Solidification cracking(SC)of 2024 high-strength aluminium alloy during fusion welding or additive manufacturing has been a long-term issue.In this work,crack-free weld could be obtained using a Zr-core-Alshell wire(Z...Solidification cracking(SC)of 2024 high-strength aluminium alloy during fusion welding or additive manufacturing has been a long-term issue.In this work,crack-free weld could be obtained using a Zr-core-Alshell wire(ZCASW filler material,a novel filler)coupled with an oscillating laser-arc hybrid welding process,and we investigated the solidification cracking susceptibility(SCS)and cracking behavior of AA2024 weld fabricated with different filler materials.The cracking inhibition mechanism of the weld fabricated with ZCASW filler material was elucidated by combined experiments and phase-field simulation.The results show that the effectiveness of filler materials in reducing the SC gradually improves in the order of ER2319 filler material<ER4043 filler material<ZCASW filler material.The main cracking(when using the ER2319 filler material)branches and the micro cracking branches interact with each other to produce cracking coalescence,which aggravates the cracking propagation.The formation of the Al_(3) Zr phase(when using the ZCASW filler material)promotes heterogeneous nucleation of α-Al,thereby resulting in finer and equiaxed non-dendrite structures,which shortens the liquid phase channels and decreases cracking susceptibility index|d T/d(f_(s))^(1/2)|(T is temperature and f_(s) is solidification fraction)at final solidification.A higher proportion(7.65%area fraction)of inter-dendrite phase with spherical distribution state,a shorter(8.6 mm liquid channel length)inter-dendrite phase coupled with round non-dendrite structure(6μm dendrite size)effectively inhibit the SC.The present study can be a useful database for welding and additive manufacturing of AA2024.展开更多
This paper has analyzed the influences of the heat input of welding arc, the latent heat of solidifica- tion,fluid flow of liquid metal on the heat conductivity pertaining to welding solidification crack of stainles...This paper has analyzed the influences of the heat input of welding arc, the latent heat of solidifica- tion,fluid flow of liquid metal on the heat conductivity pertaining to welding solidification crack of stainless steels. As a result,two - dimensional heat conduction models with prescribed heat flux mov- ing along the the have been developed that can simulate welding arc, convection and radiation heat loss from top and bottom surfaces of the workpiece. Finally, the finite element model was used to ana- lyze and calculate the temperature field.展开更多
The high-strength and creep-resistant Mg-Al-Ca-Mn alloys have broad application prospects.However,solidification cracking occurs in these alloys in certain conditions and the origin is still unclear.This work investig...The high-strength and creep-resistant Mg-Al-Ca-Mn alloys have broad application prospects.However,solidification cracking occurs in these alloys in certain conditions and the origin is still unclear.This work investigated the relationship between the solidification path,microstructure evolution and solidification cracking behavior of the Mg-xAl-2Ca-Mn alloys during tungsten inert gas(TIG)welding.Results show that when the fusion zone’s Ca/Al mass ratio ranges from 0.4 to 1.64,solidification cracking occurs at a Ca/Al mass ratio of∼0.7.As the Ca/Al mass ratio approaches this value,the grain size increases,and the Laves phases are reduced gradually.The early formed Laves phases play an important role in promoting dendrite segmentation,refining grain size and enhancing grain boundaries.When a solidification path delays the formation of Laves phases,the Laves phases will be reduced accompanied by grain coarsening.In such a solidifying microstructure,intergranular cavitation is easy to occur,and the resistance of the semi-solid alloy to crack propagation is severely reduced.展开更多
The double ellipsoidal model of heat source is used to analyze the thermal distributions with a three dimensional finite element method (FEM). In the mechanical model, solidification effects are treated by a dynamic e...The double ellipsoidal model of heat source is used to analyze the thermal distributions with a three dimensional finite element method (FEM). In the mechanical model, solidification effects are treated by a dynamic element rebirth scheme. The driving force is obtained in the cracking susceptible temperature range. Moreover, this paper presents the effect of solidification shrinkage, external restraint, weld start locations and material properties on the driving force. The comparison between the simulated driving force and the experimental measurements of the material resistance predicts the susceptibility of weld metal solidification cracking.展开更多
This paper has analyzed the influences of the heat input of the welding arc, the latent heat of solidification, the fluid flow of liquid metal on the heat conductivity pertaining to the welding solidification crack of...This paper has analyzed the influences of the heat input of the welding arc, the latent heat of solidification, the fluid flow of liquid metal on the heat conductivity pertaining to the welding solidification crack of stainless steels. As a result, two dimensional heat conduction models with the prescribed heat flux moving along the weld have been developed that can simulate welding arc, convection and radiation heat loss from top and bottom surfaces of the workpiece. Finally, the finite element model was used to analyze and calculate the temperature fields.展开更多
According to the characteristics of welding process, this paper divided the welding joint of a weldment into three zones: the liquid zone in the molten pool, the solid liquid co existing zone and the solid zone. In ...According to the characteristics of welding process, this paper divided the welding joint of a weldment into three zones: the liquid zone in the molten pool, the solid liquid co existing zone and the solid zone. In order to develop the stress/strain numerical model, the mechanical behaviors of the three zones were analyzed in detail. Moreover, Based on the solid fractions during solidification process and loading unloading deforming curves of stainless steel SUS310, this paper also studied the effects of deformation of molten pool, the rheologic properties and solidification shrinkage on stress/strain evaluating processes. Finally, the influence of the deformation in the molten pool was eliminated by element rebirth method. Furthermore, the algorithm of the thermal stress/strain for the solid metal formulated on the basis of the incremental thermo elastoplastic constitutive theory. As a result, a numerical simulation model of stress/strain distributions for welding solidification crack was developed.展开更多
This paper analyzed the characteristics of welding solidification crack of stainless steels,and clearly re- vealed the the of the deformation in the molten - the pool and the solidification shrinkage on the stress -...This paper analyzed the characteristics of welding solidification crack of stainless steels,and clearly re- vealed the the of the deformation in the molten - the pool and the solidification shrinkage on the stress - strain fields in the trail of molten - weld pool.Moreover, rheologic properties of the alloys in solid - liquid zone were also obtained by measuring the hading and unloading deform curves of the steels.As a result, a numerical model for simulation of stress - strain distributions of welding solidifi- cation crack was developed. On the basis of the model,the thesis simulated the driving force of solidifi- cation crack of stainless steels, that is, stress - strain fields in the trail of molten-weld pool with fi- nite element method.展开更多
On the basis of quantitative evaluation of susceptibility to solidification cracking with Trans-Varestraint-Test, the microstructures of two stainless steels of 316L and alloy 800H with different Creq/Nieq ratios duri...On the basis of quantitative evaluation of susceptibility to solidification cracking with Trans-Varestraint-Test, the microstructures of two stainless steels of 316L and alloy 800H with different Creq/Nieq ratios during solidification process were analyzed with several methods. It is concluded that the susceptibility to solidification cracking of 316L-stainless steel is much lower than that of alloy 800H due to different solidification behaviors of the weld metal of the two materials. The weld metal of alloy 800H solidifies in the form of primary austenite whose boundaries are straight and smooth and easily wetted by low melting-point liquid phases, which increases the susceptibility to solidification cracking; while the 316L weld metal solidifies into primary austenite/ferrite. Owing to a series of dynamic microstructure changes during solidification such as peritectic reactions, migration of austenitic boundaries and nailing of δ-ferrite to the boundaries, the grains become finer, the orientations of columnar grains get disordered and the boundaries are curved and complex. Also high temperature δ-ferrite exists, segregation of impurities at boundaries decreases and the boundaries are hard to be wetted by liquid films, which reduces the cracking susceptibility.展开更多
This paper has simulated the driving force of solidification crack of stainless steels, that is, stress/strain field in the trail of molten pool. Firstly, the effect of the deformation in the molten pool was eliminate...This paper has simulated the driving force of solidification crack of stainless steels, that is, stress/strain field in the trail of molten pool. Firstly, the effect of the deformation in the molten pool was eliminated after the element rebirth method was adopted. Secondly, the influence of solidification shrinkage was taken into account by increasing thermal expansion coefficients of the steels at elevated temperatures. Finally, the stress/strain distributions of different conditions have been computed and analyzed. Furthermore, the driving force curves of the solidification crack of the steels have been obtained by converting strain time curves into strain temperature curves, which founds a basis for predicting welding solidification crack.展开更多
The characteristics and sensitivity of solidification cracks in peritectic steels were investigated using directional solidifi-cation technology.Interdendritic cracks were observed in both hypoperitectic steels(12CrlM...The characteristics and sensitivity of solidification cracks in peritectic steels were investigated using directional solidifi-cation technology.Interdendritic cracks were observed in both hypoperitectic steels(12CrlMoV,15CrMo)and hyper-peritectic steel(20CrMo)during solidification at growth velocities of 15,50,and 80 pm/s.At the dendritic boundaries,sulphide precipitates were found,promoting crack formation.Based on the statistical analysis of interdendritic cracks in peritectic steels,the area ratio(RA)of interdendritic cracks in a directional solidification structure was proposed to evaluate the crack sensitivity of peritectic steels.Furthermore,the crack sensitivities of peritectic steels(12CrlMoV,15CrMo,and 20CrMo)were tested,evaluated,and compared with the surface crack rates of three types of steels produced from a steel plant.The results demonstrated that RA was in good agreement with that of the steel plant,and the crack sensitivity of 12CrlMoV steel was the strongest,followed by that of 15CrMo and 20CrMo steels.Thus,RA can be used to evaluate the crack sensitivity of peritectic steel.展开更多
A computer-aided system for simulating weld solidification crack has been developed by which a welding engineer can carry out the welding solidification crack simulation on the basis of a commercial finite element ana...A computer-aided system for simulating weld solidification crack has been developed by which a welding engineer can carry out the welding solidification crack simulation on the basis of a commercial finite element analysis software package. its main functions include calculating the heat generations of the moving arc. mesh generation, calculating stress-strain distributions with element rebirth technique.展开更多
AA6061 is a widely used aluminum alloy with significant applications in the aerospace and automotive industries.Despite its popularity,the utilization of additively manufactured AA6061 through the laser powder bed fus...AA6061 is a widely used aluminum alloy with significant applications in the aerospace and automotive industries.Despite its popularity,the utilization of additively manufactured AA6061 through the laser powder bed fusion(LPBF)process has been hindered by the pronounced formation of pores and cracks during rapid solidification.This study quantitatively investigated defects,including pores and cracks,and microstructures,including texture,grain size,subgrain structure,and precipitates,of LPBF-manufactured AA6061 across a broad spectrum of laser power and speed combinations.A high relative density of more than 99%was achieved with a low-power and low-speed condition,specifically 200 W and 100 mm s−1,with minimal cracks.Large pores,akin to or exceeding melt pool dimensions,emerged under either low or high energy densities,driven by the lack of fusion and vaporization/denudation mechanisms,re-spectively.Solidification cracks,confirmed by the fractography,were propagated along grain boundaries and are highly dependent on laser scanning speed.Elevated power and speed exhibited finer grain size with refined subgrain cellular structures and increased precipitates at interdendritic regions.The cooling rate and thermal gradient estimated from thermal analytical solutions explain the microstructures’char-acteristics.Nano-sized Si-Fe-Mg enriched precipitates are confirmed in both as-built and heat-treated conditions,whereas T6 heat treatment promotes a uniform distribution with coarsening of those precipi-tates.The low-power and low-speed conditions demonstrated the highest yield strength,consistent with defect levels.A minimum of 102.3%increase in yield strength with reduced ductility was observed after heat treatment for all examined conditions.This work sheds light on printing parameters to mitigate the formation of pores and cracks in additively manufactured AA6061,proposing a process window for op-timized fabrication and highlighting the potential for enhanced material properties and reduced defects through process control.展开更多
WMoTaNbTi RHEAs formed by SEBM with negative defocus distance were investigated.Four scanning speeds were applied,an electron beam with scanning speed at 2.5 m/s completely fused the premixed WMoTaNb alloyed powder an...WMoTaNbTi RHEAs formed by SEBM with negative defocus distance were investigated.Four scanning speeds were applied,an electron beam with scanning speed at 2.5 m/s completely fused the premixed WMoTaNb alloyed powder and pure Ti powder.Significant vaporization of Nb and Ti elements happened during the formation of WMoTaNbTi RHEAs,however,the single BCC phase remains stable.Weakened solid-solute strengthening caused by elemental vaporization,dropping percentage of Nb and Ti solutes in the matrix as well as improved ductilizing effects with decreasing scanning speeds leads to falling microhardness and better local ductility.Microhardness of scanning speed at 4.0 m/s,3.5 m/s,3.0 m/s and 2.5 m/s is 578±17 HV,576±12 HV,573±10 HV and 511±2 HV,respectively.The as-deposited WMoTaNbTi RHEA formed at a scanning speed of 2.5 m/s displays ultimate strength of 1312 MPa.展开更多
Pulse laser welding of 0.6 mm-thick AA5052-H32 was performed to determine the optimum set of parameters including laser pulse current,pulse frequency and pulse duration that meets the AWS D17.1 specifications for aero...Pulse laser welding of 0.6 mm-thick AA5052-H32 was performed to determine the optimum set of parameters including laser pulse current,pulse frequency and pulse duration that meets the AWS D17.1 specifications for aerospace industry.The microstructure and mechanical properties of the weldments were also investigated.Relationships between the parameters and weld bead geometry were found.High quality weld joints without solidification crack that met AWS D17.1 requirements were obtained at(I)high pulse energy(25 J)and high average peak power(4.2 kW)and(II)low pulse energy(17.6 J)and low average peak power(2.8 kW).The weld joint formed at lower heat energy input exhibited finer dendritic grain structure.Mg vapourisation and hard phase compound(Al0.5Fe3Si0.5)formation decreased in the weld joint formed at lower heat energy input.Consequently,the tensile strength of the weldment formed at lower heat energy input(168 MPa)is by a factor of 1.15 higher but showed^29%decrease in hardness(111 HV0.1)at the joint when being compared with the weldment formed at higher heat energy input.Appropriate parameters selection is critical to obtaining 0.6 mm-thick AA5052-H32 pulse laser weld joints that meet AWS D17.1 requirements for aircraft structures.展开更多
Ni3Al-based alloys are excellent candidates for the structural materials used for turbine engines due to their excellent high-temperature properties.This study aims at laser powder bed fusion and post-hot isostatic pr...Ni3Al-based alloys are excellent candidates for the structural materials used for turbine engines due to their excellent high-temperature properties.This study aims at laser powder bed fusion and post-hot isostatic pressing(HIP)treatment of Ni3Al-based IC^(-2)21 M alloy with a highγ0 volume fraction.The as-built samples exhibits unavoidable solidification cracking and ductility dip cracking,and the laser parameter optimization can reduce the crack density to 1.34 mm/mm^(2).Transmission electron microscope(TEM)analysis reveals ultra-fine nanoscaleγ0 phases in the as-built samples due to the high cooling rate during rapid solidification.After HIP treatment,a fully dense structure without cracking defects is achieved,which exhibits an equiaxed structure with grain size~120-180μm and irregularly shapedγ0 precipitates~1-3μm with a prominently high fraction of 86%.The room-temperature tensile test of as-built samples shows a high ultimate tensile strength(σUTS)of 1039.7 MPa and low fracture elongation of 6.4%.After HIP treatment,a significant improvement in ductility(15.7%)and a slight loss of strength(σUTS of 831.7 MPa)are obtained by eliminating the crack defects.Both the as-built and HIP samples exhibit retained highσUTS values of 589.8 MPa and 786.2 MPa,respectively,at 900C.The HIP samples exhibita slight decrease in ductility to~12.9%,indicating excellent high-temperature mechanical performance.Moreover,the abnormal increase in strength and decrease in ductility suggest the critical role of a highγ0 fraction in cracking formation.The intrinsic heat treatment during repeating thermal cycles can induce brittleness and trigger cracking initiation in the heat-affected zone with notable deteriorating ductility.The results indicate that the combination of LPBF and HIP can effectively reduce the crack density and enhance the mechanical properties of Ni_(3)Al-based alloy,making it a promising material for high-temperature applications.展开更多
Two batches of commercial IN738LC alloy powders with different Zr contents were printed under the same parameters.The influences of Zr content(0.024 wt.% and 0.12 wt.%,respectively) in powders on crack density,distrib...Two batches of commercial IN738LC alloy powders with different Zr contents were printed under the same parameters.The influences of Zr content(0.024 wt.% and 0.12 wt.%,respectively) in powders on crack density,distribution,formation mechanism and mechanical properties of selective laser melting(SLM)-treated parts were systematically studied.It was found that the crack density(area ratio) increases from 0.15% to 0.87% in the XOY plane and from 0.21% to 1.81% in the XOZ plane along with the Zr content increase from 0.024 wt.% to 0.12 wt.% in the original powders.Solidification cracks are formed along the epitaxially grown <001>-oriented columnar grain boundaries in molten pool center.The ultimate tensile strength of Sample 1(0.024 wt.% Zr) is 1113 MPa,and there are dimples in tensile fracture.With an increase in the Zr content to 0.12 wt.%(Sample 2),the ultimate tensile strength of Sample 2 decreases to 610 MPa,and there are numerous original cracks and exposed columnar grain boundaries in tensile fracture.The optimization of printing parameters of Sample 2 considerably increases the ultimate tensile strength by 55.2% to 947 MPa,and the plasticity is greatly improved.展开更多
A novel Al-Zn-Mg-Cu alloy free of cracks was produced utilizing laser powder bed fusion(LPBF)and modified with SiC and TiB_(2) particles.The interdependent effects of SiC and TiB_(2) particles on morphology,microstruc...A novel Al-Zn-Mg-Cu alloy free of cracks was produced utilizing laser powder bed fusion(LPBF)and modified with SiC and TiB_(2) particles.The interdependent effects of SiC and TiB_(2) particles on morphology,microstructure,and crystallographic texture were examined.The mechanisms behind phase evolution and crack inhibition were elucidated.The results show that a nearly dense Al-Zn-Mg-Cu alloy could be obtained when the mass fraction of SiC and TiB2 particles was 4%.TiB_(2) particles remained stable and acted as nucleation agents in the molten pool.Partial SiC particles reacted with the Al matrix to form rod-like Al_(4)C_(3),lamellate Al_(4)SiC_(4),and flocculent Si phases,which provided nucleation agents and liquid replenishment for matrix grains.The columnar grains of the matrix were refined into equiaxed grains,and the average size decreased from 37.15μm to 7.54μm.The preferential growth of grains along the(001)〈001〉direction was suppressed and transformed into a disordered random growth.The innovative Al-Zn-Mg-Cu alloy demonstrated an ultimate tensile strength of 492±12 MPa and an elongation of 7.2%±0.7%.The microhardness was enhanced,and the microhardness heterogeneity was reduced.The solidification properties were regulated,the temperature interval between solidus and liquidus was narrowed,and the liquidity of the molten pool was improved.The hot cracking of Al-Zn-Mg-Cu alloy was inhibited due to the interdependent effects of grain refinement by TiB2 particles and sufficient liquid metal replenishment by SiC particles.展开更多
Low-expansion superalloys are susceptible to weld solidification cracks and heat,affected zone （HAZ）microflssures. To predict solidification cracking, QBasic procedures were developed and solidification reaction se...Low-expansion superalloys are susceptible to weld solidification cracks and heat,affected zone （HAZ）microflssures. To predict solidification cracking, QBasic procedures were developed and solidification reaction sequence, type, and amount of eutectic product were caiculated As manifested, primary solidification is followed by L→（Y＋ NbC） and L → （Y＋ Laves） eutectic reaction sequentially for G H903 and GH907; hence, the terminal eutectic constitue Y/Laves, While for GH909, intsare made up of Y/NbC and Y/only reaction L → （Y ＋ Laves） occurs and more Y/Laves eutectic forms. Therefore, GH909is more sensitive to solidification cracking. To predict HAZ liquation, cracking Visual FORTRAN procedures were developed, and constitutional liquation of NbC was simulated. As shown, solid dissolution of NbC prior to liquation decreases, and initial liquid film increases with the rate of thermal cycle. Higher rate of thermal cycle promotes the melting of the matrix adjacent to the liquid film and postpones the solidification of the at the eutectic n size and peak rifled indirectly by hot ductility tests.展开更多
基金financially supported by the National Natural Science Foundation of China under Grant Nos.52305467,52188102,U22A20196,and 52075201the Guangdong Basic and Applied Basic Research Foundation Nos.2023A1515010081 and 2022B1212020003the Fundamental Research Funds for the Central Universities under Grant No.YCJJ20230360.
文摘Solidification cracking(SC)of 2024 high-strength aluminium alloy during fusion welding or additive manufacturing has been a long-term issue.In this work,crack-free weld could be obtained using a Zr-core-Alshell wire(ZCASW filler material,a novel filler)coupled with an oscillating laser-arc hybrid welding process,and we investigated the solidification cracking susceptibility(SCS)and cracking behavior of AA2024 weld fabricated with different filler materials.The cracking inhibition mechanism of the weld fabricated with ZCASW filler material was elucidated by combined experiments and phase-field simulation.The results show that the effectiveness of filler materials in reducing the SC gradually improves in the order of ER2319 filler material<ER4043 filler material<ZCASW filler material.The main cracking(when using the ER2319 filler material)branches and the micro cracking branches interact with each other to produce cracking coalescence,which aggravates the cracking propagation.The formation of the Al_(3) Zr phase(when using the ZCASW filler material)promotes heterogeneous nucleation of α-Al,thereby resulting in finer and equiaxed non-dendrite structures,which shortens the liquid phase channels and decreases cracking susceptibility index|d T/d(f_(s))^(1/2)|(T is temperature and f_(s) is solidification fraction)at final solidification.A higher proportion(7.65%area fraction)of inter-dendrite phase with spherical distribution state,a shorter(8.6 mm liquid channel length)inter-dendrite phase coupled with round non-dendrite structure(6μm dendrite size)effectively inhibit the SC.The present study can be a useful database for welding and additive manufacturing of AA2024.
文摘This paper has analyzed the influences of the heat input of welding arc, the latent heat of solidifica- tion,fluid flow of liquid metal on the heat conductivity pertaining to welding solidification crack of stainless steels. As a result,two - dimensional heat conduction models with prescribed heat flux mov- ing along the the have been developed that can simulate welding arc, convection and radiation heat loss from top and bottom surfaces of the workpiece. Finally, the finite element model was used to ana- lyze and calculate the temperature field.
基金supported by the National Natural Science Foun-dation of China(Nos.U2102212,52301134,52271092,52371095)Natural Science Foundation of Chongqing(Nos.CSTB2022NSCQ-MSX1438,CSTB2022NSCQ-MSX0891)+1 种基金Scientific and Technological Research Program of Chongqing Municipal Education Commission(No.KJQN202001527)Innovative research team of universities in Chongqing(No.CXQT21030).
文摘The high-strength and creep-resistant Mg-Al-Ca-Mn alloys have broad application prospects.However,solidification cracking occurs in these alloys in certain conditions and the origin is still unclear.This work investigated the relationship between the solidification path,microstructure evolution and solidification cracking behavior of the Mg-xAl-2Ca-Mn alloys during tungsten inert gas(TIG)welding.Results show that when the fusion zone’s Ca/Al mass ratio ranges from 0.4 to 1.64,solidification cracking occurs at a Ca/Al mass ratio of∼0.7.As the Ca/Al mass ratio approaches this value,the grain size increases,and the Laves phases are reduced gradually.The early formed Laves phases play an important role in promoting dendrite segmentation,refining grain size and enhancing grain boundaries.When a solidification path delays the formation of Laves phases,the Laves phases will be reduced accompanied by grain coarsening.In such a solidifying microstructure,intergranular cavitation is easy to occur,and the resistance of the semi-solid alloy to crack propagation is severely reduced.
基金Financial support by the National Natural Science Foun-dation of China under grant No.50175040 is gratefully ac-KnowledgedThis project(HIT-2002-41)is also supported by the Scientific Research Foundation of Harbin Institute of Technology.
文摘The double ellipsoidal model of heat source is used to analyze the thermal distributions with a three dimensional finite element method (FEM). In the mechanical model, solidification effects are treated by a dynamic element rebirth scheme. The driving force is obtained in the cracking susceptible temperature range. Moreover, this paper presents the effect of solidification shrinkage, external restraint, weld start locations and material properties on the driving force. The comparison between the simulated driving force and the experimental measurements of the material resistance predicts the susceptibility of weld metal solidification cracking.
文摘This paper has analyzed the influences of the heat input of the welding arc, the latent heat of solidification, the fluid flow of liquid metal on the heat conductivity pertaining to the welding solidification crack of stainless steels. As a result, two dimensional heat conduction models with the prescribed heat flux moving along the weld have been developed that can simulate welding arc, convection and radiation heat loss from top and bottom surfaces of the workpiece. Finally, the finite element model was used to analyze and calculate the temperature fields.
文摘According to the characteristics of welding process, this paper divided the welding joint of a weldment into three zones: the liquid zone in the molten pool, the solid liquid co existing zone and the solid zone. In order to develop the stress/strain numerical model, the mechanical behaviors of the three zones were analyzed in detail. Moreover, Based on the solid fractions during solidification process and loading unloading deforming curves of stainless steel SUS310, this paper also studied the effects of deformation of molten pool, the rheologic properties and solidification shrinkage on stress/strain evaluating processes. Finally, the influence of the deformation in the molten pool was eliminated by element rebirth method. Furthermore, the algorithm of the thermal stress/strain for the solid metal formulated on the basis of the incremental thermo elastoplastic constitutive theory. As a result, a numerical simulation model of stress/strain distributions for welding solidification crack was developed.
文摘This paper analyzed the characteristics of welding solidification crack of stainless steels,and clearly re- vealed the the of the deformation in the molten - the pool and the solidification shrinkage on the stress - strain fields in the trail of molten - weld pool.Moreover, rheologic properties of the alloys in solid - liquid zone were also obtained by measuring the hading and unloading deform curves of the steels.As a result, a numerical model for simulation of stress - strain distributions of welding solidifi- cation crack was developed. On the basis of the model,the thesis simulated the driving force of solidifi- cation crack of stainless steels, that is, stress - strain fields in the trail of molten-weld pool with fi- nite element method.
文摘On the basis of quantitative evaluation of susceptibility to solidification cracking with Trans-Varestraint-Test, the microstructures of two stainless steels of 316L and alloy 800H with different Creq/Nieq ratios during solidification process were analyzed with several methods. It is concluded that the susceptibility to solidification cracking of 316L-stainless steel is much lower than that of alloy 800H due to different solidification behaviors of the weld metal of the two materials. The weld metal of alloy 800H solidifies in the form of primary austenite whose boundaries are straight and smooth and easily wetted by low melting-point liquid phases, which increases the susceptibility to solidification cracking; while the 316L weld metal solidifies into primary austenite/ferrite. Owing to a series of dynamic microstructure changes during solidification such as peritectic reactions, migration of austenitic boundaries and nailing of δ-ferrite to the boundaries, the grains become finer, the orientations of columnar grains get disordered and the boundaries are curved and complex. Also high temperature δ-ferrite exists, segregation of impurities at boundaries decreases and the boundaries are hard to be wetted by liquid films, which reduces the cracking susceptibility.
文摘This paper has simulated the driving force of solidification crack of stainless steels, that is, stress/strain field in the trail of molten pool. Firstly, the effect of the deformation in the molten pool was eliminated after the element rebirth method was adopted. Secondly, the influence of solidification shrinkage was taken into account by increasing thermal expansion coefficients of the steels at elevated temperatures. Finally, the stress/strain distributions of different conditions have been computed and analyzed. Furthermore, the driving force curves of the solidification crack of the steels have been obtained by converting strain time curves into strain temperature curves, which founds a basis for predicting welding solidification crack.
基金financially supported by the Science and Technology Plan Foundation of Xingtai,China (Grant No.2022zz099)the Jiangsu Key Laboratory of Oil-Gas Storage and Transportation Technology (Grant No.CDYQCY202204)Science and Technology Project of Hebei Education Department (Grant No.ZD2021338).
文摘The characteristics and sensitivity of solidification cracks in peritectic steels were investigated using directional solidifi-cation technology.Interdendritic cracks were observed in both hypoperitectic steels(12CrlMoV,15CrMo)and hyper-peritectic steel(20CrMo)during solidification at growth velocities of 15,50,and 80 pm/s.At the dendritic boundaries,sulphide precipitates were found,promoting crack formation.Based on the statistical analysis of interdendritic cracks in peritectic steels,the area ratio(RA)of interdendritic cracks in a directional solidification structure was proposed to evaluate the crack sensitivity of peritectic steels.Furthermore,the crack sensitivities of peritectic steels(12CrlMoV,15CrMo,and 20CrMo)were tested,evaluated,and compared with the surface crack rates of three types of steels produced from a steel plant.The results demonstrated that RA was in good agreement with that of the steel plant,and the crack sensitivity of 12CrlMoV steel was the strongest,followed by that of 15CrMo and 20CrMo steels.Thus,RA can be used to evaluate the crack sensitivity of peritectic steel.
基金The project was supported by the National Scaling BPlan of China.
文摘A computer-aided system for simulating weld solidification crack has been developed by which a welding engineer can carry out the welding solidification crack simulation on the basis of a commercial finite element analysis software package. its main functions include calculating the heat generations of the moving arc. mesh generation, calculating stress-strain distributions with element rebirth technique.
基金Savannah River National Laboratory(SRNL).SRNL is operated by Battelle Savannah River Alliance,LLC under Contract No 89303321CEM000080 for the US Department of Energy.
文摘AA6061 is a widely used aluminum alloy with significant applications in the aerospace and automotive industries.Despite its popularity,the utilization of additively manufactured AA6061 through the laser powder bed fusion(LPBF)process has been hindered by the pronounced formation of pores and cracks during rapid solidification.This study quantitatively investigated defects,including pores and cracks,and microstructures,including texture,grain size,subgrain structure,and precipitates,of LPBF-manufactured AA6061 across a broad spectrum of laser power and speed combinations.A high relative density of more than 99%was achieved with a low-power and low-speed condition,specifically 200 W and 100 mm s−1,with minimal cracks.Large pores,akin to or exceeding melt pool dimensions,emerged under either low or high energy densities,driven by the lack of fusion and vaporization/denudation mechanisms,re-spectively.Solidification cracks,confirmed by the fractography,were propagated along grain boundaries and are highly dependent on laser scanning speed.Elevated power and speed exhibited finer grain size with refined subgrain cellular structures and increased precipitates at interdendritic regions.The cooling rate and thermal gradient estimated from thermal analytical solutions explain the microstructures’char-acteristics.Nano-sized Si-Fe-Mg enriched precipitates are confirmed in both as-built and heat-treated conditions,whereas T6 heat treatment promotes a uniform distribution with coarsening of those precipi-tates.The low-power and low-speed conditions demonstrated the highest yield strength,consistent with defect levels.A minimum of 102.3%increase in yield strength with reduced ductility was observed after heat treatment for all examined conditions.This work sheds light on printing parameters to mitigate the formation of pores and cracks in additively manufactured AA6061,proposing a process window for op-timized fabrication and highlighting the potential for enhanced material properties and reduced defects through process control.
基金the State Key Laboratory of Porous Metal Materials,Northwest Institute for Non-ferrous Metal Research for providing the research funding。
文摘WMoTaNbTi RHEAs formed by SEBM with negative defocus distance were investigated.Four scanning speeds were applied,an electron beam with scanning speed at 2.5 m/s completely fused the premixed WMoTaNb alloyed powder and pure Ti powder.Significant vaporization of Nb and Ti elements happened during the formation of WMoTaNbTi RHEAs,however,the single BCC phase remains stable.Weakened solid-solute strengthening caused by elemental vaporization,dropping percentage of Nb and Ti solutes in the matrix as well as improved ductilizing effects with decreasing scanning speeds leads to falling microhardness and better local ductility.Microhardness of scanning speed at 4.0 m/s,3.5 m/s,3.0 m/s and 2.5 m/s is 578±17 HV,576±12 HV,573±10 HV and 511±2 HV,respectively.The as-deposited WMoTaNbTi RHEA formed at a scanning speed of 2.5 m/s displays ultimate strength of 1312 MPa.
基金the funding (UniversityIndustry Engagement Grant)support provided by the Universiti Sains Malaysia under the Teaching Fellowship Scheme
文摘Pulse laser welding of 0.6 mm-thick AA5052-H32 was performed to determine the optimum set of parameters including laser pulse current,pulse frequency and pulse duration that meets the AWS D17.1 specifications for aerospace industry.The microstructure and mechanical properties of the weldments were also investigated.Relationships between the parameters and weld bead geometry were found.High quality weld joints without solidification crack that met AWS D17.1 requirements were obtained at(I)high pulse energy(25 J)and high average peak power(4.2 kW)and(II)low pulse energy(17.6 J)and low average peak power(2.8 kW).The weld joint formed at lower heat energy input exhibited finer dendritic grain structure.Mg vapourisation and hard phase compound(Al0.5Fe3Si0.5)formation decreased in the weld joint formed at lower heat energy input.Consequently,the tensile strength of the weldment formed at lower heat energy input(168 MPa)is by a factor of 1.15 higher but showed^29%decrease in hardness(111 HV0.1)at the joint when being compared with the weldment formed at higher heat energy input.Appropriate parameters selection is critical to obtaining 0.6 mm-thick AA5052-H32 pulse laser weld joints that meet AWS D17.1 requirements for aircraft structures.
基金supported by the National Key Research and Development Program of China[grant numbers 2019YFA0705300,2021YFB3702502]National Natural Science Foundation of China[grant numbers 52001191,52127807,52271035]+3 种基金Independent Research Project of State Key Laboratory of Advanced Special Steel,Shanghai Key Laboratory of Advanced FerrometallurgyShanghai University,China[grant numbers SKLASS 2022-Z10]the Natural Science Foundation of Shanghai,China[grant.23ZR1421500]SPMI Project from Shanghai Academy of Spaceflight Technology,China[grant.SPMI2022-06].
文摘Ni3Al-based alloys are excellent candidates for the structural materials used for turbine engines due to their excellent high-temperature properties.This study aims at laser powder bed fusion and post-hot isostatic pressing(HIP)treatment of Ni3Al-based IC^(-2)21 M alloy with a highγ0 volume fraction.The as-built samples exhibits unavoidable solidification cracking and ductility dip cracking,and the laser parameter optimization can reduce the crack density to 1.34 mm/mm^(2).Transmission electron microscope(TEM)analysis reveals ultra-fine nanoscaleγ0 phases in the as-built samples due to the high cooling rate during rapid solidification.After HIP treatment,a fully dense structure without cracking defects is achieved,which exhibits an equiaxed structure with grain size~120-180μm and irregularly shapedγ0 precipitates~1-3μm with a prominently high fraction of 86%.The room-temperature tensile test of as-built samples shows a high ultimate tensile strength(σUTS)of 1039.7 MPa and low fracture elongation of 6.4%.After HIP treatment,a significant improvement in ductility(15.7%)and a slight loss of strength(σUTS of 831.7 MPa)are obtained by eliminating the crack defects.Both the as-built and HIP samples exhibit retained highσUTS values of 589.8 MPa and 786.2 MPa,respectively,at 900C.The HIP samples exhibita slight decrease in ductility to~12.9%,indicating excellent high-temperature mechanical performance.Moreover,the abnormal increase in strength and decrease in ductility suggest the critical role of a highγ0 fraction in cracking formation.The intrinsic heat treatment during repeating thermal cycles can induce brittleness and trigger cracking initiation in the heat-affected zone with notable deteriorating ductility.The results indicate that the combination of LPBF and HIP can effectively reduce the crack density and enhance the mechanical properties of Ni_(3)Al-based alloy,making it a promising material for high-temperature applications.
基金the financial supports from the Major Project of Science and Technology of Gansu Province,China(No.17ZD2GC011)the Hongliu First-class Discipline Construction Plan of Lanzhou University of Technology,China(No.CGZH001).
文摘Two batches of commercial IN738LC alloy powders with different Zr contents were printed under the same parameters.The influences of Zr content(0.024 wt.% and 0.12 wt.%,respectively) in powders on crack density,distribution,formation mechanism and mechanical properties of selective laser melting(SLM)-treated parts were systematically studied.It was found that the crack density(area ratio) increases from 0.15% to 0.87% in the XOY plane and from 0.21% to 1.81% in the XOZ plane along with the Zr content increase from 0.024 wt.% to 0.12 wt.% in the original powders.Solidification cracks are formed along the epitaxially grown <001>-oriented columnar grain boundaries in molten pool center.The ultimate tensile strength of Sample 1(0.024 wt.% Zr) is 1113 MPa,and there are dimples in tensile fracture.With an increase in the Zr content to 0.12 wt.%(Sample 2),the ultimate tensile strength of Sample 2 decreases to 610 MPa,and there are numerous original cracks and exposed columnar grain boundaries in tensile fracture.The optimization of printing parameters of Sample 2 considerably increases the ultimate tensile strength by 55.2% to 947 MPa,and the plasticity is greatly improved.
基金financially supported by the National Natural Science Foundation of China(No.52175308)the National Key Research and Development Program of China(No.2022YFB340024500)the Guangdong Provincial General University Innovation Team Project(No.2020KCXTD047).
文摘A novel Al-Zn-Mg-Cu alloy free of cracks was produced utilizing laser powder bed fusion(LPBF)and modified with SiC and TiB_(2) particles.The interdependent effects of SiC and TiB_(2) particles on morphology,microstructure,and crystallographic texture were examined.The mechanisms behind phase evolution and crack inhibition were elucidated.The results show that a nearly dense Al-Zn-Mg-Cu alloy could be obtained when the mass fraction of SiC and TiB2 particles was 4%.TiB_(2) particles remained stable and acted as nucleation agents in the molten pool.Partial SiC particles reacted with the Al matrix to form rod-like Al_(4)C_(3),lamellate Al_(4)SiC_(4),and flocculent Si phases,which provided nucleation agents and liquid replenishment for matrix grains.The columnar grains of the matrix were refined into equiaxed grains,and the average size decreased from 37.15μm to 7.54μm.The preferential growth of grains along the(001)〈001〉direction was suppressed and transformed into a disordered random growth.The innovative Al-Zn-Mg-Cu alloy demonstrated an ultimate tensile strength of 492±12 MPa and an elongation of 7.2%±0.7%.The microhardness was enhanced,and the microhardness heterogeneity was reduced.The solidification properties were regulated,the temperature interval between solidus and liquidus was narrowed,and the liquidity of the molten pool was improved.The hot cracking of Al-Zn-Mg-Cu alloy was inhibited due to the interdependent effects of grain refinement by TiB2 particles and sufficient liquid metal replenishment by SiC particles.
文摘Low-expansion superalloys are susceptible to weld solidification cracks and heat,affected zone （HAZ）microflssures. To predict solidification cracking, QBasic procedures were developed and solidification reaction sequence, type, and amount of eutectic product were caiculated As manifested, primary solidification is followed by L→（Y＋ NbC） and L → （Y＋ Laves） eutectic reaction sequentially for G H903 and GH907; hence, the terminal eutectic constitue Y/Laves, While for GH909, intsare made up of Y/NbC and Y/only reaction L → （Y ＋ Laves） occurs and more Y/Laves eutectic forms. Therefore, GH909is more sensitive to solidification cracking. To predict HAZ liquation, cracking Visual FORTRAN procedures were developed, and constitutional liquation of NbC was simulated. As shown, solid dissolution of NbC prior to liquation decreases, and initial liquid film increases with the rate of thermal cycle. Higher rate of thermal cycle promotes the melting of the matrix adjacent to the liquid film and postpones the solidification of the at the eutectic n size and peak rifled indirectly by hot ductility tests.
