Metallurgy Commons^™

Investigation On The Mechanical Properties And Microstructure Analysis Of Micro-Resistance Spot Welding Between Stainless Steel 316l And Tl-6al-4v, Mohd Mansor Muhammad Safwan

Student Works (2020-2029)

In this study, ASS 316L and Ti-6Al-4V were welded together by micro-resistance spot welding (μRSW) at different combinations of welding parameters using specifically design electrode geometry in order to acquire the optimal combination of welding parameters. The welded joint were subjected to tensile shear strength test to determine the influence of welding current, welding time, welding force and different design of elctrode tip on the mechanical properties and the strength of the welded joint. The experiment was conducted by using full factorial design of experiment (DoE) with L27 orthogonal array and utilizing the analysis of variance (ANOVA) to obtain the …

Influence Of Rapid Solidification And Wrought Processing On Precipitation Strengthening And Deformation Mechanisms In Al-Sc-Zr Alloys, Yang Yang

Dissertations, Master's Theses and Master's Reports

Al-Sc-Zr alloys have drawn increasing attention in the last several decades due to their strengthening and coarsening resistance. In this study, solute concentrations of Sc and Zr were increased beyond their equilibrium solubilities without primary precipitate formation using melt-spinning. The melt-spun ribbon was metallurgically bonded into bulk shape using extrusion. With the proper aging treatment, the mechanical properties of the supersaturated melt-spun ribbon and extruded rod were found to be significantly higher than a baseline dilute alloy. Increased mechanical properties include microhardness, tensile strength at ambient-temperature, and compressive strength and threshold stress at and elevated-temperature. These increases were related to …

Contamination Of Coupling Glass And Performance Evaluation Of Protective System In Vacuum Laser Beam Welding, Yongki Lee, Jason Cheon, Byung-Kwon Min, Cheolhee Kim

Mechanical and Materials Engineering Faculty Publications and Presentations

Vacuum laser beam welding enables deeper penetration depth and welding stability than atmospheric pressure laser welding. However, contaminated coupling glass caused by welding fumes in the vacuum space reduces laser transmittance, leading to inconsistent penetration depth. Therefore, a well-designed protective system is indispensable. Before designing the protective system, the contamination phenomenon was quantified and represented by a contamination index, based on the coupling glass transmittance. The contamination index and penetration depth behavior were determined to be inversely proportional. A cylindrical protective system with a shielding gas supply was proposed and tested. The shielding gas jet provides pressure-driven contaminant suppression and …

Modifying Casting Parameters To Improve The High Temperature Ductility Of Investment Cast Nickel-Based Superalloy Pwa 1455, Lars Alexander Hedin, Cole Magnum Introligator

Materials Engineering

PCC Structurals, an industry leader in superalloy investment castings, has observed inconsistencies in the stress rupture performance of polycrystalline nickel-based superalloy PWA 1455. PCC has changed their casting parameters to reduce the thermal gradient during cooling but have been unable to correlate these changes with an increase in stress rupture elongation. Metallographic examination of past samples indicated microstructures composed of non- equiaxed dendritic grains with mean diameter of .021 inches along the test axis. A similar study on polycrystalline superalloys has indicated that excessive superheat temperatures above the liquidus can result in large grains identical to those observed, limiting the …

Investigating Microalloying Elements To Accelerate Zirconium Trialuminide Precipitation In Aluminum Alloys, Philip D. Staublin

Dissertations, Master's Theses and Master's Reports

Precipitation of the L1₂-structured coherent Al₃Zr trialuminide phase in aluminum-zirconium alloys increases the alloy strength. Precipitation of a more refined dispersion of Al₃Zr can further increase the strength of these alloys. The addition of microalloying elements which bind to zirconium may accelerate the precipitation kinetics, allowing for nucleation of a greater number of precipitates and faster precipitate growth. Zirconium binding energies are computed for a wide range of elements, based on which the elements tin, antimony, and tellurium were selected for investigation. Ternary Al-Zr-X alloys (X = Sn, Sb, Te) were cast and heat …

Compensation Of Vertical Position Error Using A Force–Deflection Model In Friction Stir Spot Welding, Jinyoung Yoon, Cheolhee Kim, Sehoon Rhee

Mechanical and Materials Engineering Faculty Publications and Presentations

Despite increasing need for friction stir spot welding (FSSW) for high-temperature softening materials, system deflection due to relatively high plunging force remains an obstacle. System deflection results in the vertical position error of a welding tool and insufficient plunge depth. In this study, we used adaptive control to maintain plunge depth, the plunging force was coaxially measured, and the position error was estimated using a force–deflection model. A linear relationship was confirmed between the force and deflection; this relationship is dependent on the stiffness of the welding system while independent of process parameters and base materials. The proposed model was …

Prediction Of Metal Sample Failure From Scanning Electron Microscope Images Using Deep Learning Neural Network, Lawrence Madriaga, Ivan Novikov, Morteza Nurcheshmeh

Posters-at-the-Capitol

We present the preliminary results on using a deep learning neural network to predict a metal sample failure based on a set of images obtained with a Scanning Electron Microscope.

Various metal alloy samples were prepared according to ASTM E8/E8M-11 standards for a tensile test. Each sample was prepared for circle grid analysis and then stressed on a tensile machine. Stress and strain values were obtained for each position along the sample by measuring dimensions of each elongated circle. Increasing stress and strain values were found closer to the breakage of the sample with low values found at the holding …

Modeling And Simulation Of Mass Flow Of Steel Plate/Slab During Hot Rolling, X. Wang, S. Ganguly, K. Chandrashekhara, Mario F. Buchely, Semen Naumovich Lekakh, David C. Van Aken, Ronald J. O'Malley, D. Bai, Y. Wang, T. Natarajan

Mechanical and Aerospace Engineering Faculty Research & Creative Works

The ability to predict mass flow behavior during hot rolling is essential to product quality. In this study, viscoplastic models of the steels from SSAB and U.S. Steel were developed based on experimental stress-strain curves. A three-dimensional nonlinear finite element model was built to simulate a reverse plate hot rolling and a hot strip rolling process. For plate rolling, a seven pass schedule was simulated. The plastic strain distributions during rolling were investigated. The results show that the surface of the plate has larger plastic strain than the center. In the case of hot strip rolling, the simulation predicts that …

Anomalous 304 Stainless Steel Mechanical Properties In Medical Guide Wires, Andrew Joseph Freeman

Materials Engineering

Stainless steel medical guide wire cores, processed by Abbott Vascular, are returning anomalous mechanical properties upon strain hardening and heat treatment. As theory dictates, mechanical strength properties increase with strain hardening, and decrease with an annealing treatment. The opposite response is being observed. This is counter intuitive to fundamental materials knowledge, and a perfect materials engineering paradox. This project was designed to characterize these behaviors, and attempt to determine causation. To accomplish this, tensile testing of all processing steps mapped the mechanical property evolution of the wire. Published literature research revealed the potential of nitrogen and chromium solid state diffusion …

The Effects Of Varying Composition And Build Direction On Direct Metal Deposition Fabricated Inconel 718, Abigail P. Nilan, Jessica M. Fordham

Materials Engineering

Inconel 718 (IN718) is a popular wrought superalloy, and is currently being investigated for additive manufacturing (AM) applications in the aerospace industry. However, overaging and the presence of microcracks have caused a significant reduction in properties. The purpose of this study is to meet or exceed the mechanical properties of wrought IN718 by varying the composition and build direction of the AM alloy. Alternative compositions were selected with Oerlilon Metco’s Rapid Alloy Development (RAD) software, and differ in niobium content, which increases the fraction of the primary strengthening phase (γʺ). Direct metal deposition (DMD) was used to fabricate the samples, …

Direct Strength Approach To Predict The Flexural Strength Of Cold-Formed Z-Section Purlins On Sloped Roofs, Ali Parva, Michael W. Seek

Engineering Technology Faculty Publications

In this study, the strength of cold-formed Z-section purlins is predicted considering the effects of roof slope in real roof systems. The study applies to simple span purlins with torsion restraints at support locations and at paired locations along the length of the member. A previously developed method has shown through comparisons to base tests that when the biaxial bending and torsion stresses are incorporated into the analysis, the Direct Strength Method can accurately predict the strength of a purlin. These stress distributions can deviate substantially from the constrained bending approximation typically assumed in analysis and therefore impacts the local …

A Microstructure-Based Model Validated Experimentally For Quantification Of Short Fatigue Crack Growth In Three-Dimensions, Pei Cai

Theses and Dissertations--Chemical and Materials Engineering

Built on the recent successes in understanding the crystallographic mechanism for short fatigue crack (SFC) growth across a grain boundary (GB) and developing an experimental method to quantify the GB resistance against short crack growth, a microstructure-based model was developed in this study to simulate the growth behaviors of SFCs in 3-D, by taking into account both the driving force and resistance along at each point along the crack front in an alloy. It was found that the GB resistance was a Weibull function of the minimum twist angle of crack deflection at the boundary in AA2024-T3 Al alloys. In …

The Formation Mechanism Of Α-Phase Dispersoids And Quantification Of Fatigue Crack Initiation By Experiments And Theoretical Modeling In Modified Aa6061 (Al-Mg-Si-Cu) Alloys, Gongwang Zhang

Theses and Dissertations--Chemical and Materials Engineering

AA6061 Al alloys modified with addition of Mn, Cr and Cu were homogenized at temperatures between 350 ^ºC and 550 ^ºC after casting. STEM experiments revealed that the formation of α-Al(MnFeCr)Si dispersoids during homogenization were strongly affected by various factors such as heating rate, concentration of Mn, low temperature pre-nucleation treatment and homogenization temperature. Through analysis of the STEM results using an image software Image-Pro, the size distributions and number densities of the dispersoids formed during different annealing treatments were quantitatively measured. It was revealed that increasing the heating rate or homogenization temperature led to a reduction of …

Analysis And Modeling Of The Growth Of Intermetallic Compounds In Aluminum–Steel Joints, Gang Zhang, Manjiao Chen, Yu Shi, Jiankang Huang, Fuqian Yang

Chemical and Materials Engineering Faculty Publications

In this work, we experimentally and numerically studied the microstructures and growth of intermetallic compounds (IMCs) formed in Al–Fe (aluminum–steel) joints welded by a pulsed double electrode gas metal arc welding (DE-GMAW)-brazing method. The IMCs consist of Fe₂Al₅ and FeAl₃, with Fe₂Al₅ being the main compound in the joints. The thickness of an IMC layer increases with an increase of the welding current (heat input) into the base metal. EBSD measurement suggests that the preferred crystal orientation of the Fe₂Al₅ IMC likely provides the necessary path for Al atoms …

The Mechanism Of Radiation-Induced Nanocluster Evolution In Oxide Dispersion Strengthened And Ferritic-Martensitic Alloys, Matthew John Swenson

Boise State University Theses and Dissertations

The objective of this study is to evaluate the mechanism of irradiation-induced nanoparticle evolution in a model Fe-9%Cr oxide dispersion strengthened steel and commercial ferritic-martensitic alloys HCM12A and HT9. Each alloy is irradiated with Fe²⁺ ions, protons, or neutrons to doses ranging from 1-100 displacements per atoms at 500°C. The morphology of nanoclusters are characterized using atom probe tomography. The evolution of clusters in each alloy are notably different with each irradiating particle, and the competing effects of ballistic dissolution and radiation-enhanced, diffusion-driven growth are attributed to the respective differences in cluster evolution. A phase evolution model, originally theorized …

Characterization Of Slm Printed 316l Stainless Steel And Investigation Of Microlattice Geometry, Finley H. Marbury

Materials Engineering

The goal of this project was firstly to characterize Cal Poly’s SLM printed 316L stainless steel. SEM analysis showed Cal Poly’s as-printed 316L material to have a cellular dendritic microstructure containing mostly austenite and a small amount of δ-ferrite. After being heat treated to eliminate warp, its yeild and ultimate tensile strength were on par with the literature, however higher modulus and lower elongation were observed. XRD analysis confirmed residual stresses in the material, and that grains are preferentially oriented in both heat treated and non heat treated samples. The amount of porosity in the material was found to be …

Development Of Low Cost Braze Alloys For Aerospace Applications, Alyssa M. Elliott, Sandy Babich, Blake Whitmee

Materials Engineering

Non-precious metal braze alloys can help lower the cost of brazing, which is a commonly-used joining process in the aerospace industry. A-286, a stainless steel superalloy, and Inconel© 718, a nickel-based superalloy, are both commonly used alloys at Aerojet Rocketdyne. Both alloys were brazed into butt joints using nickel-based braze alloys: AMS 4776, 4777, and 4778. The brazed samples were machined into a modified version of the ASTM E8 subsize specimen samples and tensile tested to compare the strength and calculated elongation of the brazed samples to the base metals’ properties. All of the brazed samples fractured at the joint, …

Fabrication And Study Of The Structure And Magnetism Of Rare-Earth Free Nanoclusters, Bhaskar Das

Department of Physics and Astronomy: Dissertations, Theses, and Student Research

No abstract provided.

Tensile Specimen Punch, John Allen

All Undergraduate Projects

This project comes from a need to have tensile specimens made for the MET 351, Metallurgy/Materials and Processes, and 426, Applied Strengths of Materials, labs. This punch is designed to be used with an arbor press to create the desired tensile specimen shape out of plastic blanks. The initial concept was suggested by Dr. Craig Johnson. The designs went through many changes, for example getting rid of the sides originally proposed to hold the specimen in place, and modifications to other parts to make them more efficient. Additional parts were also added to the design with the help and advice …

Control Of Columnar To Equiaxed Transition In Solidification Macrostructure Of Austenitic Stainless Steel Castings, Semen Naumovich Lekakh, Ronald J. O'Malley, Mark C. Emmendorfer, Brenton Hrebec

Materials Science and Engineering Faculty Research & Creative Works

Solidification macrostructure is of great importance for the properties and the quality of castings made from austenitic grade stainless steels (ASS) because there are limited options to change as-cast macrostructure in the solid condition. A typical cast macrostructure of ASS has a fine surface chilled zone followed by an elongated dendrite zone, columnar to equiaxed transition (CET) zone, and centrally located equiaxed crystals. Several castings from ASS were produced to determine the effects of casting geometry, chilling, and grain refinement on CET. The transient thermal field in solidified heavy castings was simulated and used to determine an isotherm velocity (V) …

Pitting Corrosion Of 410 Stainless Steel In Hcl Solutions, Paul D. Krell

Williams Honors College, Honors Research Projects

410 stainless steel (SS) is a material used in HCl services, such as distillation column trays in oil refineries. Unlike other alloys, however, the oil refining industry lacks a good reference for the corrosion rate of 410 SS at the varying HCl concentrations and temperatures the material might experience as trays in crude unit distillation columns. The goal of this project is to fill that knowledge gap. The corrosion behavior of 410 SS in HCl environments of pH 0.50, 1.25, 2.25, 3.25, and 4.25 at temperatures of 38, 52, 79, and 93°C was investigated using several methods. Cyclic potentiodynamic polarization …

Microstructures And Properties Of Sintered Cu–Mos2/Cu Functional Gradient Materials, Aiqin Wang

The 8th International Conference on Physical and Numerical Simulation of Materials Processing

No abstract provided.

(Alpha + Gamma) Ultrafine Duplex Structure Formation In Twophase Stainless Steel By High-Pressure Torsion And Annealing, Mie Ota, Kei Ameyama, Daiki Nanya, Sanjay Kumar Vajpai

The 8th International Conference on Physical and Numerical Simulation of Materials Processing

No abstract provided.

Study On The Impact Abrasive Wear Of New Super-High Manganese Steel, Wenyan Wang

The 8th International Conference on Physical and Numerical Simulation of Materials Processing

No abstract provided.

A Bubble Floatation Process For Purification Of Aluminum Foundry Alloys, Jianmin Zeng, Li Luo, Ling Chen, Jiacheng Wang, Yafei Duan

The 8th International Conference on Physical and Numerical Simulation of Materials Processing

No abstract provided.

Oxidation And Mechanical Properties Of In Situ Hybrid (Ticp+Tibw)/Ti6al4v Composites With Tailored Network Microstructure, L. J. Huang, X. P. Cui, Y. Jiao, T. B. Duan, X. T. Li, Y. N. Gao, L. Geng

The 8th International Conference on Physical and Numerical Simulation of Materials Processing

No abstract provided.

Void Closure And The Sensitivity Analysis Of The Process Parameters During Forging Of Large Steel Ingot, Bo Jiang, Yazheng Liu, Jianlin Sun, Guanglei Liu, Zhilin Wang, Zhigang Zhao

The 8th International Conference on Physical and Numerical Simulation of Materials Processing

No abstract provided.

Materials Processing For Building High Field Magnets, Ke Han

The 8th International Conference on Physical and Numerical Simulation of Materials Processing

No abstract provided.

Thermal Simulation Of The Steel Solidification During Continuous Casting, Honggang Zhong, Zhiqiang Wei, Renxing Li, Qijie Zhai

The 8th International Conference on Physical and Numerical Simulation of Materials Processing

No abstract provided.

The Study On Kinetics Of Metadynamic Recrystallization Of A Nb–V Microalloyed Non-Quenched And Tempered Steel, Li-Wen Zhang, Wen-Fei Shen, Chi Zhang, Ying-Nan Xia, Xin-Hua Shi, Fei Xia

The 8th International Conference on Physical and Numerical Simulation of Materials Processing

No abstract provided.