Maciej Motyka

Modeling of Directional Solidification of Columnar Grain Structure in CMSX-4 Nickel-Based Superalloy Castings

The paper presents the analysis of numerical simulation of the Bridgman directional solidification process performed on CMSX-4 rods. The numerical simulation was studied applying the ProCAST software. The constitutive law parameters of the normal Gaussian distribution were used to describe the nucleation process. The coefficients of the equation were determined and used to calculate the growth rate of dendrite tip. The analysis of the as-cast microstructure was carried out with the use of Aphelion software in order to determine the average area of grains and their quantity. The experimental verification of both nucleation and grain growth coefficients used for the simulation of the directional solidification process confirmed that the model was correct and described well the investigated process of directional solidification using the Bridgman method.

Phase Transformations and Characterization of α + β Titanium Alloys

Phase transformations the effects of which are used in manufacturing processes of structural elements made of two-phase titanium alloys are discussed in the chapter. In order to describe the effect of microstructure on mechanical properties of titanium alloys, phase constituents of microstructure and possible phase compositions too were characterized. Authors presented methods of developing of microstructure and analyzed factors determining technological properties of titanium alloys, like hot plasticity (including superplasticity).

Analysis of Tensile Test of Titanium EBW Sheet

The continuous pursuit of vehicle weight reduction forces the industry to look for alternative materials to steel. Light alloys such as aluminium or titanium are materials that provide a decrease in weight using conventional technologies. Additional weight reduction results from using tailor-welded blanks (TWB). While the joining and forming steel or even aluminium TWBs is quite well known and described in the technical literature, joining and forming titanium TWBs still poses a significant problem. In the paper, experimental tests carried out with welded samples manufactured from commercially pure titanium Gr 2 and titanium alloy Gr 5 sheets are presented. The samples were joined by electron beam welding. Mechanical testing and optical microscopy were used to characterise the welds and the base metal of the samples. The samples were subjected to uniaxial tension up to final failure. The 3‑D Digital Image Correlation system ARAMIS was used for monitoring the whole deformation process. This makes it possible for real-time observation of sample deformation. The test results and the numerical analysis of the tensile tests are compared. The numerical simulations were carried out with the ADINA System based on the Finite Element Method (FEM). The mechanical analysis leads to calculation of the strain state after sample deformation in uniaxial tension (mechanical model).

Influence of Grain Refining on Abrasive Wear of Submicrocrystalline Al-Si Alloys

Light weight nano/submicrocrystalline materials are promising group of constructional materials combining low density with high mechanical properties. However, their potential application requires extensive testing of functional properties, e.g. tribological ones, which may be significant and determine their practical use. Available information on abrasive wear and friction coefficients in nano/submicrocrystalline materials is rather poor. Therefore the aim of this paper is to fill the gap in the literature in this field. The AlSi12Fe5Cu3Mg alloy (RS422) produced by rapid solidification and plastic consolidation with grain size of basic phase components in the range from 50 nm to 300 nm was examined. Microstructure and mechanical properties of the materials were determined. Abrasive wear tests, static and kinematics friction coefficients measurement were carried out under the surface condition including dry, wet and oil lubricant. The results have been compared to the values of similar quantities determined in the same conditions for conventionally produced alloy AlSi11FeCuMn (AK11). Substantial increase of friction coefficients for RS442 comparing to AlSi11FeCuMn material was found, however, abrasive wear for nano/submicron grained materials were low in comparison to conventional one. Considerable increase of abrasive wear at water presence and very weak attrition at oil lubrication was observed. Relationship between structure and mechanical properties of tested materials was analyzed.

The Effect of α-Phase Grains Morphology in Initial Microstructure on Superplasticity of Two-Phase Titanium Alloys

It is generally accepted that fine-grained and equiaxed microstructure enables superplastic deformation of two-phase titanium alloys. Appropriate microstructure is usually developed in the thermomechanical processing with careful selection of the parameters of plastic deformation and heat treatment. Based on results of own research in this area increased superplasticity was found in Ti6Al4V alloy having microstructure containing highly deformed and elongated α-grains – considerably different from equiaxed ones. It was found that during heating up and first stage of superplastic deformation fragmentation of elongated α-phase grains occurred, followed by formation and growth of globular grains of that phase. Particular role of quenching of the Ti6Al4V alloy from the stable β-phase temperature range in thermomechanical processing was identified. It leads to increase of elongation coefficient of α-phase grains after plastic deformation but also restrains nucleation of the precipitates of secondary α-phase in further stages of thermomechanical processing. It was established that developed phase morphology of the alloy determined its hot plasticity – especially in the range of low strain rates typical for superplastic deformation.

Decomposition of deformed α′(α″) martensitic phase in Ti–6Al–4V alloy

ABSTRACT The process of martensitic α′(α″) phase decomposition in titanium alloys has not been sufficiently characterised in the literature – especially in terms of plastically deformed martensite. The research results of water-quenched Ti–6Al–4V alloy, subsequently cold deformed in compression test and tempered at the temperature range of 600–900°C for 1 and 2 h were presented in the paper. Light and scanning electron microscopy observations revealed the influence of plastic deformation on tempered martensite laths morphology – particularly at the temperature of 900°C – it favoured their fragmentation and spheroidisation. The effect of plastic deformation on characteristic temperatures of α′(α″)→α + β phase transformation, phase composition and alloying elements distribution in phase constituents of Ti–6Al–4V alloy was identified and evaluated too. This paper is part of a thematic issue on Titanium. GRAPHICAL ABSTRACT

Dynamic fragmentation and spheroidization of α phase grains during hot deformation of Ti-6Al-4V alloy: Paper presented at the “XIII Scientific Conference on Titanium and Titanium Alloys 2017”, 24–27 September 2017, Janów Podlaski, Poland

Abstract Development of mechanical properties of titanium alloys is usually achieved by the control of their microstructure (globular, lamellar, bimodal). Dynamic fragmentation and spheroidization of elongated α phase grains, formed from martensite laths, in the microstructure of Ti-6Al-4V alloy are considered in the paper. The effects of α phase grain spheroidization was evaluated in tensile tests over a temperature range of 800–900°C and strain rate range of 10−3–10−2 s−1. Completed spheroidization of elongated α phase grains and subsequent growth of equiaxed grains for all deformation modes were found. A low value of apparent activation energy for deformation was calculated – suggesting grain boundary sliding was the main deformation mechanism. The results showed good correlation with the kinetic rate equation based on the Zener–Hollomon parameter.

Protective Coatings on Steel Dies for Wax Injection Process

Protective coatings are used today in many applications for reducing friction and wear of tools in hot-working process e.g. metal die casting, hot forging, metal die plastics injection. The main goal of undertaken investigation was to evaluate usability of those coatings for improving wear resistance of metal die applied in investment casting process for wax injection. The (Ti,Al)N and (Al,Cr)N PVD coatings were deposited onto X37CrMoV5-1 hot-work tool steel and their mechanical and tribological properties are characterized in the paper. Based on the results of microscope examinations, scratch test, hardness measurement the similar properties of (Ti,Al)N and (Al,Cr)N coatings were found. Moreover it was established that type of steel surface machining before coating deposition, i.e. grinding, electrical discharge machining (EDM) and milling, did not affect coating properties. Thin coatings replicate steel base roughness parameters as Ra, Rz and Rmax with over 95% of correlation. Based on tensile test results of wax/coated steel samples and wax/uncoated steel samples the lowest wax adhesion to (Ti,Al)N coating was confirmed.

The Role of Martensitic Transformation in Thermomechanical Development of Microstructure and Plasticity of Two-Phase Ti-6Al-4V Titanium Alloy

Phase constituent morphology in microstructure of two-phase α+β titanium alloys is determined by conditions of thermomechanical processing consisting of sequential heat treatment and plastic deformation operations. Results of previous research indicate that particularly solution treatment preceding plastic deformation significantly changes α-phase morphology and determines hot plasticity of titanium alloys. In the paper thermomechanical processing composed of β solution treatment and following hot forging of Ti-6Al-4V titanium alloy was analysed. Development of martensite plates during heating up and hot deformation was evaluated. Microscopic examinations revealed that elongated and deformed α-phase grains were fragmented and transformed into globular ones. Significant influence of martensitic transformation on elongation coefficient of α-phase grains after plastic deformation was confirmed. Based on results of elevated temperature tensile tests it was established that α-phase morphology in examined two-phase α+β titanium alloy, developed in the thermomechanical processing, can enhance their hot plasticity – especially in the range of low strain rates.

The Effect of Heat Treatment on Static and Dynamic Mechanical Properties of Rapidly Solidified and Plastically Consolidated RS442 Aluminium Alloy

Ultra-fine grained metallic materials are characterized by higher mechanical properties comparing with their conventional equivalents. However increase in strength under static load is not always accompanied by improved fatigue behaviour. Previous investigations on submicrocrystalline RS442 aluminium alloy produced by plastic consolidation of rapidly solidified flakes in the extrusion process revealed increase in its high cycle fatigue bending strength caused by annealing at 450°C. The aim of present studies was to evaluate the influence of heat treatment – also precipitation hardening – on static mechanical properties (hardness, tensile and yield strength) and fatigue strength of the alloy determined in high cycle stress controlled bending tests. Correlation between microstructure, static mechanical properties and fatigue behaviour was analyzed too.