No 3 (2021)

Full Issue

The influence of postweld tempering on mechanical behavior of friction welded joints of 32G2 and 40HN steels under high-cycle fatigue

Atamashkin A.S., Priymak E.Y.

Abstract

At modern mechanical facilities, the friction-welded joints are getting widespread as the most advanced production technique characterized by high efficiency, processability, cost-effectiveness, and safety. Moreover, it allows producing high-quality joints of a large number of different analogous and opposite metals and alloys. Despite all these advantages, one should consider that metal, in the process of welded joint formation, suffers a local thermo-deformational effect, which causes the gradient nature of the structure and residual strains of a welded joint. These factors directly influence the structure’s working ability and durability under fatigue loads, which are the most common cause for parts failure. The paper contains the assessment of the post-weld tempering influence on the cyclic life of welded joints of 32G2 and 40HN steels produced using the rotational friction welding technique. The authors tested laboratory specimens with welded joints under the high-cycle fatigue using the simulation machine with the two-point fastening of a revolving specimen under the action of even twisting moment. The study involved the statistical processing of the obtained results of cyclic life. Based on the metallographic analysis, the authors identified the weak points in welded points where the fatigue cracks initiation and progress occurred in the initial state and after tempering. The paper presents the fractographs illustrating the fracture mechanism of specimens under the study. The authors identified the influence of different tempering temperature modes on the cyclic life of the studied welded joints and the nature of their fracture. The study shows that tempering at the temperature over 400 °C promotes fracture acceleration under the effect of fatigue loads due to the development of return and polygonization processes in the vulnerable area of the thermomechanical action zone.

Frontier Materials & Technologies. 2021;(3):7-18
pages 7-18 views

Identification of acoustic emission sources in a polimer composite material under the cycle tension loading

Bryansky A.A., Bashkov O.V.

Abstract

The structure of polymer composite materials (PCM) provides high mechanical properties but, at the same time, is highly sensitive to the formation of internal defects. Therefore, when designing, manufacturing products, and assessing their reliability in service, much attention is paid to the methods of non-destructive testing, among which the method of acoustic emission (AE) has proven itself to study structural changes in material under external influence. The paper deals with the identification of typical damages in fiberglass samples made of T11-GVS9 glass fiber cloth and DION 9300 FR binder and tested under cyclic tension using the AE method. In the work, the authors solved the problem of selecting the AE informative parameters and used a clustering method to identify the nature and the formation kinetics of the AE sources. The authors performed clustering using the Kohonen self-organization map (SOM) with the Fourier spectra calculated for the AE signals recorded during cyclic tests. Based on the peak frequencies analysis of the produced clusters, the researchers determined their nature and calculated the periods of critical accumulation. When characterizing the AE sources, the authors used the peak frequencies analysis of the wavelet spectra performed for different levels of decomposition. The authors determined the damage accumulation stages of samples during testing based on own research and research by other authors’ results. The study established that registration of AE signals identified as adhesion failure can be used to identify the onset of the material destruction and characterized the local formation of micro-damages in the matrix and fracture of fibers can be used to predict the destruction of PCM.

Frontier Materials & Technologies. 2021;(3):19-27
pages 19-27 views

Epoxy antifriction coatings filled with the rice husks ash treated with surfactants

Valeeva A.R., Gotlib E.M., Yamaleeva E.S.

Abstract

The use of epoxy antifriction coatings can significantly reduce thermal stress in the friction zone and expand the coating working temperature interval while keeping high wear resistance. The paper considers the effect of non-activated and activated by surfactants silicate filler – rice husk ash on the physicochemical and mechanical properties of epoxy materials applied as antifriction coatings. All studied samples of rice husk ash, both initial and activated with surfactants, have an alkaline surface nature. The study identified that all cationic quaternary ammonium salts (QAS) reduce the pH of rice husk ash. At the same time, nonionic OXIPAV increases this indicator. Activation of the rice husk ash surface, both by the quaternary ammonium salts and aminosilanes, significantly reduces the porosity of this silicate. In this case, the average pore diameter does not change significantly, and their specific surface area decreases significantly, to a lesser extent, when activated by nonionic quaternary ammonium salts. The application of quaternary ammonium salts and aminosilanes in the amount of 33 % for activation of the surface of the investigated silicate filler reduces its modifying effect in epoxy compositions, regardless of the chemical structure of the surfactants used, which is not a typical effect. Therefore, the authors assumed that the suboptimal concentration of quaternary ammonium salts and aminosilanes was used. The study identified that the optimal concentration of 50 % alcohol solution of KATAPAV is 14.7–21 %. In this range of the QAS content, there is a significant increase in hardness (about 40 %), a slight decrease in wear (about 10 %), and a significant decrease in the coefficient of static friction (up to 2 times). At the same time, the authors observed an increase in adhesion to metal up to 3 times and bending strength up to 25 %. Thus, rice husk ash activated with an optimal amount of quaternary ammonium salts is an effective modifier of epoxy coatings, which improves their antifriction properties and increases wear resistance, hardness, strength, and adhesion characteristics.

Frontier Materials & Technologies. 2021;(3):28-36
pages 28-36 views

The influence of elemental powder raw material on the formation of the porous frame of Ti3AlC2 MAX-phase when obtaining by the SHS method

Davydov D.M., Umerov E.R., Latukhin E.I., Amosov A.P.

Abstract

The ternary carbide compound Ti3AlC2 belongs to the so-called MAX-phases – a new type of ceramic materials with unique properties. A simple energy-saving method of self-propagating high-temperature synthesis (SHS) based on combustion is one of the promising methods for the production of this MAX-phase. is The application of the SHS technology to produce a Ti3AlC2 MAX-phase porous frame with the homogeneous porous structure without such defects as large pores, laminations, and cracks is of great interest. The paper investigates the possibility of producing such a porous frame with the maximum content of the Ti3AlC2 MAX-phase using powders of Ti, Al, and C elements of various grades different in particle sizes and carbon forms (soot or graphite) as initial components. Porous frame samples were produced by the open-air burning of pressed briquettes of charge of the initial powders of the selected grades without applying external pressure. The authors studied the macro- and microstructure of the obtained samples, their density, and phase composition. The study shows that using the finest titanium and carbon powders leads to the excessively active combustion with gas evolution and the synthesis of the defective porous samples with the charge briquette shape distortion, large pores, laminations, and cracks. Besides the titanium carbide by-phase, the highest values for the MAX-phase amount in the SHS-product were obtained using the titanium powder of the largest-size fraction together with the graphite powder, rather than soot. The excess aluminum powder addition to the stoichiometric ratio to the initial charge leads to an increase in the MAX-phase amount in the SHS product, compensating for the loss of aluminum due to evaporation. An increase in the sample volume (scale factor) also leads to an increase in the MAX-phase amount in the SHS product due to the slower cooling of the product after the reaction.

Frontier Materials & Technologies. 2021;(3):37-47
pages 37-47 views

Determination of sustainable levels of design alternatives selection in the workflow cap system

Mitin S.G., Bochkarev P.Y., Shalunov V.V., Razmanov I.A.

Abstract

The development of the mechanical treatment workflow CAP system is aimed at the solution of a crucial task of reduction of terms and the improvement of quality of multiproduct machining manufactures work preparation, as the existing workflow CAP systems have not got the possibility of fast response to changes in a production situation often arising within the multiproduct manufacture. The authors of this paper developed the workflow CAP system, which contains the requirements of the design activity full automation, design solution multivariance, and the feedback with the engineering process implementation subsystem. The paper deals with the development of a mathematical model and the technique of searching for sustainable levels of selecting design alternatives depending on the production situation for the whole design procedures of the workflow CAP system. The authors prove the application of a mathematical tool of genetic algorithms; describe the mathematical model using its terms. As a gene, the level of selection in a separate project procedure is specified. A chromosome is a set of genes according to the project procedures. The objective function determines the minimum total time of processing of the specified nomenclature of parts based on the ranges of gene aggregates resulting from crossing and mutation operations. The result of the work is the mathematical model and the technique for identifying the sustainable levels of selection in each project procedure ensuring the possibility of self-adjustment of the workflow CAP system depending on the production situation.

Frontier Materials & Technologies. 2021;(3):48-56
pages 48-56 views

Characteristics of a gradient material based on Ni-Cr stainless steel and H20N80 alloy produced by electron-beam 3D-printing

Moskvina V.A., Melnikov E.V., Zagibalova E.A.

Abstract

The main problem of additively manufactured chromium-nickel austenitic stainless steels is the formation of a two-phase γ-austenite/δ-ferrite dendritic microstructure, which complicates their use and distinguishes them from cast single-phase analogs. The reasons for the formation of a two-phase structure are nonequilibrium solidification conditions, complex thermal history, and melt depletion by austenite-forming elements (nickel and manganese). Therefore, additional nickel alloying under the additive manufacturing of steels can stabilize the austenitic structure in them. In this work, the authors used electron-beam additive production with simultaneous feeding of two wires from austenitic stainless steel Fe-18.2Cr-9.5Ni-1.1Mn-0.7Ti-0.5Si-0.08C wt.% (SS, Cr18Ni10Ti) and alloy 77.7Ni-19.6Cr-1.8Si-0.5Fe-0.4Zr wt.% (Ni-Cr alloy, Cr20Ni80) to obtain two gradient billets. The authors used two wire-feeding strategies (the first one is four layers of SS/one layer of Cr20Ni80; the second one is one layer of SS/one layer of a mixture 80 % SS + 20 % Cr20Ni80). The study identified that the Ni-Cr alloying in the process of electron-beam additive production of SS billets suppressed δ-ferrite formation and contributes to the stabilization of the austenite phase. The deposition of Ni-Cr alloy next to the four layers of SS leads to inhomogeneity of the structure and chemical composition in the billet, low plasticity, and premature failure of these specimens during tensile tests. The sequential alternation of pure SS layers with those of a mixture of wires (80 % SS + 20 % Cr20Ni80) promotes the uniform mixing of two wires components and the formation of a more homogeneous structure in the gradient billet, which leads to an increase in the ductility of the specimens during mechanical tests.

Frontier Materials & Technologies. 2021;(3):57-66
pages 57-66 views

The research of aging and mechanical properties of nanostructural titanium

Rezyapova L.R., Valiev R.R., Usmanov E.I., Valiev R.Z.

Abstract

It is known that titanium and its alloys are one of the promising materials in the industry, especially in medicine, due to their excellent biocompatibility and corrosion resistance. The latest modern equipment and instruments used in traumatology, orthopedics, dentistry, etc. demand increasingly higher mechanical properties for materials. In comparison with commercially pure titanium, alloys do not have such high corrosion-resistant properties and biocompatibility. In this regard, improving the mechanical characteristics of a pure material is an urgent issue. The authors studied the effect of annealing on the structure and properties of commercially pure grade 4 titanium in the coarse-grained and ultrafine-grained states. The ultrafine-grained state was obtained using high-pressure torsion (HPT) under the pressure of 6 GPa at N=10 revolutions at room temperature. In the microstructure investigated using transmission electron microscopy, the authors could detect particles of precipitated phases after annealing, which had different morphologies. Deformation leads to an increase in the precipitated particles after annealing. The authors carried out an X-ray phase analysis, which showed the approximation of the lattice parameters of the α-phase after deformation and annealing at 700 °C to the values of the parameters of pure titanium. Thus, aging processes occur in the material, accompanied by the decomposition of the supersaturated solid solution and the release of particles of the second phase. The paper shows the results of titanium microhardness measurements in different states. The combined treatment, consisting of HPT at N=5 revolutions, annealing at 700 °C, and additional HPT deformation at N=5 revolutions, allowed obtaining the record strength for commercially pure grade 4 titanium.

Frontier Materials & Technologies. 2021;(3):67-73
pages 67-73 views

Obtaining graphene structures and nanopolymers using ultrasonic vibrations

Rubanik V.V., Savitsky V.O., Rubanik jr. V.V., Lutsko V.F., Nikiforova I.V., Bui H., Doan D.

Abstract

Graphene-based polymer nanocomposites are considered a promising class of future materials. The degree of filling, the filler and binder nature, and the shape, size, and mutual arrangement of filler particles determine the properties of a polymer composite material. The destruction of nanoparticles aggregates occurs most effectively in liquid media under the action of ultrasonic vibrations. The authors proposed the technique and designed laboratory equipment for ultrasonic treatment of the finely-dispersed graphite suspension, carried out the ultrasonic treatment (UST) of finely-dispersed graphite powder. The suspensions based on graphite with a solvent were obtained. The authors carried out the experiments on producing graphene using the graphite liquid-phase exfoliation method at the ultrasonic treatment with different ultrasonic treatment times, analyzed experimental data, and selected the UST optimal time. The paper contains the results of the study of the effect of the graphite suspension base on the degree of ultrasonic liquid-phase exfoliation of graphite. The most effective synthesis of graphene structures using UST is synthesis from graphite suspensions based on dichloroethane, benzol, and dichlorobenzene. Graphene structures’ output ratio amounts to up to 66 %. The authors developed the technology for producing polymers modified with graphene structures using ultrasonic dispersion. Based on graphene synthesized by the graphite liquid-phase exfoliation, the authors obtained nanopolymers using ultrasonic vibrations, carried out DSC measurements, and studied their strength properties. The limit strength of elastic polymers is from 1.9 to 3.6 MPa at different concentrations of graphene inclusions. The residual elongation of samples within the deviation did not change and amounted to 200 %.

Frontier Materials & Technologies. 2021;(3):74-83
pages 74-83 views

Effect of γ′-phase particles on the mechanical behavior and deformation mechanism of (CoCrFeNi)94Ti2Al4 high entropy alloy single crystals

Saraeva A.A.

Abstract

Recently, the interest of researchers has focused on a new FCC class (FCC – face-centered cubic lattice) high-entropy alloys (HEA), due to their unique properties – high values of the strain hardening coefficient, good plasticity, and ductile fracture at low test temperatures. Such a combination of properties in an FCC of HEA is achieved by mixing five or more elements in equal atomic proportions. Due to the strong temperature dependence of stresses at the σ0.1(T) yield point, these alloys have low σ0.1 values at temperatures above room temperature, which hinders their practical application. A precipitation hardening is an effective way to achieve high strength and is successfully used for hardening HEA FCC. The paper studied the influence of ageing at 923 K for 4 hours and at 1073 K for 18 and 30 hours on the mechanical behavior of single crystals of (CoCrFeNi)94Ti2Al4 (at.%) HEA FCC oriented along the [001] direction under tension. Ageing at 923 K for 4 hours and at 1073 K for 18 and 30 hours leads to the precipitation of γ′-phase particles, the size and volume fraction of which depend on the ageing temperature and time. The γ′-phase particles precipitation leads to an increase in stresses at the yield point from 47 MPa (ageing at 923 K, 4 hours) to 226 MPa (ageing at 1073 K, 30 hours) relative to quenched crystals at 296 K. The study identified the dependence of the strain hardening coefficient, plasticity, and the maximum stress level before fracture on heat treatment. The author discussed the reasons for the growth of stresses at the yield point and the strain hardening coefficient upon precipitation of γ′-phase particles. 

Frontier Materials & Technologies. 2021;(3):84-90
pages 84-90 views

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