M. Faccoli

Cold Spray Repair of Martensitic Stainless Steel Components

The possibility of using cold spray as repair technique of martensitic stainless steel components was evaluated through laboratory investigations. An austenitic stainless steel feedstock powder was chosen, instead of soft metals powders like nickel, copper, or aluminum, used for repairing components made in light alloy or cast iron. The present study directly compares the microstructure, the residual stresses, and the micro-hardness of repairs obtained by cold spray and by TIG welding, that is commonly used as repair technique in large steel components. XRD and optical metallographic analysis of the repairs showed that cold spray offers some advantages, inducing compressive residual stresses in the repair and avoiding alterations of the interface between repair and base material. For these reasons, a heat treatment after the cold spray repair is not required to restore the base material properties, whereas a post-weld heat treatment is needed after the welding repair. Cold spray repair also exhibits a higher micro-hardness than the welding repair. In addition, the cavitation erosion resistance of a cold spray coating was investigated through ultrasonic cavitation tests, and the samples worn surfaces were observed by scanning electron microscopy.

Rolling Contact Fatigue and Wear Behavior of High-Performance Railway Wheel Steels Under Various Rolling-Sliding Contact Conditions

An experimental investigation was carried out to study and compare the response to cyclic loading of the high-performance railway wheel steels ER8 EN13262 and SUPERLOS®. Rolling contact tests were performed with the same contact pressure, rolling speed and sliding/rolling ratio, varying the lubrication regime to simulate different climatic conditions. The samples, machined out of wheel rims at two depths within the reprofiling layer, were coupled with UIC 900A rail steel samples. The wear rates, friction coefficients and hardness were correlated with the deformation beneath the contact surface. The crack morphology was studied, and the damage mechanisms were identified. The distribution of crack length and depth at the end of the dry tests was analyzed to quantify the damage. The main difference between the steels lies in the response of the external samples to dry contact: SUPERLOS® is subjected to a higher wear and lower friction coefficient than ER8, and this reduces the density of surface cracks that can propagate under wet contact conditions. The analysis of feedback data from in-service wheels confirmed the experimental results.

Effects of artificial aging conditions on mechanical properties of gravity cast B356 aluminum alloy

Abstract The age hardening behavior of gravity cast B356 aluminum alloy was investigated by differential scanning calorimetry (DSC), hardness measurements and tensile tests. Three different artificial aging temperatures were selected, namely 155, 165 and 180 °C, with heat treatment time from 40 min to 32 h. DSC analysis results show that cluster formation begins below room temperature (at around −10 °C). Since cluster formation influences the subsequent precipitation of the main strengthening β″ phase, it can be inferred that a delay between solutionizing and artificial aging has a detrimental effect on the mechanical properties of the alloy. It was also confirmed that the hardness and the tensile properties of the alloy reach the maximum values when β″ phase is completely developed during the artificial aging. This happens after 16 h for samples aged at 155 °C, after 6 h for samples aged at 165 °C and after 4 h for samples aged at 180 °C. A subsequent decrease of the mechanical properties, observed only in the sample aged at the highest temperature, with increasing aging time can be associated with the transformation of the coherent β″ phase into the semi-coherent β′ phase. Finally, the activation energy associated with the precipitation of β″ phase was calculated to be 57.2 kJ/mol.

Influence of aging on microstructure and toughness of die-casting die steels

This study investigates the modification of the carbide type, size, shape and the associated changes in the toughness properties after prolonged aging at temperatures close to that of maximum hardening during tempering treatment. The aging effects on the microstructure of both steels still consist of a tempered martensite matrix, with an increased amount of precipitates and more marked prior austenitic grain boundaries. For H13 steel, the aging effects on fracture toughness show an appreciable increase in up to 50 h treatment; raising the aging time to 250 h causes considerable embrittlement. For H11 steel, however, the fracture toughness decreases early, from the first stages of aging; this behaviour has been associated with an increase in the carbide size. At increasing aging time, also for H11 steel, the embrittlement of prior austenite grain boundaries prevails in controlling fracture initiation and in decreasing fracture toughness.

A study of the strengthening mechanisms in the novel precipitation-hardening KeyLos? 2001 steel

KeyLos? 2001 is a new precipitation-hardening steel especially developed for plastic moulds. In this study the precipitation stage of KeyLos? 2001 steel has been investigated and compared to the results obtained with 17-4 PH steel. Precipitation-hardening has been carried out at three different temperatures and the stages of hardening and overageing have been studied in order to clarify the hardening mechanisms. It has been found that hardening and softening mechanism during the precipitation-hardening treatment occur at higher temperatures and in correspondence with more prolonged treatment times than those typical for the best known 17-4 PH steel; hardness is then expected to remain stable also for very extended mould lives. Microstructural investigations by means of Scanning Electron Microscopy (SEM) and Transmission Electron Microscopy (TEM) have also been carried out and the microstructural parameters responsible for the hardening and overageing have been pointed out.

Effect of Wear on Surface Crack Propagation in Rail–Wheel Wet Contact

The interaction between wear and rolling contact fatigue in wet contact was investigated by means of experiments on a two-disk test bench. Specimens of various railway wheel steels were coupled with specimens of the same rail steel, subjected to rolling and sliding wet contact with varying sliding/rolling ratio. Some tests with a dry rolling–sliding contact phase preceding wet contact were carried out as well (dry–wet tests). The pressurization of the fluid entrapped in the surface cracks was the cause of a rapid and severe damage in the dry–wet tests, due to the nucleation of surface cracks by ratcheting in the dry phase, which subsequently propagate in the wet phase. In the wet tests, the fluid pressurization effect was much mitigated due to the absence of initial surface cracks; the specimens subjected to higher sliding/rolling ratio showed the best performance against rolling contact fatigue, due to the effect of wear in reducing the length of surface cracks. A model for assessing the interaction between wear and rolling contact fatigue was proposed, based on the correction of the classical Paris law for crack propagation by taking into account the effect of wear on crack length reduction. The application of the model to the experimental tests allowed finding a correlation between the model predictions and the occurrence of fatigue failure.

A Pin-on-Disc Study on the Wear Behaviour of Two High-Performance Railway Wheel Steels

The wear behaviour of two railway wheel steels, ER8 and SUPERLOS®, was studied through pin-on-disc tests, and the results were correlated with those previously obtained with twin-disc tests. The work-hardening of the steels was investigated with Vickers hardness measurements, and the wear mechanisms were studied using scanning electron microscopy. ER8 discs showed higher wear resistance, lower work-hardening ability and less wear damage than SUPERLOS® ones, confirming the results of the twin-disc tests. Therefore, sliding pin-on-disc experiments are recommended as a simple laboratory technique that can be used as a screening method for wheel steel performance prior to more complex and more expensive tests. The damage in both steels was due to the concomitance of oxidative wear, abrasive wear and fatigue wear. Iron oxide formation protects the steels from severe wear, whereas its detachment causes abrasive wear; furthermore, surface fatigue cracks initiate and propagate leading to the detachment of material flakes.

Optimization of heat treatment of gravity cast Sr-modified B356 aluminum alloy

Abstract In recent years, certain foundry processes have made it possible to obtain products with very thin parts, below the 4 mm threshold of the permanent mold casting technology. The safety margins of these castings have been reduced, so the T6 heat treatment conditions adopted for the Al–7Si–Mg alloys need to be investigated to identify the best combination of strength and ductility. Furthermore, the cost and the production time associated with T6 heat treatment have to be optimized. In the present work, an experimental study was carried out to optimize the solution treatment and artificial aging conditions in gravity cast thin bars of B356 aluminum alloy modified with Sr. Two solution temperatures were selected, 530 °C and 550 °C, respectively, with solution time ranging from 2 to 8 h, followed by water quenching and artificial aging at 165 °C with aging time from 2 to 32 h. The results of hardness and tensile tests were correlated with differential scanning calorimetry (DSC) analysis. The best combination of mechanical properties and heat treatment duration was obtained with 2 h solutionizing at 550 °C and 8 h aging at 165 °C. DSC analysis showed that the alloys mechanical properties reach the maximum value when the β″ phase is completely developed during the artificial aging.

Warm spray applied to steel component repair: experimental study

Experimental investigations were carried out in order to evaluate the possibility of using warm spray as a repair technique for steel components. A high velocity oxygen fuel system was modified to deposit an AISI 316 stainless steel feedstock powder in solid state. A preliminary study was carried out on the spray conditions to optimise the deposition process. The powder was deposited on a steel sample, and the quality of the coating was evaluated by optical microscope observations: a limited porosity was observed in the repair. Test damage was produced in another steel sample and was repaired by warm spray. Residual stresses and microhardness of the repaired area were measured. It was found that beneficial compressive residual stresses were produced in the repaired area, which also exhibits a good microhardness, slightly higher than that of the substrate. Finally, adhesion tests were carried out, and a strength >46 MPa was found.