P. Ramesh Narayanan

Metallographic investigations of the heat-affected zone II/parent metal interface cracking in 18Ni maraging steel welded structures

During the fabrication of a large diameter pressure vessel out of 18 Ni maraging steel by manual TIG welding, microcracks were noticed at the heat-affected zone (HAZ)/parent metal interface. The location of these cracks was very different from those reported at the fusion zone/HAZ I interface due to “constitutional liquation”. Extensive optical metallography, scanning electron microscopy and energy dispersive X-ray analyses were carried out to identify the cause for the occurrence of these cracks. It is inferred from the experimental results that the microsegregation of titanium and nickel due to repeated thermal cycling during multipass welding led to the formation of TiC/Ti(CN) and stable austenite film on the grain boundaries. Under severe thermal stresses developed during welding, microvoids generated at the interface of TiC/Ti(CN) inclusions and austenite and further propagated intergranularly due to the premature failure of the austenite films.

Stress Corrosion Cracking of a Maraging Steel Shear Bolt Used in the Interstage Structure of a Satellite Launch Vehicle

M250 grade maraging steel is used widely in satellite launch vehicle structures due to its excellent combination of strength and toughness. One of the maraging steel bolts used in interstage structures was found broken during the visual inspection of the hardware. The failed bolt was in assembled condition for several months. The bolt has failed at the stepped region before the start of threads. Crack initiated at the corrosion pits located at the stepped region and propagated inward in an intergranular mode. Fractography revealed brittle intergranular features and corrosion products were noticed on the outer periphery of the fracture surface. EDS analysis of the corrosion products near the fracture edge indicated the presence of chlorine. However, at the center of the bolt, the fractographic features correspond to transgranular mode of failure. Based on detailed metallurgical analysis, the failure of the bolt was attributed to ‘stress corrosion cracking.’

Microstructural Investigations on ATIG and FBTIG Welding of AA 2219 T87 Aluminum Alloy

Limitation in penetration depth is a concern in conventional TIG welding process. To improve penetration capability of TIG process, both Activated TIG (ATIG) and Flux Bounded TIG (FBTIG) are investigated in aluminum alloy AA 2219 T87. Undesirable arc wandering and cracking tendency are observed in ATIG welds. Microstructural investigation reveals ATIG welds are prone for liquation cracks. Morphology of the cracks along with the attributable factors are explained with optical and SEM (Scanning Electron Microscope) micrographs. Energy Dispersive Spectroscopy (EDS) results are also presented to explain the solute enrichment in the grain boundaries of the ATIG welds. FBTIG is found to produce good quality welds and is more suitable for welding aluminum alloys. Key words: Flux Assisted TIG; ATIG; FBTIG; Penetration Improvement; Microstructure; AA2219.

Study of LCF Behavior of IN718 Superalloy at Room Temperature

nconel 718 is an age hardenable nickel base supper alloy with high strength at elevated temperatures, and excellent creep properties. It is used extensively in turbine discs, blades where components experience elevated temperatures for prolonged duration, leading to coarsening of the microstructure. To evaluate the life of such components after prolonged exposure to service conditions, LCF properties at such large grain sizes are essential. For this purpose, low cycle fatigue (LCF) behavior of forged Inconel 718 turbine rotor disc having large grain size was studied at room temperature. Total strain controlled fatigue tests were conducted in air at ambient temperature on this alloy in solution treated and aged condition. The results indicated that the material exhibits cyclic strain softening and the cyclic yield strength is lower by 40% compared to the monotonic yield strength. The deformation takes place by multiple planar slip.

Corrosion and Multi-Scale Mechanical Behaviour of Plasma Electrolytic Oxidation (PEO) and Hard Anodized (HA) Coatings on AA 2219 Aluminum Alloy

The electrochemical corrosion and mechanical properties of ceramic coatings fabricated by plasma electrolytic coating (PEO) and hard anodizing (HA) methods comparatively examined for AA2219. Potentiodynamic polarization results revealed that the corrosion resistance of both coatings are comparable to each other. However, the indentation and scratch testing indicated that the hardness and modulus of the PEO coating was significantly higher when compared to HA coating. The critical load (Lc2) causing adhesive failure of the PEO coating was much high (19N) when compared to HA coating (10N) showing better adhesive strength of the PEO coating.Key words: Plasma electrolytic oxidation (PEO), potentiodynamic polarization, nanoindentation, hard anodizing

Microstructural Characterisation of AA2219 Weldments

Aluminium alloy AA 2219 has been selected for fabrication of both earth storable and cryogenic propellant tanks of launch vehicles due to its high specific strength, compatibility with liquid propellants, good resistance to stress corrosion cracking (SCC), excellent properties at cryogenic temperatures and good fabricability including weldability. Propellant tanks are fabricated by welding sheets in T87 and rings in T851 temper conditions. Microstructural characterization was carried out on the weldments with sheet-sheet and sheet-forge configuration using optical microscopy and electron microscopy with energy dispersive spectroscopy. Microstructure of weld pool had dendritic pattern, typical of weld cast structure. Fine recrystallised grains were observed near fusion line. Heat affected zone on either side of the weld revealed thickened grain boundaries. EDS on these thickened grain boundaries indicated composition of eutectic. Microhardness and tensile strength for both the configurations was evaluated. Fractures surface of tensile tested specimens were examined for fracture morphology and to understand the role of eutectic film in fracture. Presence of the eutectic film along the grain boundaries was explained with the help of liquation mechanism and Al-Cu phase diagram. This paper brings out details of the investigation carried out.

Environmentally assisted cracking resistance of Al–Cu–Li alloy AA2195 using slow strain rate test in 3.5% NaCl solution

Abstract The general corrosion and environmental cracking resistances of Al–Cu–Li alloy AA2195 were investigated in 3.5% NaCl environment and compared with those of another high strength alloy AA2219. The general corrosion resistance of these alloys was examined using immersion corrosion and potentiodynamic polarization tests, while the stress corrosion cracking (SCC) resistance was evaluated by slow strain rate test (SSRT) method. The tested samples were further characterized by SEM–EDS and optical profilometry to study the change in corrosion morphology, elemental content and depth of corrosion attack. The reduction in ductility was used as a parameter to evaluate the SCC susceptibility of the alloys. The results indicated that the corrosion resistance of AA2195 alloy was better than that of AA2219 alloy as it exhibited lower corrosion rate, along with lower pit depth and density. However, the SCC index ( ɛ NaCl / ɛ air ) measured was greater than 0.90, indicating good environmental cracking resistance of both the alloys. Detailed fractography of the failed samples under SEM–EDS, in general, revealed a typical ductile cracking morphology for both the alloys.

On the Measurement of Dynamic Elastic and Internal Friction Properties of Nickel Based Super Alloys up to 650°C Temperature

Elastic constants are the fundamental key parameters to understand the mechanical behaviour of engineering materials under stressed condition. This paper explains the test methodology and provides results of experiments carried out using resonance based high temperature impulse excitation technique test facility for the measurement of technical elastic moduli i.e., Young’s modulus (E), Shear modulus (G), Poisson’s ratio (ν) and internal friction (Q-1) of two nickel-base polycrystalline super alloys IN718 and Haynes 214 from ambient to 650°C temperature in argon environment during heating and cooling.

Evaluation of Elastic Properties of CP Ti by Three Different Techniques

Elastic constants are the fundamental key parameters in the mechanical behaviour of engineering materials under stressed condition. This paper explains the determination of elastic constants of commercially pure titanium (Grade-2) at ambient temperature using three independent test methods including quasi-static tensile test with strain gauged specimen, ultrasonic pulse echo method and resonance based impulse excitation technique. The results are statistically analysed and compared.

Failure Analysis of AISI 302 Steel Compression Spring Used in Flush and Purge Valve of Liquid Engine

AISI 302 stainless steel is used for making compression springs for launch vehicle programmes. One such AISI 302 stainless steel compression spring used in flush and purge valve of liquid engine of a satellite launch vehicle failed during testing. The failure was at the second round of spring and it failed in a slanted type fracture. Detailed metallurgical analysis indicated that the failure was due to fatigue.