Metallurgy Commons^™

An Investigation Into The Challenges Of Contemporary Additive Manufacturing: Insights Into The Metallurgical Response Of Materials And Relevant Solution, Huan Ding

LSU Doctoral Dissertations

Additive Manufacturing (AM) has gained attention in recent years due to its unique capabilities in the fabrication of complex parts. As with any new research, there is still a lack of sufficient understanding in the field of additive manufacturing, and further investigation is needed to solve existing problems. Ultimately, the aim is to enable the widespread use of AM components across various industries.

Chapter One provides a brief introduction to the background and current bottlenecks of additive manufacturing technology. Chapter two focuses on the development of high-strength 7075 aluminum alloy (Al7075) for Fused Deposition Modeling and Sintering (FDMS) technology. Al7075 …

Corrosion Case Study On Pipeline, Kangze Ren

Corrosion Research

The Kashagan pipeline leaks were likely caused by sulfur stress corrosion cracking, a combined corrosion mechanism developed by the presence of high pressure, the high level of hydrogen sulfide(the main "ingredient" of sour gas), and poor metallurgical choice. Improper welding and poor metallurgical examination were blamed for causing the leaking issue. The purpose of the current review is to raise the alarm about the inappropriate corrosion management of Kashagan oil production and its societal and environmental consequences.

Machine Learning Prediction Of Hea Properties, Nicholas J. Beaver, Nathaniel Melisso, Travis Murphy

College of Engineering Summer Undergraduate Research Program

High-entropy alloys (HEA) are a very new development in the field of metallurgical materials. They are made up of multiple principle atoms unlike traditional alloys, which contributes to their high configurational entropy. The microstructure and properties of HEAs are are not well predicted with the models developed for more common engineering alloys, and there is not enough data available on HEAs to fully represent the complex behavior of these alloys. To that end, we explore how the use of machine learning models can be used to model the complex, high dimensional behavior in the HEA composition space. Based on our …

Challenges In Optimization For The Performance On Sustainability Dimensions In Reverse Logistics Social Responsibility, Sumarsono Sudarto, Katsuhiko Takahashi, Mochammad Dewo

Makara Journal of Technology

Reverse logistics social responsibility is preferred as the most acceptable solution for addressing the challenges in stakeholders’ debate regarding social responsibility in supply chains because it involves as many actors as possible in the supply chain to perform social responsibility to achieve sustainability. This paper explores the challenges in achieving optimal policies in sustainability dimensions for collection and recycling facilities in reverse logistics. Sustainability dimensions include economic, environmental, and social aspects. The reverse logistics is modeled on System Dynamics, and a simplified statistical analysis using a contour chart is employed in numerical experiments. Results show a narrow area of optimal …

Additive Manufacturing Of High-Performance Nanolamellar Eutectic High-Entropy Alloys, Jie Ren

Doctoral Dissertations

Additive manufacturing, also called three-dimensional (3D) printing, is an emerging technology for printing net-shaped components layer by layer for applications in automotive, aerospace, biomedical and other industries. In addition to the vast design freedom offered by this approach, metal 3D printing via laser powder-bed fusion (L-PBF) involves large temperature gradients and rapid cooling and provides exciting opportunities for producing microstructures and mechanical properties beyond those achievable by conventional processing routes. Although these extreme printing conditions enable microstructural refinement to the nanoscale for achieving high strength. However, high-strength nanostructured alloys by laser additive manufacturing often suffer from limited ductility. Eutectic high-entropy …

Characterization Of Residual Stress And Precipitate Evolution In Aluminum 2xxx Self-Reacting Friction Stir Welds, Benjamin Joe Wing

Doctoral Dissertations

2xxx series aluminum alloys possess attractive properties for structural aerospace applications including high strength to weight ratio, corrosion resistance, and stable cryogenic performance. Solid state joining processes are often employed to reduce weld defects and improve weld performance/consistency as many alloys of this range have poor weldability for traditional fusion based joining techniques. One such process, self-reacting friction stir welding (SRFSW) allows for consistent high-quality, welding of large and curved articles is often used in the construction of large structures such as launch vehicle liquid propellant tanks.

Despite the merits of this process, joint softening (a decrease in mechanical properties …

Investigation Of Microstructure And Mechanical Behavior Of Novel Powder-Extruded Al-Ce-Mg Alloys, Mairym Vazquez

Doctoral Dissertations

Pursuing advanced structural materials with enhanced performance, reduced weight, and lower costs is a constant endeavor in the aerospace and automotive industries. Conventional structural alloys, such as cast irons, carbon steels, and titanium alloys, have strength, weight, and cost limitations. Aluminum-based alloys, known for their lightweight and high strength, have gained popularity in these industries. This dissertation focuses on investigating microstructure and mechanical behavior of novel powder-extruded Al-Ce-Mg alloys as potential candidates for high-performance structural materials.

This research explores using powder extrusion, a well-established forging methodology in the steel industry, to produce Al-Ce-Mg alloys with improved properties and aims to …

Refractory High-Entropy Alloys: Design, Fabrication, Characterization, And Nanoparticle Synthesis, John Hutson Whitlow

Masters Theses

High-Entropy Alloys have been a highly researched area of metals ever since their introduction in 2004 by Brian Cantor and Jien-Weh Yeh. In the continued research of High-Entropy Alloys (HEAs), a specific area concerning Refractory High-Entropy Alloys (RHEAs) has emerged for their high-temperature applications. Although RHEAs have maintained high strength and toughness at high temperatures, their low ductility still needs to be addressed. A dataset was created to find correlations between various characteristics of RHEAs and their composition. A set of seven compositions were selected and fabricated. Mechanical tests were run on the seven compositions, and a proposal was written …

Optimization Of Alti Pld Coating By Increasing Ti Content, N2 And Annealing Which Used For Skd61 Pins In Aluminum Die Casting, Rusman Kosasih, Maria Margaretha Suliyanti Prof, Dedi Priadi, Wisnu Usni

Journal of Materials Exploration and Findings (JMEF)

The Alumunium Titanium Nitrogen (AlTiN) coating is known as one of the best coating materials for protective coating, while Pulsed Laser Deposition (PLD) is a laser coating process used for electric layer and superconductor applications, producing thin films up to 20 µm in thickness. The combination of these two matters has already been researched and is still in progress. One major challenge in the aluminium casting industry is to minimize the damage caused to tool steel pins made from SKD61, when aluminium material sticks to the pin, and halting production. Therefore, research on effective coatings for tool steels and testing …

Calibration Of The Johnson–Cook Model At High Temperatures For An Ultra-High Strength Crnimov Steel, Mario F. Buchely, S. Chakraborty, V. Athavale, Laura Bartlett, Ronald J. O'Malley, D. Field, K. Limmer, K. Sebeck

Materials Science and Engineering Faculty Research & Creative Works

This paper presents a study on the thermo-mechanical behavior of an ultra-high strength CrNiMoV steel at high temperatures and medium strain rates through hot tensile tests. The material was examined in two conditions: as-cast/heat-treated (AC/HT) and as-rolled (AR). Tensile tests were conducted at temperatures of 800,900,1000,1100, and 1200°C, and strain rates of 0.1,1, and 10s−1. Inclusion and porosity analysis was also performed on the tensile specimens. The results revealed that the flow stress decreased by approximately 70% on average from 800°C to 1200°C, while increasing by approximately 32% on average from 0.1s−1 to 10s−1 in strain rate. The elongation exhibited …

Nonmonotonic Effect Of Chemical Heterogeneity On Interfacial Crack Growth At High-Angle Grain Boundaries In Fe-Ni-Cr Alloys, Yuchu Wang, Bita Ghaffari, Christopher Taylor, Simon Lekakh, Carlos Engler-Pinto, Larry Godlewski, Yang Huo, Mei Li, Yue Fan

Electrical and Computer Engineering Faculty Research & Creative Works

An intermittent pattern is observed in the modeling of interfacial cyclic-loading crack growth at high-angle grain boundaries in ternary Fe-Ni-Cr alloys. Different from conventional wisdom of stress-intensity factor, the abrupt crack advances are found driven by extreme value statistics - namely, the aggregation of atoms with most compressive residual stresses. In addition, inherently non-affine atomic stress fluctuations are discovered, and the fluctuations peak at intermediate level of chemical heterogeneity, causing the fastest crack growth. Implications of such nonmonotonic mechanism in regard to the origin of intermediate-temperature embrittlement phenomena are also discussed.

Engineering Heterogeneous Nucleation During Solidification Of Multiphase Cast Alloys: An Overview, Simon (Semen) N. Lekakh, Jingjing Qing

Materials Science and Engineering Faculty Research & Creative Works

The theory of heterogeneous nucleation was initially developed as a part of condensed matter physics, and later it was used as an important engineering tool to design metallurgical processes. This success has led to wide applications of the theory in metallurgical practice. For example, engineering heterogeneous nucleation in ductile iron has been used to reduce shrinkage defects, suppress cementite formation, and modify the size and shape of microstructural constituencies. This demonstrates how theoretical knowledge could benefit industry practice. This overview aims to summarize the authors' published studies in co-authorship with colleagues and students, which covers different aspects of engineering heterogeneous …

Failure Analysis Of Variably Sized 4340 Steel Mandrels Utilized In The Production Of Seamless Superalloy Rings Through The Vertical Ring Rolling Process, Mikhail Alexeyevich Vasilyev, Joshua Brady Venz

Materials Engineering

Vertical ring rolling is a forging process which forms seamless metal rings through applying a large force at elevated temperatures onto component materials stabilized by cylindrical mandrels. Carlton Forge Works, a company which produces rings of superalloy materials such as INCO718 and 718Plus, is experiencing a consistent failure of mandrels due to extreme conditions. An analysis of the lifetime (bulk material, heat treatment, and use) was performed, which aided in the identification of process variables tied to mandrel failure. Experiments were formed surrounding three variables of the mandrel heat treatment: Austenitization temperature, quenching temperature, and tempering conditions, with the goal …

Investigation Into Oxygen Diffusion As It Relates To Alpha Case Formation In Ti-6al-4v Based On Different Forging Thermal Cycles, Tyler J. Meador, Jon Leduc, Francesca Hope

Materials Engineering

An investigation into the growth kinetics of alpha case in Ti-6Al-4V in the presence of oxygen was conducted for different forging thermal cycles. This was done to determine whether the alpha case should be removed after each thermal cycle or as the final step after forging. The thermal cycles consisted of four hours at 1750 °F. Samples were subjected to this treatment one, two, three, and four times along with a continuous sixteen hour hold. Four cycle and Hold samples were subjected to an additional thermal cycle above the beta transus at 1925 °F. These then went through a final …

Improving The Tensile Mechanical Properties Of Direct Energy Deposited (Ded) Inconel 718 Aircraft Components Using A Standard Heat Treatment, Spencer Vincent Flynn

Materials Engineering

This project aimed to improve the mechanical properties of as-printed additively manufactured Inconel 718 samples using a heat treatment usually used for cast and wrought Inconel 718. The mechanical properties sought to be optimized were yield strength, ultimate tensile strength, elongation, and reduction in area. The property goals were to match or exceed those of cast and heat treated Inconel 718. Wire-fed electron beam direct energy deposition (DED) was used to manufacture the samples, which were then heat treated using the AMS 5663 standard in an inert atmosphere. The samples were then tested in tension to obtain data on their …

Effect Of Cr And Ni Concentrations On Resilience Of Cast Nb-Alloyed Heat Resistant Austenitic Steels At Extreme High Temperatures, Simon N. Lekakh, Mario F. Buchely, Mei Li, Larry Godlewski

Materials Science and Engineering Faculty Research & Creative Works

Austenitic Cr–Ni Alloyed Heat Resistant Steels with Nb Additions Are Used for Intensively Thermo-Mechanically Loaded Cast Components Working in Extreme High Temperature Oxidizing Environment. their Performance during Static Oxidation and Transient Thermo-Mechanical Loading Was Investigated to Recommend an Optimal Cost-Effective Cr/Ni Composition of Nb-Alloyed Austenitic Class Steels. the Static Oxidation and Transient Thermo-Mechanical Behavior of Three Austenitic Steels with Different Cr/Ni Alloying Levels Were Investigated and Compared for Variety of Working Conditions. Static Oxidation Was Performed between 900 °C and 1000 °C in Air for 400 H. the Critical Temperature Which Increases Spallation during Static Oxidation Was Determined for Each …

Machinability Of High Mn Steel Using Tool Life Criteria, Dika Handayani, Victor F. Okhuysen, Nicole Wagner

Engineering Faculty Articles and Research

High Mn steel alloys have shown to provide both high strength and ductility. However, current literature offers limited guidance on the machinability of these steel alloys. Therefore, this work provides turning recommendations for high Mn steel that is based on tool life data. Several indexable carbide inserts with various rake angles were used to machine cast billets of high Mn steel. Turning characteristics from various feed rates, cutting speeds, and depths of cut were analyzed. Through a design of experiments, it was determined that the feed rate was the most significant factor affecting tool life and that a tool with …

Classification Of Electrical Current Used In Electroplastic Forming, Tyler Grimm

All Dissertations

Electrically assisted manufacturing (EAM) is the direct application of an electric current to a workpiece during manufacturing. This advanced manufacturing process has been shown to produce anomalous effects which extend beyond the current state of modeling of thermal influences. These purported non-thermal effects have collectively been termed electroplastic effects (EPEs).

While there is a distinct difference in results between steady-state (ideal DC) testing and pulsed current testing, the very definition of these two EAM methods has not been well established. A "long" pulse may be considered DC current; a "short" pulse may produce electroplastic effects; and even "steady-state" current shapes …

Mesoscale Modeling And Machine Learning Studies Of Grain Boundary Segregation In Metallic Alloys, Malek Alkayyali

All Dissertations

Nearly all structural and functional materials are polycrystalline alloys; they are composed of differently oriented crystalline grains that are joined at internal interfaces termed grain boundaries (GBs). It is well accepted that GB dynamics play a critical role in many phenomena during materials processing or under operating environments. Of particular interest are GB migration and grain growth processes, as they influence many crystal-size dependent properties, such as mechanical strength and electrical conductivity.

In metallic alloys, GBs offer a plethora of preferential atomic sites for alloying elements to occupy. Indeed, recent experimental studies employing in-situ microscopy revealed strong GB solute segregation …

A Study Of The Effect Of Machine Parameters On Defects Produced In Eos Additive Manufacturing Builds, Tina White Malone

Doctoral Dissertations

⁵Additive Manufacturing (AM) is defined in the American Society for Testing and Materials (ASTM) standard F2792 as “a process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies. It provides an advanced method for building complex geometries and parts for high performance with a significant cost savings. ⁵⁵It’s advantages include the reduced need for tools and molds commonly used in manufacturing, a large reduction in wasted material, much shorter manufacturing cycles for the building of hardware, and its uniquely inherent ability to produce much more complex shapes. …