanical and tribological properties of Fe3Al-TiB2 composite coatings against an alumina counterpart. The feedstock was produced by milling Fe3Al and TiB2 powders in a high energy ball mill. The high-velocity oxy-fuel (HVOF) technique was used to deposit the feedstock powder on a steel substrate. The effect of TiB2 addition on mechanical properties and dry sliding wear rates of the coatings at sliding speeds ranging from 0.04 to 0.8 m·s−1 and loads of 3, 5 and 7 N was studied. Coatings made from unreinforced Fe3Al exhibited a relatively high wear rate. The Vickers hardness, elastic modulus and wear resistance of the coatings increased with increasing TiB2 content in the Fe3Al matrix. The wear mechanisms strongly depended on the sliding speed and the presence of TiB2 particles but were less dependent on the applied load. This study reveals the effect of TiB2 particles on the mechanical and tribological properties of Fe3Al-TiB2 composite coatings against an alumina counterpart. The feedstock was produced by milling Fe3Al and TiB2 powders in a high energy ball mill. The high-velocity oxy-fuel (HVOF) technique was used to deposit the feedstock powder on a steel substrate. The effect of TiB2 addition on mechanical properties and dry sliding wear rates of the coatings at sliding speeds ranging from 0.04 to 0.8 m·s−1 and loads of 3, 5 and 7 N was studied. Coatings made from unreinforced Fe3Al exhibited a relatively high wear rate. The Vickers hardness, elastic modulus and wear resistance of the coatings increased with increasing TiB2 content in the Fe3Al matrix. The wear mechanisms strongly depended on the sliding speed and the presence of TiB2 particles but were less dependent on the applied load.

Characterization of Nickel Diffusion and its Effect on the Microstructure of Nickel PM Steels

Admixing pure elements to powder mixes can cause the formation of heterogeneous microstructures in sintered parts. For instance, nickel is renowned for forming nickel-rich areas (NRA) in powder metallurgy (PM) nickel steels due to its poor diffusivity in iron matrix (or lattice). The present work is aimed at characterizing the principal diffusion mechanisms of nickel and their influence on microstructures and properties of PM nickel steels. A new wavelength dispersive X-ray spectrometry (WDS) approach linking line scans and X-ray maps to concentration maps is proposed. Grain boundary and volume diffusion coefficients of admixed nickel have been determined in PM nickel steels using Suzuoka’s equation. Results also show that nickel distributes itself in the iron matrix mainly by surface and grain boundary diffusion.

Strain induced martensite formation in PM nickel steels

Abstract Powder metallurgy (PM) nickel steels are often selected because they have high strength, high impact resistance and good abrasion resistance. The microstructure of slowly cooled PM nickel steels typically contains pearlite, bainite, martensite and a fair volume fraction of retained austenite. Since volume diffusion is really low at conventional sintering temperatures [1120–1150°C (≈2050–2100°F)], nickel rich areas are usually found where prior admixed nickel particles were located, i.e. at the surface of iron particles and in sintering necks. Therefore, there is a discrepancy between the rather low mechanical properties of austenite and the high strength of PM nickel steel. Hence, the hypotheses that stress induced or strain induced martensite formation takes place during mechanical testing have been investigated. Results show that martensite forms during mechanical testing, and its final volume fraction is proportional to nickel content.

Fatigue Crack Propagation Rates and Local Texture Relationship in 2099-T83 Al-Li Alloy

An integrally stiffened panel (ISP) made from extruded 2099-T83 Al-Li alloy was subjected to fatigue loadings to investigate the influence of both the local texture and grain structure on fatigue crack propagation (FCP) behavior. The microstructure was mainly unrecrystallized. Grains were mostly layered in the web and fibrous in the other locations. Fiber texture components were present in the stiffener locations, and a rolling-type texture in the web. Resistance to FCP decreases as the local aspect ratio increases. Changes in FCP rates in the web, stiffener base and stiffener web were consistent with the microstructural features and texture. The stiffener cap with a strong fiber texture similar to that of the stiffener base exhibited a lower resistance to FCP, suggesting that the influence of the texture is convoluted in the stiffener cap by the markedly different grain structure. Therefore, FCP behavior in this alloy appears to be governed by both texture and grain structure.

Effects of additions of nickel nanoparticles on sintering response of PM hybrid low alloy steels

Abstract Addition of pure elements to powder mixes can cause the formation of heterogeneous microstructures in powder metallurgy (PM) parts upon sintering. For instance, it has been shown that additions of nickel particles to an iron powder form nickel rich areas (NRAs), since nickel has low diffusivity in iron at conventional sintering temperature [∼1121°C (2050°F)]. Thus, the present work is aimed at determining if addition of a small quantity of carbon coated nickel nanoparticles to a PM hybrid low alloy steel premix could result in a more homogeneous distribution of nickel in sintered parts. It also characterises the effect of this addition on microstructures and mechanical properties. Grain boundary and volume diffusion coefficients of nickel nanoparticles have been determined using Suzuoka’s equation and wavelength dispersive X-ray spectrometry maps. Results show that addition of nanoparticles initiates lattice diffusion at lower temperature and produces less NRA.

Modeling of the Influence of Admixing and Prealloying on the Optimisation of Compressibility and Sinter-Hardenability of Steel Powders

The automotive industry applies pressure on the PM industry to produce components with superior mechanical properties at minimum cost. In this regard, sinter-hardenable powders are particularly well suited since they allow direct quenching of components at the end of the sintering cycle, thus eliminating the extra steps required for heat treating. This paper presents the results of the modeling of the influence of admixing and/or prealloying on the optimization of compressibility and hardenability of sinter-hardenable steel powders. A first design of experiments (DOE) was used to optimize the chemical composition and to study the interactions between prealloyed elements (Nickel, Chromium, Molybdenum and Manganese) and admixed elements (Nickel, Chromium, Manganese and Copper) on hardenability and compressibility. A second DOE was generated based on the results obtained in the first series. Results show that among all of the examined alloying elements, only prealloyed nickel, chromium and molybdenum had a significant effect on compressibility and hardenability. Moreover, within the range of concentrations under study, the optimum sinter-hardenable powder had the following (prealloyed) chemistry: 1.5 wt-% Ni, 0.55 wt-% Cr and 1.25 wt-% Mo.