Metallurgical analysis of a failed maraging steel shear screw used in the band separation system of a satellite launch vehicle

Maraging steels have excellent combination of strength and toughness and are extensively used for a variety of aerospace applications. In one such critical application, this steel was used to fabricate shear screws of a stage separation system in a satellite launch vehicle. During assembly preparations, one of the shear screws which connected the separation band and band end block has failed at the first thread. Microstructural analysis revealed that the crack originated from the root of the thread and propagated in an intergranular mode. The failure is attributed to combined effect of stress and corrosion leading to stress corrosion cracking.

Effect of Rare Earth on Void Band of Diffusion Layer and Properties of Aluminized Steel

The effects of the addition of rare earth （RE） elements on the void band in the diffusion layer, and the re sistances to both oxidation and spalling of aluminized steel were investigated through high temperature oxidation and spalling tests. The results showed that RE had significant effects on the void band in the diffusion layer and the properties of aluminized steel. After diffusion treatment, a considerable number of the voids between the middle layer and transitional layer of pure aluminized coating, aggregated into wavy-line-shaped void bands parallel to the outer surface. For the RE added aluminized coating, only a few voids aggregated into intermittent block shapes. During high temperature oxidation at 800 ℃ for 200 h, the wavy void band of pure aluminized coating aggregated further into a linear crack parallel to the outer surface, and the internal oxidation occurred within them; the open cracks perpendicular to the surface penetrated through the diffusion layer. For the RE added aluminized coating, only a few voids aggregated into intermittent meniscus shapes. During cyclic spalling tests, the peeling, spallation, and pulver ulent cracking occurred along the void band in the diffusion layer of pure aluminized coating, but only a little spallation occurred in the diffusion layer of the RE-added aluminized coating, in which cracks perpendicular to the surface were much smaller than those of pure aluminized coating and did not penetrate through the diffusion layer. It is evident that RE addition can restrain the formation and aggregation of voids and subsequently improve the resistances to oxidation and spalling. The mechanism of the RE effect on the void band in the diffusion layer is also discussed.

Effect of hot-band annealing process on microstructure,texture,and r-value of final sheets of ferritic stainless steel

In this paper,the effect of different annealing processes on the microstructure,texture,and formability of ferritic stainless steel was studied in detail.The results showed that the grain size in the final sheet was larger and the recrystallization texture was more uniform after the final recrystallization annealing of hot-rolled steel with continuous annealing than that without annealing or with batch annealing.In addition,the final sheet had a higher average r-value and the lowest planar anisotropy.

基于BSCWEformer的退火炉内分组式辊速序列预测

退火炉内带钢的长度受到温度、张力等因素的影响而变化,导致辊的转速改变以及焊缝位置的不确定,从而威胁生产安全.为了准确预测辊的转速以计算焊缝的实时位置,本文提出基于带状稀疏柯西自注意力的BSCWEformer (banded sparse Cauchy weight enhanced Transformer)模型.模型采用带状稀疏的、使用基于相对位置计算的柯西分布权重值增强的自注意力结构,在提高相邻输入序列的重要性的同时,将自注意力的复杂度由二次方降低为线性.通过实际生产数据进行实验,并与LogSparse Transformer、Transformer、RNMT+等模型进行对比,得出本文所提出的BSCWEformer模型在退火炉内分组式辊速序列预测任务上具有较高的预测精度.

微合金钢等温过程中带状组织演变规律研究

采用热模拟试验机、金相显微镜和扫描电镜研究了微合金钢在等温过程中的带状组织演变规律,并对其形成机理进行了分析。结果表明:试样在650~700℃等温时,带状组织为铁素体/马氏体。在550~600℃等温时,带状组织为针状铁素体/马氏体,且随着等温温度的下降,针状铁素体的体积分数不断升高。Mn的带状偏析是导致该等温期间不完全转变现象的根本原因。当等温温度降到450℃时,组织全部为针状铁素体,带状组织基本消失。

冷轧压下率对高强无取向电工钢变形组织和磁性能的影响

借助场发射扫描电镜(SEM+EBSD)、快速升温管式炉和交流磁性能测量仪研究高强无取向电工钢冷轧变形组织和磁性能随冷轧压下率的变化规律。结果表明:冷轧高强无取向电工钢中形成含有大量亚结构的粗糙条带和变形量较小的光滑条带。粗糙条带具有γ取向,主要为{111}〈110〉,光滑条带具有{112}〈110〉和{001}〈110〉取向。粗糙条带中存在大量宽度约为2~3μm的剪切带,与轧向呈20°~35°夹角,且随压下率增大,数量逐渐增多。剪切带与基体间具有一定取向差,随压下率增大,剪切带逐渐从{111}〈110〉取向转向{223}〈110〉取向,与基体间取向差逐渐增大。退火后Goss和{111}面织构增多,{001}面织构减少;轧向磁感应强度增大,横向磁感应强度减小,各向异性显著,铁损下降。

Q460C中厚钢板折弯裂纹形成原因

某厂生产厚度为20 mm的Q460C钢板在折弯过程中出现裂纹。采用宏观观察、化学成分分析、金相检验、扫描电镜及能谱分析等方法分析裂纹产生的原因。结果表明:试样折弯裂纹产生的主要原因为炼钢过程中钢液中P、S元素含量过高,且连铸过程存在钢包下渣的情况,导致铸坯中产生P、S元素偏析,铸坯内部存在大量非金属夹杂物;随着轧制过程温度的不断降低,钢板内部形成严重的带状组织,最终导致钢板在折弯过程中发生开裂。

水泥选粉机40CrMoA钢轴断裂原因

某水泥选粉机40CrMoA钢轴在服役10 d后出现断裂事故,采用宏观观察、化学成分分析、力学性能测试、金相检验等方法对其断裂原因进行分析。结果表明:钢轴显微组织为回火索氏体+条状或块状铁素体,组织中存在硫化物等非金属夹杂物和带状组织,夹杂物和带状组织处容易产生应力集中;裂纹在缺陷处萌生并扩展,最终导致钢轴断裂。

改善55钢零件高频感应淬火金相组织的措施

通过分析55钢制造减速器零件的高频感应淬火组织,并分别对零件的基体组织、感应加热功率、加热时间及淬火液浓度等影响淬火组织的各种因素进行试验验证,最后提出了改善55钢感应淬火金相组织的有效措施。

四黄散联合间断垂直钢丝缝合加张力带对髌骨下极骨折患者膝关节活动度及骨折愈合时间的影响

目的:观察四黄散联合间断垂直钢丝缝合加张力带对髌骨下极骨折患者膝关节活动度及骨折愈合时间的影响。方法:选取2021年9月至2022年9月丰城市中医院收治的髌骨下极骨折患者40例,按照随机数字表法分为对照组和试验组,每组20例。两组患者均给予切开复位内固定,对照组给予间断垂直钢丝缝合联合张力带治疗,试验组给予四黄散联合间断垂直钢丝缝合加张力带治疗。观察两组患者术后6周、3个月、6个月、1年及末次随访时膝关节疼痛评分、屈伸活动范围(range of motion, ROM)、Bostman评分、骨折愈合时间、各项临床指标及并发症发生情况。结果:试验组术后6周、3个月、6个月、1年膝关节疼痛评分均低于对照组,差异有统计学意义(P<0.05)。试验组术后6周、3个月、6个月、1年ROM、Bostman评分高于对照组,差异有统计学意义(P<0.05)。试验组术后1年骨折愈合时间、各项临床指标均优于对照组,并发症发生率低于对照组,差异有统计学意义(P<0.05)。结论:四黄散联合间断垂直钢丝缝合加张力带能改善髌骨下极骨折患者膝关节功能,降低术后并发症发生率,促进骨折早日愈合。

硅钢连续退火机组飞剪卡钢原因及控制措施

分析某硅钢连续退火机组出口曲柄式飞剪连续剪切时,出现剪刃不能正常落回至初始低位,与运动中的板带带头相撞,造成卡钢的原因,并提出改进和控制方法,解决了飞剪相应故障,保证了稳定生产的连续性,提高了机组的机时产量和成材率,应用效果良好。

轴承钢滚动接触疲劳亚表面夹杂处损伤分析

轴承钢在滚动接触疲劳(RCF)中失效的主要原因之一是亚表面白蚀区(WEA)的形成.本文中从塑性应变累积引起剪切局域化新的角度对WEA进行了研究.通过耦合晶体塑性和相场损伤理论建立了损伤演化本构模型,研究了非金属夹杂处塑性应变累积和损伤演化.研究表明,接触疲劳载荷引起的塑性应变局域化导致了剪切带的形成.剪切带的形貌、取向和应变与WEA的一致,表明WEA实际上是应变局域化的剪切带.晶体取向对WEA损伤的形成和发展有很大的影响,WEA仅在择优的晶体取向下形成.与软夹杂周围的剪切带和损伤演化不同,硬夹杂处的剪切带与夹杂相切,形成的4条剪切变形带将夹杂“包围”.剪切带内部处于高应变和低应力的状态,带中心处应变达到最大,随带宽两侧急剧减小,而中心处应力却最小,几乎为零,沿带宽两侧增大,这说明裂纹在剪切带内萌生和扩展.该结论阐明了裂纹和WEA形成的关系,即裂纹是在WEA形成过程中因应变不协调产生,而非裂纹先产生,裂纹上下表面相互摩擦导致WEA形成.

Adiabatic shear localization evolution for steel based on the Johnson-Cook model and gradient-dependent plasticity

Gradient-dependent plasticity is introduced into the phenomenological Johnson-Cook model to study the effects of strainhardening, strain rate sensitivity, thermal-softening, and microstructure. The microstructural effect （interactions and interplay among microstructures） due to heterogeneity of texture plays an important role in the process of development or evolution of an adiabatic shear band with a certain thickness depending on the grain diameter. The distributed plastic shear strain and deformation in the shear band are derived and depend on the critical plastic shear strain corresponding to the peak flow shear stress, the coordinate or position, the internal length parameter, and the average plastic shear strain or the flow shear stress. The critical plastic shear strain, the distributed plastic shear strain, and deformation in the shear band are numerically predicted for a kind of steel deformed at a constant shear strain rate. Beyond the peak shear stress, the local plastic shear strain in the shear band is highly nonuniform and the local plastic shear deformation in the band is highly nonlinear. Shear localization is more apparent with the increase of the average plastic shear strain. The calculated distributions of the local plastic shear strain and deformation agree with the previous numerical and experimental results.

Effects of asymmetric rolling process on ridging resistance of ultra-purified 17%Cr ferritic stainless steel

In ferritic stainless steels, a significant non-uniform recrystallization orientation and a substantial texture gradient usually occur, which can degrade the ridging resistance of the final sheets. To improve the homogeneity of the recrystallization orientation and reduce the texture gradient in ultra-purified 17%Cr ferritic stainless steel, in this work, we performed conventional and asymmetric rolling processes and conducted macro and micro-texture analyses to investigate texture evolution under different cold-rolling conditions. In the conventional rolling specimens, we observed that the deformation was not uniform in the thickness direction, whereas there was homogeneous shear deformation in the asymmetric rolling specimens as well as the formation of uniform recrystallized grains and random orientation grains in the final annealing sheets. As such, the ridging resistance of the final sheets was significantly improved by employing the asymmetric rolling process. This result indicates with certainty that the texture gradient and orientation inhomogeneity can be attributed to non-uniform deformation, whereas the uniform orientation gradient in the thickness direction is explained by the increased number of shear bands obtained in the asymmetric rolling process.

Adiabatic Shear Localization for Steels Based on Johnson-Cook Model and Second-and Fourth-Order Gradient Plasticity Models

To consider the effects of the interactions and interplay among microstructures, gradient-dependent models of second- and fourth-order are included in the widely used phenomenological Johnson-Cook model where the effects of strain-hardening, strain rate sensitivity, and thermal-softening are successfully described. The various parameters for 1006 steel, 4340 steel and S-7 tool steel are assigned. The distributions and evolutions of the local plastic shear strain and deformation in adiabatic shear band （ASB） are predicted. The calculated results of the second- and fourth- order gradient plasticity models are compared. S-7 tool steel possesses the steepest profile of local plastic shear strain in ASB, whereas 1006 steel has the least profile. The peak local plastic shear strain in ASB for S-7 tool steel is slightly higher than that for 4340 steel and is higher than that for 1006 steel. The extent of the nonlinear distribution of the local plastic shear deformation in ASB is more apparent for the S-7 tool steel, whereas it is the least apparent for 1006 steel. In fourth-order gradient plasticity model, the profile of the local plastic shear strain in the middle of ASB has a pronounced plateau whose width decreases with increasing average plastic shear strain, leading to a shrink of the portion of linear distribution of the profile of the local plastic shear deformation. When compared with the sec- ond-order gradient plasticity model, the fourth-order gradient plasticity model shows a lower peak local plastic shear strain in ASB and a higher magnitude of plastic shear deformation at the top or base of ASB, which is due to wider ASB. The present numerical results of the second- and fourth-order gradient plasticity models are consistent with the previous numerical and experimental results at least qualitatively.

Separation occurring during the drop weight tear test of thick-walled X80 pipeline steels

A separation phenomenon occurring during the drop weight tear test of commercial thick-walled API （American Petroleum Institute） X80 strip steel was investigated in this work. Microstructural analysis showed that the band structure of bainite elongated along the rolling direction works as the initiation sites of separation. The propagation of separation can be promoted not only by the occurrence of the band structure of martensite/austenite constituent, prior austenite grain boundaries, and elongated bainite, but also by fine acicular ferrite and bainite. Wide separation formed in the former case, while the narrow one appeared in the latter case. acicular ferrite in thick-walled X80 pipeline steel in order Some methods were proposed to obtain fine and homogeneous to minimize the occurrence of separation.

GROWTH PROCESS OF LOW-TEMPERATURE PLASMA-NITRIDING LAYER ON AUSTENITIC STAINLESS STEEL

The growth process of low-temperaturs plasma-nitriding layer was investigated by scan-ning electron microscopy (SEM) and X-ray diffraction (XRD). The layer is composedof expanded fcc phase (γN), whose lattice parameter of the layer increases with processtime resulting from increasing the nitrogen content. The layer hardness increases grad-ually with nitrogen content. The high slip band density on the layer surface observedin situ by SEM shows that the surface yield occurs when supersaturated nitrogen con-tent in the layer attains to some value, which is also responsible for the increase inlayer hardness.

Microstructure of stainless steel weld in double-sided arc welding

Double-sided arc welding with a single power source can effectively increase the weld penetration, diminish distortion, improve welding speed and save energy. Compared to conventional arc welding processes, double-sided arc welding can generate a penetrating electromaguetic field to help to form fine dendritic microstrueture in the weld due to the symmetry of heating. Type 1Cr1SNi9Ti aastenitic stainless steel was bead-on-plate welded with double-sided arc welding and conventional plasma arc welding processes, respectively, and microstructure in the weld, heat-affected zone and base metal were examined. After analyzing the black carbon-enriched band in the weld during plasma arc welding with electron probe microanalyzer （ EPMA ） and X-ray diffraction （XRD） technology, it was found that the black band was shaped from the aggregation of ferrite in the fasion boundary. Hardness measurement showed that this black band does not apparently affect the microhardncss distribution in the weld.

电弧增材制造不锈钢动态加载绝热剪切带内组织研究

绝热剪切失效是增材制造金属材料在高应变率载荷下的重要失效方式。使用电火花从冷金属过渡电弧增材技术制备的316L不锈钢单壁上沿着制造方向和扫描方向割出动态加载圆柱试样(尺寸为φ4 mm×4 mm)。采用分离式霍普金森杆对增材制造316L试样在应变率4 000到6 000 s^(-1)下加载至绝热剪切状态,研究了其动态剪切变形行为特别是剪切带内微观组织特征结构。不同应变率动态加载下,电弧增材制造316L不锈钢的动态应力首先由于应变硬化而增大,随后绝热剪切热软化与应变硬化的平衡导致了动态变形最后阶段的应力平台效应。绝热剪切带中亚晶经历了动态再结晶过程,具有与基体完全不同的等轴晶形貌,晶粒尺寸大约在200~300 nm。动态剪切复杂热力过程导致剪切带内的亚晶形成了双重织构,既有与基体一致的沿着压缩方向的<110>丝织构,也有与宏观剪切方向相关的晶体学织构,即(111)沿着宏观剪切面,<112>沿着宏观剪切方向。不同剪切带的等轴亚晶都有大量残余Σ3 60°晶界,同时存在与基体相同的孪生织构,可以证明孪生再结晶是绝热剪切带内亚晶主要的动态再结晶机制。宏观绝热剪切带发展路径沿着压缩面35°的对称路径发展,这除了符合动态加载下试样中最大应变和热场分布的外加物理条件,还符合剪切面(111)与基体(110)面交角为35.2°的晶体学条件。此外,基体中存在大量微观局部变形带来承载应变,微观局部变形带内亚晶也具有与基体孪晶组织不同的位向和形貌。

Characteristics of Strain-Induced Ferrite in Low Carbon Steel

The strain-induced ferrite formed under different conditions was observed with SEM and optical microscope.The nucleation sites of strain-induced ferrite include grain boundary,grain inside,deformed band and annealing twin boundary.The shapes of the ferrite accordingly are equiaxed irregular polygonal,strip-shaped and acicular.