Работа выполнена при финансовой поддержке совместного гранта Германской службы академических обменов (DAAD) и Министерства образования и науки Российской Федерации в рамках программы «Михаил Ломоносов III» (Проект № 3723).
The influence of Co micro-alloying (1 at. %) on the shear band diffusion and the relaxation processes in a model PdNiP bulk metallic glass is investigated. The shear bands are induced by one-pass cold-rolling. In addition to a fast shear band diffusion branch (Dsb≃10−16m2/s at 473 K), with the diffusivity being similar to that observed for the cold-rolled standard Pd40Ni40P20 composition, an ultrafast diffusion branch (Dsb≃10−14m2/s at the same temperature) is found to exist in the micro-alloyed glass. Combined with previously reported observations of faster relaxation of both the Boson peak height and the fictive temperature, the results indicate that Co micro-alloying affects the excess free volume distribution and thus changes the potential energy landscape of the glass, introducing a higher number of local atomic arrangements prone to the formation of shear transformation zones under plastic deformation.
Abstract This chapter presents results on the analysis of nonmetallic as well as intermetallic inclusions within a metal matrix. In both, steel and aluminum matrix these impurities cause detrimental effects during production as well as in service, e.g. under mechanical load. In steel, nonmetallic inclusions originate from the steelmaking process and range in the magnitude of ppm. In recycled aluminum alloys, iron-rich intermetallic phases exhibit a volume fraction in the range of percent caused by insufficient scrap separation. Both types of detrimental inclusions/precipitates were investigated within different materials such as case hardening steel, quenched and tempered steel as well as Al-Si cast alloy. In order to reduce the amount of impurities, the effects of appropriate crucible materials, reactive and active melt filtration and chemical composition of the used materials were studied. Therefore, extensive metallographic investigations on sections were conducted with optical microscopy, manual and automated scanning electron microscopy, focused ion beam preparation and transmission electron microscopy aiming to determine the compositions of inclusions and intermetallic phases. Focusing on the morphology of inclusions and intermetallic phases, experiments with electrolytic and chemical extraction as well as X-ray micro tomography were performed. The gained knowledge can be utilized to improve filtration and reduce volume fraction and size of nonmetallic inclusions and intermetallic phases. This enables the design of long-lasting and safe materials.
The use of additive manufacturing (AM) and its particular realization – laser powder bed fusion (L-PBF) – is on the rise. However, the method is not free from flaws, mainly represented by structural defects of the printed specimen, such as cracks and pores, requiring processing monitoring. In this work, we propose a concept of the in situ crack detection system for AM fabricated parts based on acoustic emission (AE) signal and machine learning (ML) methods. The detection implies the differentiation of crack AE events from background noise sound. We construct classification ML models and show that they reach the highest classification accuracy, up to 99%, for events represented in the space of spectra principal components. The presented in situ crack detection approach can be easily implemented or used as a basis for a more sophisticated detection procedure.
Abstract This chapter concerns the influence of internal defects (i.e. nonmetallic inclusions, secondary phases and cast defects) on the fatigue lifetime of steel and aluminum alloys in the high cycle fatigue (HCF) and very high cycle fatigue (VHCF) regime. The detrimental effect of internal defects depends on multiple factors such as size, morphology, chemical composition, test temperature or position in the material. Specimens were tested after active and/or reactive melt filtration processes of the materials which served to influence the amount and size distribution of internal defects. Fatigue experiments up to 10 9 cycles were carried out using ultrasonic fatigue testing equipment. In addition, in situ methods, as e.g. full surface view thermography and acoustic emission (AE), were applied to study the processes of crack initiation and propagation, which finally lead to fatigue failure. Furthermore, the cyclically strained samples were subjected to fractographic analysis and the S–N-curves were discussed according to the characteristics of the crack-initiating defects. Based on these investigations, an enhanced knowledge about the correlation of internal defects on the materials’ fatigue strength enables a specific melt filtration strategy adjusted to the materials’ service conditions.
Carbon‐bonded ceramic foam filters with different functional coatings are immersed in a 42CrMo4 steel melt within a steel casting simulator. The solidified steel is analyzed with respect to the size distribution and the chemical composition of the remaining nonmetallic inclusions (NMI). Cyclic loading and quasi‐static tests are performed to determine the fatigue limit, the strength, deformability, and toughness of the steel after filter immersion. The immersion of filter with calcium hexaluminate (CA6) coating significantly reduces the population of small (4–20 μm) NMIs. This leads to an increased deformability and, thus, ability for energy dissipation during deformation. However, the maximum size of NMIs is increased from 100 to 150 μm, which results in fatigue limit reduction, despite the decrease in NMIs total density. The majority of inclusions are found to be pure alumina. Large (up to 150 μm) plate‐like alumina inclusions introduce most of the detrimental effects on cyclic strength, whereas significant effect on quasi‐static strength is not found.
Recent progress in steel refining shows significant reduction of non-metallic inclusions (NMIs) of which alumina (Al2O3) is one of the most problematic. Among other refining methods, metal melt filtration by ceramic foam filters shows promising results in steel cleaning. In the present work the influence of alumina inclusions on the fatigue behavior is investigated after the reaction of steel melt with filters. Different batches are compared where carbon-bonded alumina foam filters with different coatings were introduced into the steel melt of 42CrMo4 for 10 s (so called "finger test"). Fatigue tests were performed using ultrasonic fatigue testing (USFT) up to 109 cycles. Specimens were nitrided in order to prevent crack initiation from the surface and to study internal failure on NMIs. Surface hardening of quenched steel increased fatigue limit significantly. Metallographic sections were analyzed using optical and scanning electron microscopy (SEM) for the estimation of NMIs distribution properties. NMI size distribution analysis based on maximum Feret diameter (instead of area) is found to be an effective method for detecting plate-shaped inclusions. Fracture surfaces after fatigue tests were investigated by methods of SEM and confocal laser scanning microscopy (CLSM), revealing that plate-like NMIs initiate crack with all their area even being inclined to the crack plane. Properties of crack initiating NMIs – alumina plates and MnS dendrites – are compared and analyzed. Formation of alumina NMI as plate lead to significant enlargement of its stress-concentrating area in comparison to the spherical shape of the same volume. Thus, total NMI content reduction in steel could give no fatigue limit improvement if NMI morphology changes from spherical to plate-like.
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