Metallurgy Commons^™

Studying Chromium And Nickel Equivalency To Identify Viable Additive Manufacturing Stainless Steel Chemistries, Zachary T. Hilton, Joseph William Newkirk, Ronald J. O'Malley

Materials Science and Engineering Faculty Research & Creative Works

Chromium and nickel equivalency modeling has long been used in welding to determine the weldability of steel chemistries. A study was conducted to determine the applicability of Cr-Ni modeling to the additive manufacturing process. Many AM methods involve rapid solidification of small melt pools, similar to welding. Chemistries with varying Cr/Ni ratios were selected for use in a selective laser melting process and modeled using known models. Initial results indicate that the standard "safe welding zone" may not directly apply to additive manufacturing. The capability to build with chemistries outside the weldability “safe zone” could result in improved and varied …

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) …

Strain Phase Separation: Formation Of Ferroelastic Domain Structures, Fei Xue, Yongjun Li, Yijia Gu, Jinxing Zhang, Long-Qing Chen

Materials Science and Engineering Faculty Research & Creative Works

Phase decomposition is a well-known process leading to the formation of two-phase mixtures. Here we show that a strain imposed on a ferroelastic crystal promotes the formation of mixed phases and domains, i.e., strain phase separation with local strains determined by a common tangent construction on the free energy versus strain curves. It is demonstrated that a domain structure can be understood using the concepts of domain/phase rule, lever rule, and coherent and incoherent strain phase separation, in a complete analogy to phase decomposition. The proposed strain phase separation model is validated using phase-field simulations and experimental observations of PbTiO …

Protective Conversion Coating On Mixed-Metal Substrates And Methods Thereof, Matthew O'Keefe, Surender Maddela

Materials Science and Engineering Faculty Research & Creative Works

Mixed-metal automotive vehicle bodies-in-white comprising ferrous metal surfaces, zinc surfaces, aluminum alloy surfaces, and magnesium alloy surfaces are cleaned and immersed in an aqueous bath comprising an adhesion promoter and an aqueous electrocoat bath (the adhesion promoter may be in the electrocoat bath. The adhesion promoter, which may be a cerium salt, is selected to react with each metal in the body surfaces to form an oxide layer that provides corrosion resistance for the surface and adherence for the deposited polymeric paint coating. The body is cathodic in the electrocoat deposition.

Modeling And Experimental Investigation Of Pre-Mixed Multi-Powder Flow In Fabricating Functional Gradient Material By Laser Metal Deposition Process, Wei Li, Jingwei Zhang, Sreekar Karnati, Yunlu Zhang, Frank W. Liou, Joseph William Newkirk, Karen M. Brown Taminger, W. L. Seufzer

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Laser Metal Deposition (LMD) is an effective process to fabricate Functionally Graded Material (FGM) from pre-mixed powders. Since the supplied multi-powder directly affects the deposited FGM’s composition, investigation on Pre-Mixed Multi-Powder (PMMP) flow during LMD is greatly needed. This paper presents a comprehensive numerical PMMP flow model. By solving discrete particle force balance equations coupled with continuity equations and momentum equations for carrier gas, the dynamic behavior of PMMP flow through powder feeder tube and out of nozzle was calculated. With this model, the particle sizes of multi-powder were optimized to obtain considered FGM composition. To verify the modeling results, …

Effect Of Powder Particle Size On The Fabrication Of Ti-6al-4v Using Laser Metal Deposition From Elemental Powder Mixture, Xueyang Chen, Lei Yan, Wei Li, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

Direct Laser Metal Deposition (LMD) was used to fabricate thin-wall Ti-6Al-4V using the powder mixture of Ti-6 wt.%Al-4 wt.%V. Scanning electron microscopy (SEM), optical microscopy (OM) and energy dispersive spectroscopy (EDS) were employed to examine the chemical composition and microstructure of the as-deposited sections. Vickers hardness tests were then applied to characterize the mechanical properties of the deposit samples which were fabricated using pre-mixed elemental powders. The EDS line scans indicated that the chemical composition of the samples was homogenous across the deposit. X-ray diffraction (XRD) was used for the phase identification. After significant analysis, some differences were observed among …

Proposed Hybrid Processes For Part Building Using Fusion Welding And Friction Stir Processing, Megan A. Gegesky, Frank W. Liou, Joseph William Newkirk

Mechanical and Aerospace Engineering Faculty Research & Creative Works

It has been shown that a hybrid laser additive manufacturing and friction stir processing can deposit components with forged-like structures. This paper reports a hybrid fusion welding and friction stir process to create parts with quality structures. Combining traditional fusion welding and friction stir processing techniques for non-weldable aluminum alloys could facilitate the joining of difficult geometries in manufactured parts. This research illustrates mechanical property changes for non-weldable and weldable aluminum alloys. The Vickers hardness, and microhardness in the case of AA5052-H32, tensile strength and corrosion resistance of four processing states: base material, fusion welded material, friction stir welded material, …

A Study On Non-Metallic Inclusions In Foundry Steel Process, Marc Leonard Harris

Masters Theses

"The effects of sample area and automated SEM/EDS feature analysis parameters (step size, magnification and threshold) on nonmetallic inclusion characterization results has been investigated and optimized. A post-processing program was developed to automatically determine average inclusion chemistry, total element concentrations within inclusions, and for generating joint ternary diagrams with size visualization for representing nonmetallic inclusion populations. Using these tools the evolution of nonmetallic inclusions was examined for 4320 steel at a participating industrial steel foundry. The steel was sampled throughout electric arc furnace melting through ladle refining to the final casting where an in-mold sampling procedure was developed to procure …

Structure And Corrosion Behavior Of Sputter Deposited Ce-Al-O Coating On Al 2024-T3 Alloy Substrates, Yuanyuan Liu, Jiamu Huang, James B. Claypool, Matthew J. O'Keefe

Materials Science and Engineering Faculty Research & Creative Works

Deposition of Ce-Al-O coatings on Al 2024-T3 alloy substrates was conducted by magnetron co-sputtering of CeO₂ and Al targets. The incorporation of Al into the CeO₂ film resulted in an amorphous or nanocrystalline structure with binding energy states different from Al, Al₂O₃, and CeO₂. Electrochemical measurements indicated that the amorphous or nanocrystalline Ce-Al-O coating increased the corrosion resistance of bare Al 2024-T3 substrates by more than three orders of magnitude and exhibited a very different cathodic and anodic protective mechanism compared to Al and CeO₂ coated and as-polished Al 2024-T3 samples. …

Evolution Of Non-Metallic Inclusions In Foundry Steel Casting Processes, Marc Harris, Von Richards, Ronald J. O'Malley, Semen Naumovich Lekakh

Materials Science and Engineering Faculty Research & Creative Works

The evolution of nonmetallic inclusions was examined for 4320 steel at an industrial steel foundry. The steel was followed from electric arc furnace melting through ladle refining to final casting. Timed sampling was performed at all stages of the process. Samples were analyzed using an automated SEM/EDS system. The overall evolution of oxide inclusions in terms of nucleation, growth, and flotation during liquid processing was studied using area fraction and average diameter. Chemical composition evolution was observed using a joint ternary plotting tool developed under this program. It was found that the use of zirconium as an addition for nitrogen/oxygen …

Structure And Corrosion Behavior Of Sputter Deposited Cerium Oxide Based Coatings With Various Thickness On Al 2024-T3 Alloy Substrates, Yuanyuan Liu, Jiamu Huang, James B. Claypool, Carlos E. Castano, Matthew J. O'Keefe

Materials Science and Engineering Faculty Research & Creative Works

Cerium oxide-based coatings from ∼100 to ∼1400 nm in thickness were deposited onto Al 2024-T3 alloy substrates by magnetron sputtering of a 99.99% pure CeO₂ target. The crystallite size of CeO₂ coatings increased from 15 nm to 46 nm as the coating thickness increased from ∼100 nm to ∼1400 nm. The inhomogeneous lattice strain increased from 0.36% to 0.91% for the ∼100 nm to ∼900 nm thick coatings and slightly decreased to 0.89% for the ∼1400 nm thick coating. The highest adhesion strength to Al alloy substrates was for the ∼210 nm thick coating, due to a continuous …

Laser Metal Deposition Of Functionally Gradient Materials From Elemental Copper And Nickel Powders, Sreekar Karnati, Todd E. Sparks, Frank W. Liou, Joseph William Newkirk, Karen M. Brown Taminger, William J. Seufzer

Mechanical and Aerospace Engineering Faculty Research & Creative Works

This work deals with the planning and fabrication of a functionally gradient copper-nickel composition via Laser Metal Deposition (LMD). Various compositions of copper and nickel were made by blending different weight percentages which were then sequentially deposited to fabricate functionally gradient copper-nickel thin-wall structures. Analyses were performed by sectioning the thin-wall samples for metallographic, hardness, X-ray diffraction (XRD) and Energy Dispersive X-ray Spectroscopy (EDS) studies. The fabrication was studied for identifying and corroborating the deposited compositions and their corresponding gradients. XRD analyses were performed to identify the crystal structure of the deposit. EDS analysis was instrumental in identifying the variation …

Enhancing Grain Refinement Of Austenitic Steel With Ti Additions By Melt Treatment Sequence Optimization, Gun Ge, Semen Naumovich Lekakh, Ronald J. O'Malley

Materials Science and Engineering Faculty Research & Creative Works

No abstract provided.

Containment Materials For Thin-Strip Casting Of Steel, Abhishek Kumar

Doctoral Dissertations

"The focus of this research was to investigate the corrosion behavior of BN-based and ZrO₂-C refractories by molten steel. These refractories are used as side-dam and core-nozzle in the thin-strip casting of steel. The improvement and development of these refractory components will increase the process efficiency by prolonging the refractory service life.

The first part of this study focused on interaction of BN-ZrO₂-SiC side-dams with steel-inclusion system in a laboratory setup under argon gas environment. It was observed that corrosion of this ceramic was severe in contact with steel compared to slag/inclusion.

The second part of …

Formation And Evolution Of Spinel In Aluminum Killed Calcium Treated Linepipe Steels, Obinna Adaba

Masters Theses

"Magnesium aluminate (Spinel) inclusions have been observed to cause hook crack in line pipe steels. These inclusions are typically formed during liquid steel processing at the ladle metallurgy furnace (LMF) and subsequently modified by calcium to form less harmful liquid inclusions. Unfortunately, spinel inclusions are still sometimes observed in samples taken from the tundish and coil after calcium treatment.

The formation and evolution of spinel inclusions during liquid steel processing at two industrial mini mills was investigated by analysis of lollipop samples taken at different stages of the steelmaking process. The effect of reoxidation on the formation of spinels after …

Factors Affecting The Heat Transfer During The Dip Testing Of Potential Third Generation Advanced High Strength Steels, Kramer Michael Pursell

Masters Theses

"A dip tester was designed and built at Missouri University of Science and Technology to test the effects of the primary alloying elements (Mn, Si, and Al) of Fe-Mn-Al-Si-C type 3rd generation advanced high strength steel (AHSS) alloys, dipping superheat, and dipping speed on the heat transfer during rapid solidification. The difficulties associated with casting 3rd generation AHSS were compiled as well to serve as a best-practices guide. An extensive list of potential 3rd generation AHSS alloys was developed and tested, and the effects of various dip testing parameters were examined.

Manganese was found to increase the heat flux by …

Understanding Impurities In Copper Electrometallurgy, Paul Laforest

Masters Theses

"This work involves examining two industrial reports of methods to handle impurities in copper electrowinning and electrorefining. The first part evaluates the addition of Hydrostar, Cyquest N-900, DXG-F7, and Guartec EW to copper electrowinning electrolyte to affect MnO₂ deposition on coated titanium anodes (CTAs). The second part examines the effects of anode chemistry and thiourea addition on the ductility of electrorefined copper starter sheet.

In part one, a laboratory cell was used to simulate a short cycle electrowinning cell via chronopotentiometric operation with an IrO₂-Ta₂O₅ CTA at 40⁰C. A cyclic voltammetric sweep was applied …

Metallurgical Optimization Of High Strength Cast Steels With Stage I Tempering, Terrell Owen Webb Jr.

Doctoral Dissertations

“Eglin steel was developed by the U.S. Air Force and Ellwood National Forge Company as a cost-effective, ultrahigh strength steel for use in armament, aerospace, and commercial applications. Eglin steel has been successfully substituted for high alloy steels, such as AF1410 and HP-9-4-20/30, to produce the casing for “bunker buster” bombs where penetration of concrete barriers and rock at high velocity ( > 1000 ft/sec) is desired. Unlike AF1410 and HP-9-4-20/30, Eglin steel is low nickel (nominal 1 wt.%) and contains no cobalt. Given the successful performance of Eglin steel in the casings applications, the Department of Defense has directed that …

Thermodynamics And Crystallography Of The Γ→Ε→Α' Transformation In Femnalsic Steels, Scott Thomas Pisarik

Masters Theses

"FeMnAlSiC steels which exhibit two-stage transformation induced plasticity (TRIP) behavior characterized by the γ→ε→α' dual stage martensitic transformation promise to take a leading role in the development of 3rd generation advanced high strength steels. The crystallographic orientation relationship of the γ→α' and γ→ε athermal martensitic transformations in these steels has been determined as the Kurdjumov-Sachs and the Shoji-Nishiyama, respectively. Six crystallographic variants of α-martensite consisting of three twin-related variant pairs were observed in ε- bands. A planar parallelism of {0001}ε || {110}α' and a directional relation of α' lying within 1⁰ of ε existed for these variants. Two regular solution …

Crystallographic Orientation Of The Ε → Α' Martensitic (Athermal) Transformation In A Femnalsi Steel, S. T. Pisarik, D. C. Van Aken

Materials Science and Engineering Faculty Research & Creative Works

The presence of a thermal ε- and α-martensite (α') in the as-cast structure of a Fe-_0.08C-_1.95Si-_15.1Mn-_1.4Al-_0.017N alloy has been revealed by electron backscattered diffraction analysis. The alloy exhibited two a thermal martensitic transformation described by γ → α' and γ → ε → α'. The Shoji-Nishiyama orientation relationship was observed between γ-austenite and ε-martensite, while α-martensite nucleated from γ-austenite exhibited a Kurdjumov-Sachs orientation relationship. Six crystallographic variants of α-martensite consisting of three twin-related variant pairs were observed in ε-bands. A planar parallelism of {0001}ε || {110}α' and a directional relation …

A Preliminary Study Of Deformation Behavior Of Friction Stir Welded Ti-6al-4v, Jiye Wang, Jianqing Su, Rajiv S. Mishra, Ray Xu, John A. Baumann

Materials Science and Engineering Faculty Research & Creative Works

A preliminary study of deformation behavior of friction stir welded (FSW) Ti-6Al-4V was performed using two different tools with cylindrical and stepped spiral pin design for the welding process. The nugget regions experienced temperature above β transus and the matrix transformed to fine acicular α during cooling of the nugget. By using stepped spiral pin design, a local region with much refined grain structure and significant tool debris particles were observed. Room temperature tensile test showed increased strength and decreased ductility in the material from this region. Fractographic analysis revealed that tool debris particles served as void nucleation sites. Tensile …

An Evaluation Of Creep Behaviour In Friction Stir Welded Ma754 Alloy, Jiye Wang, Wei Yuan, Rajiv S. Mishra, Indrajit Charit

Materials Science and Engineering Faculty Research & Creative Works

Effect of friction stir welding (FSW) on microstructure and creep properties of oxide dispersion strengthened (ODS) alloy MA754 were investigated. Fine-grained microstructure developed in the weld zone. TEM results showed some degree of particle agglomeration as a result of intense material flow. Creep tests of the FSW material were carried out at 973 and 1073 K. Power law creep behavior was observed with stress exponent values of 6.9 and 6.3 at 973 and 1073 K, respectively. The results were compared to those of the as-received material. Creep resistance of FSW material was lower than that of as-received material associated with …

Scrap Dissolution In Molten Iron Containing Carbon For The Case Of Coupled Heat And Mass Transfer Control, Ajay Kumar Shukla, Brahma Deo, D. G.C. Robertson

Materials Science and Engineering Faculty Research & Creative Works

The scrap dissolution in an actual process like the BOF is affected both by mass transfer and heat transfer. In this paper, the mass transfer of carbon in liquid melt is considered along with heat transfer. The approaches used in this paper to model the scrap dissolution phenomenon include the application of Green's function, quasi-static, integral profile, and the finite difference approach for different Biot numbers. Mass transfer coefficients are calculated using the Chilton-Colburn's analogy for the case of forced convection. Since the quasi-static approach requires the least computational time, it is used for a detailed parametric study, including the …

Role Of Air Gap In Scrap Dissolution Process, Ajay Kumar Shukla, Brahma Deo, D. G.C. Robertson

Materials Science and Engineering Faculty Research & Creative Works

The role of the air gap formed between scrap and a solidified metal shell at the beginning of the scrap dissolution process has been investigated. The effect of air gap has been investigated for different Biot numbers (10 to 100) and ratios of air gap to liquid melt heat transfer coefficient (0.1 to 0.9). The predictions of the mathematical model are compared with the experimental results reported elsewhere. The role of air gap is found to be significant only for low Biot numbers (< 50) and for low ratios of air gap to liquid melt heat transfer coefficient (< 0.25). © 2013 The Minerals, Metals & Materials Society and ASM International.

Microstructural Evolution And Mechanical Properties Of Friction Stir Welded Ods Alloy Ma754, Jiye Wang, Wei Yuan, Rajiv S. Mishra, Indrajit Charit

Materials Science and Engineering Faculty Research & Creative Works

Microstructural evolution and mechanical properties of MA754, an yttrium oxide dispersion-strengthened nickel-based superalloy, were investigated after friction stir welding (FSW). A tool rotation rate of 1000 revolution per minute and a traverse speed of 50.8 mm per minute were employed using a cermet (WC-Co) tool. After FSW, fine equiaxed grain structure with a high dislocation density and a random texture was achieved. Agglomeration of yttrium oxide dispersoids was observed in FSW MA754. Room-temperature tensile properties of FSW MA754 were compared to those of as-received MA754 alloy, and the results indicated that particle strengthening contribution decreased as a result of dispersoid …

Additivity Of Strengthening Mechanisms In Ultrafine Grained Al-Mg-Sc Alloy, N. Kumar, R. S. Mishra

Materials Science and Engineering Faculty Research & Creative Works

In the light of unique and anomalous properties of ultrafine grained (UFG) alloys, an effort was made to develop a predictive capability of the yield strength (YS) of UFG Al-Mg-Sc alloy. UFG microstructure was introduced using friction stir processing. Microstructural characterization of grain size, dislocations, and nano-sized Al3(Sc,Zr) particles was carried out using electron backscatter diffraction and transmission electron microscope. The contribution from Peierls-Nabarro stress, solid solution strengthening, precipitation strengthening, grain boundary strengthening, and dislocation strengthening were assessed using existing strengthening models. Additivity law to predict the YS of the alloy was chosen based on the microstructural state of the …

Probabilistic Simulation Of Solidification Microstructure Evolution During Laser-Based Metal Deposition, Jingwei Zhang, Frank W. Liou, William Seufzer, Joseph William Newkirk, Zhiqiang Fan, Heng Liu, Todd E. Sparks

Mechanical and Aerospace Engineering Faculty Research & Creative Works

A predictive model, based on a Cellular Automaton (CA) - Finite Element (FE) method, has been developed to simulate microstructure evolution during metal solidification for a laser based additive manufacturing process. The macroscopic FE calculation was designed to update the temperature field and simulate a high cooling rate. In the microscopic CA model, heterogeneous nucleation sites, preferential growth orientation and dendritic grain growth kinetics were simulated. The CA model was able to show the entrapment of neighboring cells and the relationship between undercooling and the grain growth rate. The model predicted the dendritic grain size, structure, and morphological evolution during …

Effect Of Zinc Galvanization On The Microstructure And Fracture Behavior Of Low And Medium Carbon Structural Steels, Ignatius C. Okafor, Ronald J. O'Malley, Kaushal R. Prayakarao, Heshmat A. Aglan

Materials Science and Engineering Faculty Research & Creative Works

Microstructure and fracture behavior of ASTM 572 Grade 65 steels used for wind tower applications have been studied. Steels of two carbon level chemistries designed for this grade were used in the study. Fracture toughness of the steels was studied using 3-point bend test on samples coated with zinc and not coated with zinc. Lower carbon steel showed higher resistance to fracture than medium carbon steel after zinc galvanization. SEM study suggests that zinc and zinc bath additives that migrated to crack tips are responsible for the loss in ductility. The phenomenon of Liquid Metal Embrittlement (LME) is suggested to …

Achieving High Strength And High Ductility In Friction Stir-Processed Cast Magnesium Alloy, Wei Yuan, Sushanta K. Panigrahi, Rajiv S. Mishra

Materials Science and Engineering Faculty Research & Creative Works

Friction stir processing (FSP) is emerging as an effective tool for microstructural modification and property enhancement. As-cast AZ91 magnesium alloy was friction stir processed with one-pass and two-pass to examine the influence of processing conditions on microstructural evolution and corresponding mechanical properties. Grain refinement accompanied with development of strong basal texture was observed for both processing conditions. Ultrafine-grained (UFG) AZ91 was achieved under two-pass FSP with fine precipitates distributed on the grain boundary. The processed UFG AZ91 exhibited a high tensile strength of ∼435 MPa (117 pct improvement) and tensile fracture elongation of ∼23 pct. The promising combination of strength …

Influence Of Strain And Strain Rate On Microstructural Evolution During Superplasticity Of Mg-Al-Zn Sheet, A. Mohan, S. K. Panigrahi, R. S. Mishra, R. Verma

Materials Science and Engineering Faculty Research & Creative Works

Strain-induced abnormal grain growth was observed along the gage length during high-temperature uniaxial tensile testing of rolled Mg-Al-Zn (AZ31) sheet. Effective strain and strain rates in biaxial forming of AZ31 sheets also affected the nature of grain growth in the formed sheet. For the uniaxial testing done at 400 C and a strain rate of 10^-1 s^-1, abnormal grain growth was prevalent in the gage sections that experienced true strain values between 0.2 and 1.0. Biaxial forming of AZ31 at 5 x 10 ^-2 s^-1 and 400 C also exhibited abnormal grain growth at the cross …