Preparation of Ni60-WC Coating by Plasma Spraying, Plasma Re-melting and Plasma Spray Welding on Surface of Hot Forging Die

In order to produce the hear-resistant inner layer of hot-forging die, the plasma spraying and plasma re-melting and plasma spray welding were adopted. Substrate material was W6Mo5Cr4V2, including 10%, 20%, 30% tungsten carbide （WC） ceramic powder used as coating material to obtain different Nickel-based WC alloys coating. Micro-structure and micro-hardness analysis of the coating layer are conducted, as well as thermophysical properties for the coating layer were measured. The experimental results show that the coating prepared with 70%Ni60, 30%WC powder has the best properties with plasma spray welding, in which the micro-hardness can achieve 900HV, meanwhile it can improve the thermal property of hot-forging die dramatically.

PHYSICAL SIMULATION OF INTERFACIAL CONDITIONS IN HOT FORMING OF STEELS

In the last few years,substantial experimental simulation and mumerical modelling hare been carried out in IMMPETUS to characterise the interfacial heat transfer and friction conditions during hot forging and rolling of steels. Emphasis has been placed on the influence of the oxide scale which forms on the steel workpiece. In the present paper, the experimental methods used for investigating interfacial heat transfer and friction conditions are described. Theses include hot flat rolling of steel slabs and hot axi- symmetric forging of steel cylinders and rings.Temperature measurements and computations demon- strate that for similar conditions, similar conditions, the effective interfacial heat transfer coefficients (IHTC) derived for hot rolling are significantly higher than those for forging, mainly due to the contribution of scale cracking during rolling. On the basis of experimental observations and numerical analysis,physical models for interfacial heat transfer in forging and rolling have been established. In addition, hot' sandwich' rolling and hot tensile tests with finite element modelling have been carried out to evaluate the hot ductility of the oxide scale.The results indicate that the defomation, cracking and decohesion behaviour of the oxide scale depend on deformation temperature, strain and relative strengths of the scale layer and scale - steel interface.Finaly, friction results from hot ring compression tests and from hot rolling with forward/backward slip measurements are reported.

STUDY ON DESIGN TECHNIQUES OF A LONG LIFE HOT FORGING DIE WITH MULTI-MATERIALS

A new design technique for the long life hot forging die has been proposed. By finite element analysis, the reason .for the failure of hot forging die was analyzed and it was concluded that thermal stress is the main reason for the failure of hot forging die. Based on this conclusion, the whole hot forging die was divided into the substrate part and the heat-resistant part according to the thermal stress distribution. Moreover, the heat-resistant part was further subdivided into more zones and the material of each zone was reasonably selected to ensure that the hot forging die can work in an elastic state. When compared with the existing techniques, this design can greatly increase the service life because the use of multi-materials can alleviate the thermal stress in hot forging die.

Ni60-SiC Coating Prepared by Plasma Spraying, Plasma Re-melting and Plasma Spray Welding on Surface of Hot Forging Die

In order to produce the hear-resistant inner layer of hot-forging die, plasma spraying and plasma re-melting and plasma spray welding were adopted. Substrate material was W6Mo5Cr4V2, including 10%, 20%, 30% SiC ceramic powder used as coating material to obtain different Ni-based SiC alloys coating. Micro-structure and micro-hardness analysis of the coating layer were followed, as well as thermophysical properties for the coating layer were measured. The experimental results show that the coating prepared with 70% Ni60, 30% SiC powder has best properties with plasma spray welding, in which the micro-hardness can achieve 1100 HV, meanwhile can improve the thermal property of hot-forging die dramatically.

FINITE ELEMENT SIMULATION AND OPTIMIZATION OF MULTISTAGE WARM/HOT FORMING FOR OUTER RACE

A multistage warm/hot forming is simulated for the cross grove outer race ofconstant velocity joint, using a thermo-mechanical coupled rigid viscoplastic finite element method,and specially some problem for process development and die design are analyzed. A forming testshows that computed results have good agreement with experimental results. Above obtained resultscan be applied to development of multistage warm/hot forming process and die design for outer race.

Carbide Coating Preparation of Hot Forging Die by Plasma Processing

To meet the performance requirements of hot forging die heat resistant layer, the Ni60-SiC coating, Ni60-Cr3C2 coating, and Ni60-WC coating were prepared using W6Mo5Cr4V2 as substrate material with 30%SiC, 10%Cr3C2, 30%WC powder by means of plasma spraying and plasma spray re-melting and plasma spray welding, respectively. Microstructure of each carbide coating was analyzed, micro-hardness was tested, and mainly thermal parameters of coating were detected. The experimental results show that using plasma spray welding, the performance of 70%Ni60/30%SiC powder is the best, and its micro-hardness can achieved 1100HV, showing good thermal-physical property.

Microstructure and Deformation Behavior of Ti-10V-2Fe-3Al Alloy during Hot Forming Process

The microstructure evolution and formability of Ti-10V-2Fe-3Al alloy related to the initial microstructures and processing variables were investigated during hot forming process. The experimental results show that the α-phase growth is controlled by solute diffusion during the heat treatment processes. Four different microstructures were established by combinations of several heat treatments, and Ti-10V-2Fe-3Al alloy shows excellent formability both above and below the β transus temperature. The alloy possesses low deformation resistance and active restoration mechanism during the deformation. A constitutive equation describing the hot deformation behavior of Ti-10V-2Fe-3Al alloy was obtained. Higher fl ow stress was observed for the acicular morphology of α phase in microstructures with large aspect ratios as compared with that of small aspect ratios. Due to the dynamic recovery in soft β phase, and the dynamic recrystallization and breakage of acicular α-phase, fl ow softening occurred signifi cantly during deformation. Dynamic recrystallization also occurred especially in the severely deformed regions of forged parts.

Hot-forging Die Cavity Surface Layer Temperature Gradient Distribution and Determinant

Based on the car front-wheel-hub forging forming process of numerical simulation, the temperature gradient expression of forging model cavity near the surface layer was got ten, which illustrates that the forging temperature gradient is related to forging die materials thermal conductivity, specific heat and impact speed, and the correlation coefficient is 0.97. Under the different thermal conductivity, heat capacity and forging speed, the temperature gradient was compared with each other. The paper obtained the relevant laws, which illustrates the temperature gradient relates to these three parameters in a sequence of thermal conductivity 〉 impact speed〉 specific heat capacity. To reduce thermal stress in the near-surface layer of hot forging cavity, the material with greater thermal conductivity coefficient and specific heat capacity should be used.

Texture Engineering to Boost the Thermoelectric Properties

A round 60% of useful energy is wasted in industry, homes, or transportation. Therefore, there has been increasing attention on thermoelectric materials for their ability to harvest waste heat into useful energy. The efficiency of a thermoelectric material depends on its electrical conductivity, Seebeck coefficient, and thermal conductivity in a conflicting manner which results in efficiency optimization challenges. Single crystals and polycrystalline layered materials have comparatively better thermoelectric and mechanical properties in a certain direction. Texture engineering is a special strategy that allows the exploitation of superior material properties in a specific direction. Texturing could be achieved by various sintering and deformation methods, which yield defects improving thermoelectric and mechanical properties. The results show that for(Bi,Sb)_(2)Te_(3), Bi_(2)(Se,Te)_(3), C uSbSe_(2), and SnSe, significant enhancement in the thermoelectric figure of merit is achieved by enhancing the preferred orientation. Texture engineering provides a wide range of strategies to elevate the zT of anisotropic materials to values comparable to those of their single crystalline counterparts.

Microstructure and Thermal Physical Parameters of Ni60-Cr_3C_2 Composite Coating by Laser Cladding

To satisfy performance and long life requirements for hot forging die,Ni60-Cr3C2 composite coatings were prepared on the high-speed steel W6Mo5Cr4V2 using laser cladding technology.Laser clad coatings with different ratios of Ni60：Cr3C2 were investigated by scanning electron microscopy（SEM）,X-ray diffraction（XRD）,energy-dispersive X-ray analysis（EDX） and micro-hardness tester,respectively.Specific heat capacity and thermal conductivity were measured by Laser Thermal Constant Meter.Thermal expansion coefficient and elastic modulus were measured by Dynamic Mechanical Thermal Analyzer and Electro-Hydraulic Servocontrolled Testing System,respectively.The results indicated that Ni60＋50wt% Cr3C2 composite coating had dense and homogeneous structure,as well as a metallurgical bonding with the substrate.With the increase of Cr3C2 content,volume of chromium-containing compounds in the composite coating increased,microhardness increased and microstructure refined.The thermal physical parameters results showed that Ni60＋50wt% Cr3C2 composite coating was overall worse than W6Mo5Cr4V2,but had a higher hot yield strength to alleviate hot fatigue and surface hot wear of hot forging die during hot forging and thus improve the service life of hot forging die.

Mechanism of Cracking Resistance of Hardfacing Specimens of Steel 5CrNiMo Improved by Rare Earth Oxide

The cracking morphology of the hardfacing specimens taken from steel 5CrNiMo was observed. Meanwhile, the residual stress fields were measured and simulated. Based on experiment mentioned above, the improved structure and modified inclusion in hardfacing metal with rare earth （RE） oxide were analyzed. The results show that, the hardfacing crack is initiated from the coarse dendritic crystal grain boundary, inclusions and coarse austenite grain boundary in the HAZ and propagated by the residual stress existing in the center of the hardfacing metal and HAZ. The primary columnar grain structure can be refined by adding RE oxide in the coating of the electrode. The inclusion in the hardfacing metal can be modified as well. Meanwhile, if the martensite transformation temperature is decreased, the largest value of the residual tensile stress in the dangerous region can be reduced.

PHSICAL MODELLING AND PROCESSING OF Ti-6Al-4V ELI

Titanium has been widely used as the implant materials of joint prostheses. This paper simulates the microstructures of the hot forged titanium knee joint component by physical modeling. Ti-6Al-4V ELI were deformed by GLEEBLE 2000 hot deforma- tion simulator in compression mode to determine the hot workability, in the range of 900 to 1100℃, with the strain rates between 0.05 to 5 s^(-1). Test results derived from specimens processed by on-cooling test and on-heating test were compared, thereby estimating the effect due to thermal history. The forging process of Ti-6Al-4V ELI tibial base plate of knee joint prostheses was design based on the workability data obtained.

Microstructural evolution of TiAl base alloy during three-stepped thermo-mechanical treatment

A TiAl base alloy ingot with a height to diameter ratio of 2.2 was broken down by multiple step canned forging. The microstructures after every deformation and subsequent recrystallization were observed by optical microscopy. Results show that at the first step the reduction should be carefully controlled in case of double bulge and crack of the ingot. After the first annealing, recrystallization occurred at the deformed grain boundaries and inside the grain. The recrystallized microstructure is favorable for further deformation. After the second deformation and annealing, coarsening of the lamellae occurred and the microstructure became equiaxed. By the final deformation and subsequent recrystallization, the coarse lamellar colony can be refined to about 20 μm, and homogeneous microstructure was obtained from the ingot with a large initial height to diameter ratio.

Evaluation on the interface characteristics,thermal conductivity,and annealing effect of a hot-forged Cu-Ti/diamond composite

A Cu-1.5 wt.%Ti/Diamond(55 vol.%)composite was fabricated by hot forging from powder mixture of copper,titanium and diamond powders at 1050?C.A nano-thick TiC interfacial layer was formed between the diamond particle and copper matrix during forging,and it has an orientation relationship of(111)TiC//(002)Cu&[110]TiC//[110]Cuwith the copper matrix.HRTEM analysis suggests that TiC is semicoherently bond with copper matrix,which helps reduce phonon scattering at the TiC/Cu interface and facilitates the heat transfer,further leading to the hot-forged copper/diamond composite(referred as to Cu-Ti/Dia-0)has a thermal conductivity of 410 W/m K,and this is about 74%of theoretical thermal conductivity of hot-forged copper/composite(552 W/m K).However,the formation of thin amorphous carbon layer in diamond particle(next to the interfacial TiC layer)and deformed structure in the copper matrix have adverse effect on the thermal conductivity of Cu-Ti/Dia-0 composite.800℃-annealing eliminates the discrepancy in TiC interface morphology between the diamond-{100}and-{111}facets of Cu-Ti/Dia-0 composite,but causes TiC particles coarsening and agglomerating for the Cu-Ti/Dia-2 composite and interfacial layer cracking and spallation for the Cu-Ti/Dia-1 composite.In addition,a large amount of graphite was formed by titanium-induced diamond graphitization in the Cu-Ti/Dia-2 composite.All these factors deteriorate the heat transfer behavior for the annealed Cu-Ti/Dia composites.Appropriate heat treatment needs to be continually investigated to improve the thermal conductivity of hot-forged CuTi/Dia composite by eliminating deformed structure in the copper matrix with limit/without impacts on the formed TiC interfacial layer.

Investigation of processing–microstructure–property relationship using hot compression of a cone-shaped specimen

Gradient microstructure of the specimen was achieved by applying gradient thermoplastic deformation via electric resist-ance heating and hot compression of the cone-shaped specimen. A numerical modeling and experiment tests are conducted to investigate the microstructure evolution and mechanical properties in different regions of the specimen subjected to the gradient process parameters. Microstructure analysis revealed a direct relationship between the grain size and processing parameters. The temperature distribution on the gradient specimen ranges from about 800 to 1110 ℃ and equivalent strain along the axis of symmetry of the specimen section ranges from about 0.1 to 1.2. Under a temperature of 1050 ℃ and the equivalent strain of 0.7, the middle region of the specimen section has fine and equiaxed prior-austenitic grains with an average size of (27?±?11) μm. Corresponding to the processing parameters, the lath martensite variants microstructure in this position with the highest hardness of (946?±?17) HV. Consequently, the linkages among hot compression parameters, microstructure, and material properties of hardness are established via a high-throughput method in a cone-shaped specimen.

A Physically Based Dynamic Recrystallization Model Considering Orientation Effects for a Nitrogen Alloyed Ultralow Carbon Stainless Steel during Hot Forging

The nitrogen alloyed ultralow carbon stainless steel is a good candidate material for primary loop pipes of AP1000 nuclear power plant. These pipes arc manufactured by hot forging, during which dynamic recrystallization acts as the most important microstructural evolution mechanism. A physically based model was proposed to describe and predict the microstructural evolution in the hot forging process of those pipes. In this model, the coupled effects of dislocation density change, dynamic recovery, dynamic recrystallization and grain orientation function were con sidered. Besides, physically based simulation experiments were conducted on a Gleeble 3500 thermo-mcchanical sire ulator, and the specimens after deformation were observed by optical metallography （OM） and clectron back scat toted diffraction （EBSD） method. The results confirm that dynamic recrystallization is easy to occur with increasing deformation temperature or strain rate. The grains become much finer after full dynamic recrystallization. The model shows a good agreement with experimental results obtained by OM and EBSD in terms of stress strain curves, grain size, and recrystallization kinetics. Besides, this model obtains an acceptable accuracy and a wide applying scope for engineering calculation.

Dual phase titanium alloy hot forging process design： experiments and numerical modeling

Titanium alloys materials when both good weight reduction are required are considered desirable mechanical properties and at the same time. This class of materials is widely used in those fields （aeronautics, aerospace） in which common steels and light-weight materials, e.g., aluminum alloys, are not able to satisfy all operative service conditions. During the last decade, forg- ing of titanium alloys has attracted greater attention from both industrial and scientific/academic researchers because of their potential in providing a near net shaped part with minimal need for machining. In this paper, a numerical model of the forging sequences for a Ti-6A1-4V titanium alloy aerospace component is presented. The model was tested and validated against experimental forgings. The model is then applied to predict loads final microstructure and defects of an aeronautical component. In addition to metal flow and die stresses, microstructural transformations （α and β phases） are considered for the determination of proper process parameters. It is found that transformation from α/β to β phase during forging and reverse transformations in post-forge cooling needs to be considered in the computational model for reasonable prediction of forging loads and product properties.