Fabrication of plain carbon steel/high chromium white cast iron bimetal by a liquid–solid composite casting process

High-chromium white cast iron （HCWCI） is one of the most widely used engineering materials in the mining and cement industries. However, in some components, such as the pulverizer plates of ash mills, the poor machinability of HCWCI creates difficulties. The bimetal casting technique is a suitable method for improving the machinability of HCWCI by joining an easily machined layer of plain carbon steel （PCS） to its hard part. In this study, the possibility of PCS/HCWCI bimetal casting was investigated using sand casting. The investigation was conducted by optical and electron microscopy and non-destructive, impact toughness, and tensile tests. The hardness and chemical composition profiles on both sides of the interface were plotted in this study. The results indicated that a conventional and low-cost casting technique could be a reliable method for producing PCSYdCWCI bimetal. The interfacial microstructure comprised two distinct lay- ers： a very fine, partially spheroidized pearlite layer and a coarse full pearlite layer. Moreover, characterization of the microstructure revealed that the interface was free of defects.

Electron beam welding of 304 stainless steel to QCr0.8 copper alloy with copper filler wire

Electron beam welding （EBW） of 304 stainless steel to QCr0.8 copper alloy with copper filler wire was carried out. Orthogonal experiment was performed to investigate the effects of process parameters on the tensile strength of the joints, and the process parameters were optimized. The optimum process parameters are as follows：beam current of 30 mA, welding speed of 100 mm/min, wire feed rate of 1 m/min and beam offset of-0.3 mm. The microstructures of the optimum joint were studied. The results indicate that the weld is mainly composed of dendriticαphase with little globularεphase, and copper inhomogeneity only occurs at the top of the fusion zone. In addition, a melted region without mixing exists near the weld junction of copper side. This region with a coarser grain size is the weakest section of the joints. It is found that the microhardness of the weld decreases with the increase of the copper content in solid solution. The highest tensile strength of the joint is 276 MPa.

Antibacterial Mechanism of Copper-bearing Antibacterial Stainless Steel against E.Coli

A preliminary study was made on the antibacterial mechanism of copper-bearing antibacterial stainless steels against E.coli through experiments of microbiology such as EDTA （ethylenediaminetetraacetic acid） complexing, DNA smearing and AFM （atomic force microscope） observation. It was measured that the antibacterial stainless steels showed excellent antibacterial functions with antibacterial rate to E.coli over 99.99%. The antibacterial rate was weak if the bacteria solution was complexed by EDTA, indicating that the copper ions play a dominant role in the antibacterial effect of the antibacterial stainless steels. The electrophoresis experiment did not show the phenomenon of DNA smearing for E.coli after contacting antibacterial stainless steels, which meant that DNA of E.coli was not obviously damaged. It was observed by AFM that the morphology of E.coli changed a lot after contacting antibacterial stainless steels, such as cell walls being seriously changed and lots of contents in the cells being leaked.

Microstructural evolution and mechanical properties of friction stir-welded C71000 copper–nickel alloy and 304 austenitic stainless steel

Dissimilar joints comprised of copper–nickel and steel alloys are a challenge for manufacturers in modern industries, as these metals are not thermomechanically or chemically well matched. The present study investigated the effects of tool rotational speed and linear speed on the microstructure and mechanical properties of friction stir-welded C71000 copper–nickel and 340 stainless steel alloys using a tungsten carbide tool with a cylindrical pin. The results indicated that a rotational-to-linear speed ratio of 12.5 r/mm did not cause any macro defects, whereas some tunneling defects and longitudinal cracks were found at other ratios that were lower and higher. Furthermore, chromium carbide was formed on the grain boundaries of the 304 stainless steel near the shoulder zone and inside the joint zone, directing carbon and chromium penetration toward the grain boundaries. Tensile strength and elongation percentages were 84% and 65% of the corresponding values in the copper–nickel base metal, respectively.

Antibacterial and corrosive properties of copper implanted austenitic stainless steel

Copper ions were implanted into austenitic stainless steel （SS） by metal vapor vacuum arc with a energy of 100 keV and an ions dose range of （0.5-8.0）× 10^17 cm^-2. The Cu-implanted SS was annealed in an Ar atmosphere furnace. Glancing X-ray diffraction （GXRD）, transmission electron microscopy （TEM） and Auger electron spectroscopy （AES） were used to reveal the phase compositions, microstructures, and concentration profiles of copper ions in the implanted layer. The results show that the antibacterial property of Cu-implanted SS is attributed to Cu9.9Fe0.1, which precipitated as needles. The depth of copper in Cu-implanted SS with annealing treatment is greater than that in Cu-implanted SS without annealing treatment, which improves the antibacterial property against S. aureus. The salt wetting-drying combined cyclic test was used to evaluate the corrosion-resistance of antibacterial SS, and the results reveal that the antibacterial SS has a level of corrosion-resistance equivalent to that of un-implanted SS.

Transient liquid phase diffusion bonding of copper alloy to stainless steel using CuMn alloys as interlayer

With CuMn alloy as interlayer, the transient liquid phase (TLP) diffusion bonding of Cu alloys (CuAlBe) to stainless steel (1Cr18Ni9Ti) was studied. The results show that the bonding pressure, time and temperature and the content of Mn in CuMn alloy have great effects on the strength of bonding interface; when they are 1 MPa, 40 min, 1 223 K and 30% respectively, the maximum joint strength of 487 MPa is attained. The fracture occurring at the bonding interface is a plastic one and the effect of Mn has been analyzed.

An insight into microstructural heterogeneities formation between weld subregions of laser welded copper to stainless steel joints

The effect of laser beam welding(LBW) process on the microstructure-mechanical property relationship of a dissimilar weld between the copper(Cu) and stainless steel(SS) was investigated.Backscattered electron(BSE) based scanning electron microscopy(SEM) imaging was used to characterize the highly heterogeneous microstructural features across the LBW(Cu-SS) weld.The BSE analysis thoroughly evidenced the complex microstructures produced at dissimilar weld interfaces and fusion zone along with the compositional information.Widely different grain growths from coarse columnar grains to equiaxed ultrafine grains were also evident along the Cu-weld interface.A highresolution electron backscattered diffraction(EBSD) analysis confirmed the existence of the grain refinement mechanism at the Cu-weld interface.Both tensile and impact properties of the dissimilar weld were found to be closely aligned with the property of Cu base metal.Microhardness gradients were spatially evident in the non-homogeneous material composition zones such as fusion zone and the Cu-weld interface regions.The heterogeneous nucleation spots across the weld sub-regions were clearly identified and interlinked with their microhardness measurements for a holistic understanding of structure-property relationships of the local weld sub-regions.The findings were effectively correlated to achieve an insight into the local microstructural gradients across the weld.

Effects of Nitrogen Concentration on Microstructure and Antibacterial Property of Copper-Bearing Austenite Stainless Steels

Austenite antibacterial stainless steels have been found to have wide applications in hospitals and food industries. In recent years epsilon copper precipitation in antibacterial stainless steels has obtained much research interest due to its antibacterial action. The objective of this study was to determine the effects of nitrogen concentration on the precipitation of epsilon copper and antibacterial property. Two kinds of austenite antibacterial stainless steels containing copper and different nitrogen concentration （0.02 and 0.08 wt pct, respectively） were prepared and the microstructures were characterized by a combination of electron microscopy and thermodynamic analysis. A mathematical expression was deduced to predict the effect of nitrogen concentration on the activity coefficient of copper, In（fCu/f^0cu）=0.53524＋4.11xN-0.48x^2N. Higher nitrogen was found to increase the free energy difference of copper concentration distribution between precipitation phase and austenite matrix, stimulate the aggregation of copper atoms from austenite, increase the precipitation amount and consequently enhance the antibacterial property of steel.

Thermal fatigue behavior of copper/stainless steel explosive welding joint

Thermal fatigue performance of copper/stainless steel explosive welding joint was investigated by using a highly effective thermal fatigue test device. The testing device adopted induction coil to heat and carry out two groups of thermal fatigue test at the same time. Metallurgical microscope and scanning electron microscope were used to respectively measure the surface crack and cross-section crack propagation morphology of the explosive welding joint specimen that were conducted thermal cycling for different upper limit temperatures and different cycle time.Experimental results indicated that the cyclic thermal stress and oxidation corrosion was the major factors for fatigue damage behavior of explosive welding joints, where the oxidation corrosion of the interface has become more serious with the increasing the upper limit temperature or the number of cycles rising. Thermal fatigue cracks initiation was mainly beginning from the wavy interface between copper and stainless steel, the vortex-like cast microstructure formed by explosive welding can prevent the crack from propagating along the interface edge and change the direction of crack propagation.The initiation and expansionof thermal fatigue cracks were observed in the copper matrix.

Effects of copper content on microstructure and mechanical properties of open-cell steel foams

The effects of copper content on the microstructural and mechanical properties of steel foams are investigated. Spherical urea granules, used as a water-leachable space holder, were coated with a mixture of iron, ultrafine carbon, and different amounts of copper powders. After the mixture was compacted and the space holder was removed by leaching, a sintering process was performed under an atmosphere of thermally dissociated ammonia. Microstructural evaluations of the cell walls were carried out using optical microscopy and scanning electron microscopy in conjunction with energy-dispersive X-ray spectroscopy. In addition, compression tests were conducted to investigate the mechanical properties of the manufactured steel foams. The results showed that the total porosity decreases from 77.2% to 71.9% with increasing copper content in the steel foams. In the foams' microstructure, copper islands are mostly distributed in pearlite and intergranular carbide phases are formed in the grain boundaries. When the copper content was increased from 0 to 4 wt%, the elastic modulus, plateau stress, fracture stress, and fracture strain of manufactured steel foams improved 4.5, 6, 6.4, and 2.5 times, respectively.

Application of response surface methodology to maximize tensile strength and minimize interface hardness of friction welded dissimilar joints of austenitic stainless steel and copper alloy

An attempt was made to optimize friction welding parameters to attain a minimum hardness at the interface and a maximum tensile strength of the dissimilar joints of AISI 304 austenitic stainless steel （ASS） and copper （Cu） alloy using response surface methodology （RSM）. Three-factor, five-level central composite design matrix was used to specify experimental conditions. Twenty joints were fabricated using ASS and Cu alloy. Tensile strength and interface hardness were measured experimentally. Analysis of variance （ANOVA） method was used to find out significant main and interaction parameters and empirical relationships were developed using regression analysis. The friction welding parameters were optimized by constructing response graphs and contour plots using design expert software. The developed empirical relationships can be effectively used to predict tensile strength and interface hardness of friction welded ASS-Cu joints at 95% confidence level. The developed contour plots can be used to attain required level of optimum conditions to join ASS-Cu alloy by friction welding process.

Precipitation of Epsilon Copper in Ferrite Antibacterial Stainless Steel

The precipitation of epsilon copper at 1023 K ageing in ferrite antibacterial stainless steel was investigated by a combination of electron microscopy and micro-Vickers hardness measurement. The results show that epsilon copper precipitation occurs within 90 s, Complex multilayer structure confirmed as twins and stacking faults on {111}ε-Cu planes was observed in the precipitates. The precipitates grow by the lengthwise enlargement of a set of parallel layers, having [111]ε-Cu and [112]ε-Cu preferred growth orientations. The volume fraction of precipitates f formed within 120 min can be predicted by a modified Avrami equation （In1/1-f= kt ＋ b）. Simultaneously, substituent atom clusters with a size of 5-10 nm was found to occur in the solution and cause matrix strain. The precipitate morphology and distribution on the surface of ferrite antibacterial stainless steel are associated with surface crystallographic orientation of the matrix. The precipitates are predominantly located within the ferrite grains of 〈110〉 orientation. The precipitates located on {111}α-Fe surface planes have sphere or ellipse shape.

Surface segregation of copper in antibacterial ferritic stainless steel

By using auger electron spectroscopy （AES） and diffusion theory to analyze the surface segregation of copper in antibacterial ferritic stainless steel, establishing a diffusion model, and calculating the activation energy of diffusion of the copper in ferrite, the affect of surface segregation on the antibacterial capabilities were researched. The results show that the concentration of the copper surface at 973 K and 1 073 K could be expressed asln X^sCu/X^bCu = k0 √Dt/d（-△Hv^Cu＋△Hf^tron＋ △Hs^Cu）/3RT , with the parameters relating to the concentration of the diffusion layer, the coefficient of diffusion, the length of diffusion, the latent heat of evaporation and the latent heat of fusion. The activation energy of diffusion of copper in ferrite is approximately 221. 688 kJ/mol. The antibacterial property of the steel is improved as the surface segregation of the copper is increased. At 1 073 K for 60 min, the concentration of the surface copper is over three times higher than the basic concentration. The antibacterial property of the stainless steel can reach approximately 99.9%.

Copper Removal from Molten Steel by Gasification

A novel method is proposed to enhance the gasification and removal of copper from molten steel by adding ammonium salts or urea into molten steel under normal pressure.The decopperization experiments were conducted in a molybdenum-wire resistance furnace at 1 873 K.The copper content of about 400 g of a mild steel was reduced from 0.49%(mass fraction,the same below) and 0.51% to 0.31% and 0.38% using 0.7 g of NHC1 and 0.5 g of(NH)COrespectively,while the copper content of the molten steel was reduced from 0.61%to 0.56% using 2.00 g of NHCONH.

Microbial communities present on mooring chain steels with different copper contents and corrosion rates

Copper has long been utilized as a disinfectant for bacteria,but its impact on microbial communities attached to the steel surface in seawater remains unknown.In the present study,3 mooring chain steels of different copper contents are subjected to a 3-month marine field exposure,and the corrosion rate increases in the order of BR5 steel(without copper)<BR5 CuH steel(0.8%copper)<BR5 CuL steel(0.4%copper).The microbial community results show that copper introduction does not result in an obvious change in microbial quantity,but it alters the diversity,richness,and structure of microbial communities due to the variation in copper-resistance of different species.BR5 CuH steel holds microbial communities with the highest percentage of some well-known corrosive microbes including sulfate-reducing bacteria,sulfuroxidizing bacteria,and iron-oxidizing bacteria,but possesses the lowest community diversity/richness owing to the toxicity of copper.The microbial community diversity/richness is stimulated by the low-copper content of BR5 CuL steel,and this steel also carries an intermediate proportion of such corrosive bacteria.Both well-known corrosive bacteria and microbial community diversity/richness seem to be involved in the corrosion acceleration of copper-bearing mooring chain steels.

EFFECTS OF COPPER ION IMPLANTATION ON ANTIBACTERIAL ACTIVITY OF AISI420 STAINLESS STEEL

Antibacterial activity of AISI420 stainless steel (SS) implanted by copper was investigated. Ions extracted from a metal vapor vacuum arc (MEVVA) are sourced with 100keV energy and a dose range from 0.2×1017 to 2.0×1017ions·cm-2. The saturation dose of Cu implantation in AISI420 SS and Cu surface concentration were calculated at the energy of 100keV. The effect of dose on the antibacterial activity was analyzed. Results of antibacterial test show that the saturation dose is the optimum implantation dose for best antibacterial activity, which is above 99% against both Escherichia coli and Staphylococcus aureus. Novel phases such as Fe4Cu3 and Cu9.9Fe0.1 were found in the implanted layer by glancing angle X-ray diffraction (GXRD). The antibacterial activity of AISI420 SS attributes to Cu-contained phase.

Microstructure and mechanical properties of laser welded joints of pure copper and 304 stainless steels

A continuous wave diode laser with an output power of 2.8 kW was used to join pure copper and 304 stainless steel with a thickness of 1 mm. The focused laser beam with a diameter of O. 8 mm was irradiated on the copper side of the butt joints. In process of laser welding, effects of processing primary parameters on tensile strength of the joints were investigated. The interfacial characterizations of the joints were investigated by metallographic microscope, scanning electron microscope （SEM） and energy dispersive X-ray spectroscope （EDS）. The results showed that the element diffusion and solution occur and metallurgical bonding was achieved between pure copper and 304 stainless steel. The maximum tensile strength of the joints was 209 MPa when the laser power of welding was 2. 4 kW and welding speed was 12 mm/s.

Investigation on Electron Beam Welded Copper to AISI 316 Stainless Steel Joints

Joints of copper and stainless steels are used in a er ospace applications. Production of these joints by fusion welding faces many dif ficulties. This may be due to the differences in their physical, metallurgical a nd mechanical properties. Electron Beam Welding (EBW) process has been found to be especially well suited in this area. Selection of the appropriate welding par ameters needs thorough investigations. These parameters include: preheat tempera ture (℃), welding current (I w), focusing current (I F), welding spee d (V), height between the gun and workpiece surface (H), scan width (S w) and shift distance (S). The present work aims firstly, setting the pr oper welding conditions to get sound joint between commercially pure copper (C10 200) and AISI 316 stainless steel plates 8 mm thickness. Secondly, investigate t he effect of Electron Beam (EB) shift, single-sided and double-sided welds on the mechanical, metallurgical and chemical properties of the weld bead. Due to t he high difference in thermal conductivity between copper and stainless steel, E lectron Beam (EB) was shifted towards copper with different values. These values were ranged from 0.3 to 0.9 mm in welding without preheating of copper plate an d from 0.1 to 0.4 mm with preheating. Number of joints were welded using variabl e EBW parameters in view to obtain the sound weld bead. These parameters are as follows: gradual reduction I w=51 to 49 mA, I F=845 mA, V=8 mm/sec , H=130 mm, S w=500 μm and S=0.4 mm. The investigation has shown t hat, the copper (C10200) plate must be preheated to get sound welded joint with AISI 316 stainless steel using the EBW process. The tensile fracture in all wel ded samples occurred in copper plate away from the weld bead. This reflects that the weld bead tensile strength is greater than the copper strength. The EB shif t has slight effect on hardness distribution through weld bead. The hardness val ue (H v) reduces in gradual manner from stainless steel hardness to copper one. The EB shift distance has no significant effect on the impact toughness.

Microstructure and properties of pure iron/copper composite cladding layers on carbon steel

In the present study, pure iron/copper composite metal cladding was deposited onto carbon steel by tungsten inert gas welding. The study focused on interfacial morphological, microstructural, and mechanical analyses of the composite cladding layers. Iron liquid–solid-phase zones were formed at copper/steel and iron interfaces because of the melting of the steel substrate and iron. Iron concentrated in the copper cladding layer was observed to exhibit belt, globule, and dendrite morphologies. The appearance of iron-rich globules indicated the occurrence of liquid phase separation（LPS） prior to solidification, and iron-rich dendrites crystallized without the occurrence of LPS. The maximum microhardness of the iron/steel interface was lower than that of the copper/steel interface because of the diffusion of elemental carbon. All samples fractured in the cladding layers. Because of a relatively lower strength of the copper layer, a short plateau region appeared when shear movement was from copper to iron.

Effect of tempering temperature on the mechanical properties and microstructure of an copper-bearing low carbon bainitic steel

The effect of tempering temperature on the microstructure and mechanical properties of ultra-high strength, copperbearing, low-carbon bainitic steel has been investigated in the experiment. The results showed that the microstructure was mainly the laths of bainite in the as-quenched steel. The bainitic laths were restored and combined after the steel tempered at various tempera- tures. There were rnartensite/austenite （M/A） islands and numerous dislocations within and between the bainitic laths, while very t-me precipitates of ε-Cu were also observed within the laths. With increasing the tempered temperature from 400 to 600℃, the yield strength （YS） increased from 877 to 957 MPa, whereas the ultimate tensile strength （UTS） decreased from 1020 to 985 MPa. The Charpy V-notch （CVN） varied from 68.5 to 42 J, and the value was minimal for the steel tempered at 500℃. 2008 University of Science and Technology Beijing. All rights reserved.