Iswadi Jauhari

Impact toughness, hardness and shear strength of Fe and Bi added Sn-1Ag-0.5Cu lead-free solders

In this study, the new Fe/Bi-bearing Sn-1Ag-0.5Cu (SAC105) solder alloys were studied for their mechanical properties, including impact toughness, hardness and shear strength. Charpy impact tester with impact speed of 5.4 m/s was used to determine the impact absorbed energy during impact tests. With the 0.05 wt.% Fe and 1 wt.% Bi addition to the SAC105 alloy, the impact absorbed energy increased from 8.1 J to 9.7 J by about 20% and literally no further improvement was observed by increasing the Bi content in the alloy. Vickers hardness tests were performed with a load of 245.2 mN and load dwell time of 10 s. The addition of Fe/Bi to SAC105 increased the hardness of the alloy from 10.5 HV to 22.6 HV showing an increase of more than two fold. Shear tests were performed with a shear speed of 0.25 mm/min. Shear strength almost doubled for the Fe/Bi added SAC105, as compared to the base alloy, increasing from 17.8 MPa to 34.3 MPa. The microstructure study shows that Bi is dissolved in the solder bulk and strengthens the solder alloys by its solid solution strengthening mechanism. The β-Sn grain size, as revealed by cross-polarized optical microscopy, significantly reduced from 60–100 μm to 20–40 μm with Fe/Bi addition to SAC105. The micrographs of field emission scanning electron microscopy (FESEM) with backscattered electron detector and their further analysis via ImageJ software indicated that Fe/Bi addition to SAC105 significantly reduced the Ag3Sn and Cu6Sn5 IMCs size and refined the microstructure. These changes in the microstructure of Fe/Bi added SAC105 expectedly resulted in such improvement in their mechanical properties.

Mechanical and biological stability of superplastically embedded HA nanolayer deformed at high temperature

In this study, HA is superplastically embedded into Titanium substrate and the sample is subsequently deformed superplastically until 70% deformation degree. The former process is termed as superplastic embedment (SPE) while the later as superplastic deformation (SPD). After the SPE, HA is successfully embedded into the substrate, forming a layer with a thickness of about 249 nm. After the SPD the embedded HA layer thickness decreases to 111 nm. The SPD sample is then immersed in simulated body fluid (SBF) to evaluate its biological properties. A newly grown apatite is formed as a result of the immersion and the HA layer thickness increases with immersion time. The cohesion and adhesion strength within the HA coating and coating-substrate interface of the SPD samples before and after immersion in the SBF is evaluated through the nanoscratch test technique. The results indicate that the HA layer after SPD is still strong even though after being exposed in SBF environment for quite some time. The study suggests that the superplastically embedded HA nanolayer is still intact mechanically and functioning appropriately as biological activity base even after the SPD process.

Embedment of HA into Superplastic Ti-6Al-4V: Effects of Implantation Temperature

In this research, we present a method for the embedment of hydroxyapatite (HA) into superplastic Ti6Al4V where the elements of HA and Ti6Al4V diffuse into each other to form a high quality implanted layer. The implantation process into superplastic titanium alloy was divided to two steps; first, the superplastic forming of Ti6Al4V was carried out using high-temperature compression test machine. In the second step, HA was embedded into superplastic Ti6Al4V by using a special designed clamp with an initial compressive load at high temperatures. The EDX and Line Scanning analyses indicate that the resulted film is composed of elements of HA and titanium alloy and due to the diffusion of HA and Ti6Al4V elements into each other, a good embedment is achieved. The elemental diffusion of HA and Ti6Al4V increases by increasing the temperature of the implantation process therefore the thickness of the implanted layer and the hardness of the embedded surface increase with the temperature.

Surface Roughness and Initial Pressure Effect on Superplastically Carburized Duplex Stainless Steel

Superplastic carburizing (SPC) is a carburizing process that combines carburizing with superplastic deformation. Since SPC involves direct interaction between the superplastically deformed surface and the solid carbon medium, the effect of surface roughness on the process cannot be disregarded. This paper presents the study of surface roughness and initial pressure effects on superplastic carburizing of duplex stainless steel (DSS). SPC was conducted under four different surface roughness (Ra) conditions of 0.9, 0.3, 0.1 and 0.03 μm. The microstructure, surface hardness, and carburized layer thickness were studied. Comparisons were also done on non-superplastic material which has a coarse microstructure. The results showed that the surface roughness strongly affected the properties of the superplastically carburized duplex stainless steel while its effects on the non-superplastic material were not that obvious.

Influence of Strain Rate and Strain on the Surface Properties in Superplastically Boronized Duplex Stainless Steel (DSS)

It was reported that superplastic boronizing process (SPB) provides a much faster boronizing rate than the conventional boronizing process (CB). This process was conducted on duplex stainless steel (DSS) which exhibit superplasticity. The study concentrated on the effect of strain rate and compression strain on SPB. The process was conducted under four different strain rates and three diferent strains condition. Boronizing was successfully conducted with the best result obtained under the high strain rate range of 5 x 10-5 s-1 to 1 x 10-3 s-1 which is associated with the superplastic region. Through SPB, movement of atoms into the specimen was highly accelerated by the grain boundary sliding process leading to a formation of thick and hard boronized layer in extraordinarily short period of time.

Effect of Powder Particle Sizes on the Development of Ultra Hard Surface through Superplastic Boronizing of Duplex Stainless Steel

In this work, a further study on boronizing using compression method called superplastic boronizing (SPB) was conducted. This process was conducted on duplex stainless steel (DSS) that exhibited superplasticity. Efforts were being put in obtaining ultra hard surface through SPB by focusing on the boron powder particle size. The microstructure, hardness, and layer thickness of the boronized materials were investigated. Comparison using as-received DSS with coarse microstructure also was performed. The overall results from the study showed that the SPB process can produced a very hard surface of close to 4000 HV and significantly improved the surface properties of the DSS.

A study on properties and kinetics of carburizing superplastic duplex stainless steel

In this study, a new type of surface carburizing process was introduced using superplastic duplex stainless steel (DSS). The superplastic DSS was carburized at temperatures ranging from 1123 K to 1223 K for various durations. Initial pressures of 25 MPa, 49 MPa and 74 MPa were applied to give the superplastic deformation effect on the carburized specimens. SEM studies revealed a thick, uniform, smooth and dense hard carbon layer was formed on the surface of the superplastic DSS. By using metallographic technique and SEM, the resulting case depth of carbon layer was between 15 /m to 76 /m. The kinetics of this process in terms of carbon diffusion and its variation with processing time and temperature was determined using Arrhenius equation. Activation energy (Q) was determined as 152 kJ/mol.

Effects of Superplasticity in Boronizing of Duplex Stainless Steel

In this research, conventional boronizing process (CB) and a new method of boronizing process under compression load condition (LB) were conducted and compared in order to study the effect of superplasticity on boronized substrate. Both processes were conducted on duplex stainless steel (DSS) with two different microstructures; as-received DSS with coarse grain microstructure (CDSS); and thermo-mechanically treated DSS with fine grain microstructure (FDSS) which can show superplastic behavior at high temperatures. Both processes were conducted at duration of 6 hours and temperatures between 1123 and 1223 K. All of boronized specimens demonstrated thin, smooth and compact morphology of boride layer. For CDSS, both CB and LB processes produced about similar surface hardness values within the range of 1425 – 2330 HV. For FDSS, CB process produced surface hardness between 1522 and 2601 HV, while under LB, the highest surface hardness values in the range of 1659 - 2914 HV were obtained. The result shows that introduction of load during boronizing has initiated superplastic deformation on FDSS thus accelerated diffusion of boron atoms into surface which finally lead to significantly higher surface hardness.

Microstructural and tensile properties of Fe and Bi added Sn-1Ag-0.5Cu solder alloy under high temperature environment

Abstract In this work, the iron (Fe) and bismuth (Bi) added (0.05 wt% Fe and 1 wt% or 2 wt% Bi) Sn-1Ag-0.5Cu (SAC105) lead-free solder alloys were prepared and their microstructure and tensile properties under severe thermal environments were extensively investigated and compared with the base alloy SAC105. The isothermal aging was done at 200 °C for 100 h, 200 h, and 300 h. Fe/Bi added SAC105 showed a significant reduction in the IMCs size (Ag3Sn and Cu6Sn5), especially the Cu6Sn5 IMCs and a refinement in the microstructure, which is due to the existence of Bi in the alloys. Moreover, the existence of Fe and Bi gives the microstructure better stability under severe thermal aging conditions. The tensile testing results showed that the addition of Fe and Bi to SAC105 greatly improves yield stress and tensile strength, but decreases ductility level, which is because of the Bi solid solution strengthening mechanism. Under severe thermal aging, the Fe/Bi added SAC105 showed more stable tensile properties, because of the existence of both Fe and Bi in the alloys.

Development of Cutting Tool Through Superplastic Boronizing of Duplex Stainless Steel

In this study, a cutting tool is developed from duplex stainless steel (DSS) using the superplastic boronizing technique. The feasibility of the development process is studied, and the cutting performances of the cutting tool are evaluated and compared with commercially available carbide and high-speed steel (HSS) tools. The superplastically boronized (SPB) cutting tool yielded a dense boronized layer of 50.5 µm with a surface hardness of 3956 HV. A coefficient of friction value of 0.62 is obtained, which is lower than 1.02 and 0.8 of the carbide and HSS tools. When tested on an aluminum 6061 surface under dry condition, the SPB cutting tool is also able to produce turning finishing below 0.4 µm, beyond the travel distance of 3000 m, which is comparable to the carbide tool, but produces much better results than HSS tool. Through superplastic boronizing of DSS, it is possible to produce a high-quality metal-based cutting tool that is comparable to the conventional carbide tool.