Veli-Tapani Kuokkala

The Deformation, Strain Hardening, and Wear Behavior of Chromium-Alloyed Hadfield Steel in Abrasive and Impact Conditions

Abstract The alloying of Hadfield steels aims at enhanced mechanical properties and improvements in the wear resistance. In this work, the impact and abrasive properties of a chromium-alloyed high-manganese Hadfield steel were experimentally studied using a wide variety of testing techniques and characterization methods. In addition, an in-service sample was characterized to identify the wear and hardening mechanisms in a real application (jaw crusher). The dynamic mechanical behavior of the steel was determined using the Hopkinson split bar technique. The abrasion properties were studied with three-body abrasion tests using several different natural abrasives. The effects of existing plastic strain and normal loading on the surface hardening and wear rate were further investigated with scratch testing. High-velocity impact testing was performed to evaluate the effect of pre-strain on the impact wear behavior of the material. It was shown that the dynamic loading affects both the yield behavior and the strain hardening rate of the studied steel. The connection between pre-strain, hardness, and wear rate in abrasion was established. In impact conditions, plastic straining of the surface layer first has a positive effect on the wear resistance, but when strain hardening reached the observed ductility limit, it showed an adverse effect on the material’s performance. The addition of chromium and an increase in the manganese content from the nominal ASTM Hadfield composition provided some improvements in the strength, ductility, and surface hardening of the studied steel.

In-vivo deformation measurements of the human heart by 3D Digital Image Correlation

Fast and accurate measurements of the kinetics and deformation of the heart during cardiac surgery can be useful for assessing the best strategies for the protection of the myocardium. While measurements based on ultrasonic technology such as the transesophageal echocardiography are rapidly developing in this direction, also other analysis methods based on optical imaging have been developed within the recent decade. The improved quality of digital cameras and increased computational power of personal computers have led to the development of deformation analysis method known as Digital Image Correlation (DIC). This paper presents preliminary results on the application of the DIC technique on analysing of the movement and deformation of the myocardial movement during a cardiopulmonary bypass surgery. The results show that the natural pattern of the heart should be sufficient for DIC, but better and more accurate results could be obtained with improved contrast conditions. DIC has a potential to be used as a sensitive tool for the surgeon to monitor the cardiac function.

Iterative Determination of the Orientation Relationship Between Austenite and Martensite from a Large Amount of Grain Pair Misorientations

An automatic, iterative method to determine the orientation relationship between parent austenite and martensite is described. The algorithm generates the orientation relationship from grain boundary misorientations through an iterative procedure based on correct symmetry operator assignment. The automatic method is demonstrated to work on both martensitic and bainitic steels and to provide comparable results to a manual grain selection method.

Effect of test parameters on large particle high speed slurry erosion testing

Abstract A high speed slurry-pot wear tester was developed for close-to-reality heavy-duty wear testing of materials used in mineral applications. The samples are attached on four levels in a pin mill configuration. The tester and the developed sample rotation test method deliver reproducible results. This study focuses on the effects of testing parameters in large particle slurry testing. Parameters such as the speed, particle size and slurry concentration were varied. The effect of test duration was also examined. Round steel samples and slurry of water and granite gravel were used for testing. The test parameter variations were 4 to 10 mm for particle size, up to 23 wt-% for concentration and up to 20 m s−1 for the sample tip speed. The relationships between the parameters are discussed. The kinetic energy of the large abrasive particles is also considered. Wear surfaces studied with optical and electron microscopy are also presented and discussed.

Dynamic compression testing of particle-reinforced polymer roll cover materials

Abstract Two polymer composite roll cover materials were studied using dynamic compression tests. The main focus was determination of viscoelastic properties of the materials and development of mathematical models to describe the behavior of these materials in the contact area between two rolls. The compression tests were conducted using short rise time pulses with different durations in servohydraulic materials testing machines. In the modeling, combinations of standard elastic and viscoelastic elements were used together with the Boltzmann superposition principle. A simple spring-dashpot model was found to fit sufficiently to the experimental data with relaxation (retardation) times ranging from a few milliseconds in transient loading tests to tens of hours in static compression tests

Characterization of a Ferritic Stainless Sheet Steel in Simple Shear and Uniaxial Tension at Different Strain Rates

In this study the mechanical properties of ferritic stainless steel EN 1.4521 (AISI 444) were characterized in uniaxial tension and simple shear. The specimen geometries were designed so that tests could be carried out both with a conventional uniaxial materials testing machine and at high strain rates with the Tensile Hopkinson Split Bar method. During the tests, specimen surface deformation was measured using a three dimensional digital image correlation technique based on a two-camera stereovision setup. This technique allowed direct measurement of the specimen gauge section deformation during the test. Test results indicate that the selected approach is suitable for large strain plastic deformation characterization of ductile metals. The stress-strain data obtained from the simple shear tests shows a correlation with the tensile test results according to the von Mises effective stress-strain criterion. Since necking is absent in shear, test data can be obtained at considerably higher plastic strains than in tension. However, the final fracture occurs under a complex loading mode due to the distortion of the specimen geometry and multiaxial loading introduced by the simple shear arrangement. Test results also show that reliable material data can be obtained at high strain rates.Copyright

Investigation of the effect of different cutting parameters on chip formation of low-lead brass with experiments and simulations

Poor chip breakage causes problems in machining of low-lead brass. To improve chip breakage, finite element model simulations were implemented in cutting tool design. Finite element model simulations enable high number of experiments that would be expensive and slow to perform by conventional cutting tests. Compression tests and cutting experiments under different temperatures and strain rates were performed for lead-free brass, to acquire material parameters for the finite element model. It was observed that the coupled effect of thermal softening and rate sensitivity of the material was difficult to take into account with the existing material model. Furthermore, it was found that there are no reported material models that can take rate sensitivity–temperature coupling into account. This was counteracted by fitting the model with least square method to the stress–strain data at the cutting temperature, although this causes error in simulations with temperatures higher or lower than the supposed cutting temperature. Nevertheless, the simulated results proved accurate enough to model the chip breakage. Based on the simulations and experiments, the use of a positive rake angle, high cutting speed and low cutting feed rate improve chip breakage from continuous chip to a chip of average length of 4 mm.

Effects of Strain and Strain Rate on the Abrasive Wear Behavior of High Manganese Austenitic Steel

An abrasive wear analysis of the hardened surface layer in high austenitic manganese steel is presented to determine the effects of plastic strain and strain rate. The pre-deformation levels used in this study represent the typical surface layers resulting from the abrasive contact of Hadfield type steels. The effect of dynamic loading used in the pre-straining is accounted for alongside with various plastic strain levels. A friction study of the surface was included to determine the localization of work hardening and the ability of the microstructure to resist abrasion.

Improved specimen recovery in tensile split Hopkinson bar

This paper presents an improved specimen recovery method for the tensile split Hopkinson bar (TSHB) technique. The method is based on the trapping of residual stress waves with the use of momentum trap bars. As is well known, successful momentum trapping in TSHB is highly sensitive to experimental uncertainties, especially on the incident bar side of the set-up. However, as is demonstrated in this paper, significant improvement in the reliability of specimen recovery is obtained by using two momentum trap bars in contact with the incident bar. This makes the trapping of the reflected wave insensitive to striker speed and removes the need for a precision set gap between the incident bar and the momentum trap.

Impact-abrasion wear of wear-resistant steels at perpendicular and tilted angles

Earth moving and processing machinery has to withstand heavy wear caused by impacts and scratching by the soil. Especially, the edges are subjected to heavy wear. To simulate these conditions, impeller–tumbler impact-abrasion wear testing equipment was used to determine the wear resistance of four steel grades at perpendicular and tilted sample angles. The angles were selected to simulate the loading conditions. Natural granite rock was used as abrasive. The amount of wear was clearly smaller in the harder materials. The significance of hardness was quite similar at both sample angles in the steady-state wear of wear-resistant steels. On the initial state wear, hardness had a slightly greater effect at the perpendicular angle due to more severe wear in sample edges already at the beginning of the test. Overall, the largest differences in wear were observed in the sample edges. At the perpendicular sample angle, the sample edges were much more rounded. Some small differences were observed in the surface formations due to dissimilar movement of the abrasive. Deformed surfaces and fractured lips indicated that wear occurred mainly by the deformation of material followed by the removal of the deformed areas through impacts. In addition, scratches and dents were observed. It was found that larger sized abrasives caused higher mass loss than abrasives of similar mass but smaller size. Moreover, same amount of abrasive particles in each test reduces the scatter of the results.