M. Cieśla

Numerical Modeling as the Method to Determine the Parameters of Tube Bending with Local Induction Heating

The numerical analysis results of bending with local induction heating of 10CrMo9-10 steel tubes have been presented in the paper. The goal of conducted simulations was to determine the process parameters that allow to obtain tube bends with geometric features which meet requirements of relevant standards. The risks of wrinkling, excessive tube bend ovalization and cracking (according to Cockroft-Latham criterion) have been analysed. The obtained results prove that numerical modeling can be used to minimize the costs of tube bending technology implementation without the need of further process parameters corrections.

Influence of Pearlite Morphology on Creeping Characteristic Curves of R260 Steel

The elements of railway turnouts made from rail sections of R260 high carbon steel must have a high resistance to abrasive and contact fatigue wear, as well as a good resistance to cracking under service loads. These mechanical properties largely determine the suitability of steel for use as railway track components. In this study, two groups of specimens were subjected to tests of mechanical properties and metallurgical analyses. The first group included material obtained from the hot-rolled block section, the rolling end temperature being Tkw = 950°C, while the second group was material after the rolling process with the subsequent 20-minute isothermal annealing at a temperature of 480°C. The microstructure of tested materials (Rm, Rp0.2, A5, Z, HB) was characterized, and their basic mechanical properties and fracture toughness in the KIc plane strain condition were determined. Also the effect of temperature, ranging from-80°C to 100°C, on the KCU impact toughness of R260 steel was established. Based on the SEM observation using the Hitachi S-3400N scanning microscope, it was found that pearlitic structure with a varied distance between cementite plates, equal to 0.29 μm and 0.09 μm, respectively, appears in the hot-rolled R260 steel and in the steel subjected to additional isothermal annealing treatment. The impact of pearlite morphology on the cracking characteristics and basic mechanical properties of materials was analyzed. It was found that at room temperature, the higher fracture toughness (KIc = 66.4 MPa·m1/2) is shown by the steel after isothermal annealing at 480°C, in which less distance between the plates of cementite has been observed in the perlite. The fracture toughness of R260 steel after hot rolling at 950°C was KIc = 48.3 MPa·m1/2. As in the case of fracture toughness, the impact strength of R260 steel after isothermal annealing was significantly greater than the impact strength of steel only after hot rolling. The determined cracking characteristics of R260 steel make it possible to determine the effect of heat treatment on the formation of microstructure and material properties, which determine the service life of rail sections.

GEOMETRICAL PHENOMENA IN TUBE BENDING WITH LOCAL INDUCTION HEATING

A theoretical and experimental analysis of heat induction bending for tubes used in the power industry is performed. First, the design of the heat induction bending process for tubes is described and industrial application areas for this technology are presented. Next, the main methods for tube bending with local induction heating are discussed and the effect of the technology on geometrical parameters of bends formed is presented. Then, the heat induction bending process for tubes is modeled using numerical techniques (FEM). The simulations are performed in a three-dimensional strain state, where thermal phenomena are taken into account, using the commercial software package Simufact Forming v. 11.0. In the simulations, the changes in workpiece geometry in the region of the bend being made (cross section ovalization, darkening and thickening of walls, neutral axis position) are examined. Also, potential phenomena that could limit the stability of the bending process and cause shape defects are predicted. The results of the numerical modeling are then compared to those obtained under industrial conditions.

The Effect of Heat Treatment on Creep Resistance of Castings from the Modified Superalloy MAR-247

mpact of heat treatment on durability has been evaluated in this study in conditions of high-temperature creep of castings made from nickel superalloy MAR-247 post production rejects. Castings made in the processes of modification and filtration when pouring into moulds were subject to solubilization (1185°C/2 h) with subsequent ageing (870°C/20 h). It has been found on the basis of performed tests that in conditions of high-temperature creep at temperature 980°C with stress σ = 150 MPa the resistance of specimens of coarse-grain structure was significantly higher when compared to fine-grain material. The conditions of initiation and propagation of cracks in these specimens were analysed with consideration of morphological properties of material macro-, micro-and substructure. Moreover, it has been proven that creep resistance of heat treated MAR-247 superalloy significantly improves when compared to its condition after the process of modification only. Macrostructural changes in the MAR-247 superalloy that determine the increase of superalloy creep resistance after solubilization and ageing, as observed in the tests, were also examined.

Analysis of Cracking Process in Conditions of High-Temperature Creep of Castings Form the Modified Superalloy IN-713C

mpact of complex modification and filtration during pouring into moulds on durability has been evaluated in this study in conditions of high-temperature creep of castings made from nickel superalloy IN-713C post production rejects. The conditions of initiation and propagation of cracks in the specimens were analysed with consideration of morphological properties of material macro-, micro-and substructure. It has been demonstrated that in conditions of high-temperature creep at temperature 980°C with stress σ =150 MPa creep resistance of the IN-713C superalloy increases significantly with the increase of macrograin size. Creep resistance of specimens made of coarse grain material was significantly higher than the resistance of fine grain material.

Study on Cracking Process of Power Boiler Element

This paper presents the study of the reasons for cracking of spray steam attemperator. The element being analysed is a temperature controller of steam for turbine; its proper functioning has considerable impact on operation of power generating set of boiler and turbine. Damage to the steam attemperator may affect the durability of neighbouring components, replacement or repair of which results in a long-term outage of power generation unit. The reason for attemperator cracking has been determined on the basis of strength calculations and micro-and macro-analysis of fracture surfaces. The conducted tests were the basis for modification of attemperator design, which will ensure reliable functioning of the analysed element.

Low cycle fatigue life and creep life of material in tube bends made of 15NiCuMoNb5-6-4 steel

The article addresses results of tests of performance characteristics of a tube bend made of the 15NiCuMoNb5-6-4 steel, the latter being for manufacture of feed water pipelines used in power engineering systems. The tube bend was developed by bending with local induction heating, and the optimum tube bending parameters were established based on numerical simulations of the bending process. The mechanical properties of the tube bend were attained through quenching and tempering. Tests of mechanical properties were conducted using samples collected at different zones of the tube bend (the straight one as well as those subject to tension and compression), and compared with properties of the as-delivered tube material. The established basic mechanical properties of the tube bend, required under the applicable standards, were supplemented with results of low-cycle fatigue and creep tests, the purpose of which was to acquire information on the tube bend material service life under conditions of steady and unste...

Fatigue Behaviour of Carbide Precipitation Hardened Austenitic Steels

The paper presents the results of investigations of the microstructure and fatigue behaviour of two newly invented Cr-Ni and Cr-Ni-Mn austenitic steels of 13/13 and 12/8/8 type strengthened through carbide particle precipitation. The specimens of the investigated steels were subjected to tests after heat treatment, i.e. solution heat treatment (1200°C/0.5 h/water) and aged at a temperature of 700°C for 12 h, with cooling in air. The heat treated specimens were then subjected to low-cycle fatigue tests (LCF), carried out at room temperature and at an increased temperature of 600°C. Diagrams of fatigue characteristics of the investigated steels at room temperature as well as at elevated temperature have been worked up. It has been found that during low-cycle fatigue tests, at both temperatures, the investigated austenitic steels indicated a fatigue softening effect. The results of LCF at room temperature showed that the fatigue durability (Nt) of both austenitic steels is located in the range 0.8÷1.3×103 cycles. The results of low-cycle fatigue tests at an increased temperature 600°C indicated that the fatigue durability of the investigated steel was lower, and is located in the range Nt = 0.5÷0.6×103 cycles. It has been pointed out that the investigated austenitic steels are characterized by a stability of structure in conditions of cyclic fatigue.

Durability of Tube Bends Made of the 14MoV6-3 Steel under Low-Cycle Fatigue Conditions and Creep at a Temperature of 500°C

The paper contains the results of theoretical and experimental research on tube bending process used in manufacturing of 14MoV6-3 steel tubes. The innovative tube bending process using local induction heating and the results of finite-element numerical analysis of tube bends using Symufact Forming 11.0 software were presented. Numerical analysis covered the changes in pipe bend geometry (ovalization of cross section, wall thickness) and the results were compared with those obtained in industrial conditions. Basic mechanical properties of bended tube (diameter 323.9 mm, wall thickness 40 mm) in the supply condition and after heat treatment were determined using tensile, hardness, impact, low-cycle fatigue and creep tests. It has been shown that 14MoV6-3 steel tube bends manufactured using proposed technology meet the requirements of the PN-EN 10216-2 standard.

High-Cycle Fatigue Life of AZ31 and AZ61 Magnesium Alloys

Usefulness of the magnesium alloys for construction of structural components is determined, apart from their low density, by a number of favourable mechanical properties and in the case of their use for components of transport means additionally by good fatigue strength. In this study, 12 mm diameter extruded rods of AZ31 and AZ61 magnesium alloys were used as test material. After extrusion the rods were annealed at a temperature of 400°C, with a 60 min soaking period and subsequent cooling in air. Cylindrical specimens with a diameter of d0 = 8 mm were made for the fatigue test under high-cycle rotary bending conditions with the cycle asymmetry coefficient R = -1. The tests were carried out for a limited fatigue strength range. Examination of microstructure of tested alloys and fatigue fractography were also performed. During the high-cycle fatigue tests it was found that the AZ61 alloy has a longer fatigue life. Based on the obtained results, fatigue life characteristics of the tested materials were drawn up.