No 1 (2022)

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Simulation of the surface defects influence on the aluminum alloy behaviour under the cyclic load conditions

Almazova L.A., Sedova O.S.

Abstract

Aluminum and its alloys, such as the Al–Si–Mg alloy, are widely used in various industrial and engineering fields due to their mechanical properties. In this case, the defects occurring during the casting process adversely affect the behavior of this alloy under cyclic load conditions. Therefore, the study aimed to investigate the surface defect influence on the material's fatigue strength is currently of great importance. The paper presents a numerical investigation based on the finite element method intended to evaluate the effect of the interaction of the complex-shaped defects on the stress of the Al–Si–Mg aluminum alloy. The developed complex-defect model consists of a hemispherical main (base) defect and a secondary defect at the bottom of the main one. The authors use the Chaboche model to describe the material’s behavior under the cyclic load conditions. The paper contains the computational solution constructed with the ANSYS Workbench platform. The authors supposed that it is possible to approximate the considered complex defect form by an equivalent simplified defect. The study shows that the maximum von Mises stress values for the complex-shaped defects are achieved at the joint of the secondary defect with the main one. In the case of an equivalent defect, the maximum values are observed at the defect's bottom and on the periphery. The authors comparatively estimated the uncertainty obtained using an equivalent defect and the cases of three complex-shaped defects and three hemispherical defects without additional (secondary) damage. This estimation shows that in the case of a complex-shaped defect, the equivalent defect model has an error of 14.5 %, which is 6.5 % greater than in the case of the hemispherical defects without secondary damages at the bottom.

Frontier Materials & Technologies. 2022;(1):7-14
pages 7-14 views

The influence of chemical composition on solid solution and strain hardening of single crystals of FCC high-entropy alloys

Vyrodova A.V.

Abstract

A characteristic feature of high-entropy alloys is high strength at maintaining plasticity, wear and corrosion resistance, and fracture toughness at cryogenic temperatures. Currently, CoCrFeNiMn is the best-investigated high-entropy compound. However, its application is limited in the high-temperature region due to the low values of the deforming stress level at the plasticity breaking point at T>296 K. One of the common ways to improve the material durability is the addition of substitution atoms of larger atomic radius, and Al, Ti, and Mo are some of these atoms. The paper presents the analysis of the mechanical behavior of single crystals of CoCrFeNiMn and CoCrFeNiMо FCC high-entropy alloys (at. %) oriented along the [001] direction: the author studied the temperature dependence of critical shear stresses τcr(T) within the temperature range of T=77–973K, the type of dislocation structure, strain hardening coefficient θII, plasticity and fracture at Т=296 K under tension. The study shows that the alloying with Mo atoms 4 at. % of the CoCrFeNi system (at. %) causes the solid solution hardening, and critical shear stresses τcr increase within the entire studied temperature range. The onset of plastic deformation is associated with slip at all temperature tests. At T=296 K, the author identified a planar dislocation structure with flat dislocation pile-ups and dislocation networks in CoCrFeNiMo while in equiatomic CoCrFeNiMn, at such test temperature, a uniform distribution of dislocations was observed in several systems without flat pile-ups. Work hardening coefficient, plasticity, and the level of stresses before fracture turn out to be similar in [001]-crystals of CoCrFeNiMo and CoCrFeNiMn high-entropy alloys, which are determined by the development of slip deformation simultaneously in several systems. Crystals are destroyed viscously at 296 K at the same level of stress.

Frontier Materials & Technologies. 2022;(1):15-23
pages 15-23 views

Electrolytic production of magnesium coatings

Gnusina A.M., Gryzunova N.N.

Abstract

Magnesium, its compounds, and alloys arise recently the heightened interest among scientists all over the world. The interest in magnesium research is caused by its combination of many promising properties that find practical application in various sectors of the national economy. On an industrial scale, the bulk of magnesium is produced by the electrolysis from the melt. However, there is a problem with the environmental security of this process. This method is environmentally unfriendly since it is accompanied by the release of hazardous chlorine and organochlorine compounds into the environment. In some cases, the electrodeposition from solutions may serve as an alternative. The task to produce magnesium and magnesium-containing coatings using electrodeposition from solutions was already raised, but it is not yet possible to obtain a stable electrolyte that allows obtaining high-quality coatings. The authors propose an electrolyte in which isopropyl alcohol is used as a solvent. Magnesium-containing coatings were produced by electrodeposition on a conductive base. The authors prepared an electrolyte based on anhydrous magnesium sulfate. To increase the conductivity of the electrolyte, sodium, potassium, and calcium chlorides in different concentrations were added to the solution. The authors carried out the experimental studies of the effect of the electrolyte composition and electrodeposition modes on the morphology and elemental composition of magnesium-containing coatings. Electron microscopic studies and the studies of the elemental composition of samples by the energy-dispersive X-ray fluorescence spectrometer show that the non-stationary (two-step) electrodeposition mode is the optimal one for producing magnesium coatings with a fine crystalline structure, low porosity, and high magnesium content.

Frontier Materials & Technologies. 2022;(1):24-30
pages 24-30 views

The influence of friction stir welding conditions on thermal stability of АА6061 alloy

Kalinenko A.A., Mironov S.Y., Vysotskiy I.V., Malopheyev S.S.

Abstract

Friction stir welding (FSW) is an innovative technology for the solid-phase joining of metal materials. It allows producing permanent joints of materials conventionally considered to be nonweldable, in particular aluminum alloys. However, an essential drawback of FSW is the relatively low stability of the stir zone microstructure. In particular, during post-weld heat treatment, seams frequently demonstrate abnormal grain growth. Such an undesirable phenomenon is often interpreted in terms of the so-called Humphrey’s cellular model, according to which the abnormal behavior is attributed to the essential microstructure refinement and the dissolution of the second-phase particles occurring during FSW. Since these two processes significantly depend on the temperature, the authors suggested that the thermal stability of the produced FSW seams should also be associated with the FSW heat conditions. To test this hypothesis, the authors obtained two welded seams at different FSW conditions and then studied their microstructural behavior during T6 mode thermal treatment (involving solution heat treatment followed by artificial aging). The authors used the advanced electron backscatter diffraction technique (EBSD) to investigate microstructure. In full accordance with the initial idea, the investigation showed that microstructural evolution in both studied microstructure states varied wildly. Specifically, the study identified that the reduction in the FSW temperature causes the suppression of abnormal grain growth. The authors suggested that the enhanced thermal stability of the material is associated with the conservation of the second-phase particles during the low-temperature FSW.

Frontier Materials & Technologies. 2022;(1):31-39
pages 31-39 views

The interrelation between the electrodeposition parameters and surface morphology of nickel coatings in the presence of a growth inhibitor

Matveeva N.S., Gryzunova N.N.

Abstract

On the one hand, nickel and nickel coatings are well-studied objects in terms of their wide practical application; on the other hand, the application of various approaches to their production and structuring gives new possibilities for changing their properties. At present, the research activities related to the change in nickel physicochemical properties through nanostructuring are being carried out. Methods and techniques for producing nanostructured materials are very diverse. However, many of them are considered energy-intensive and economically unviable. The work solves the problem of obtaining nickel coatings and changing their properties through electrodeposition from aqueous solutions of electrolytes. The paper studies the effect of additives to a nickel electrolyte on the habit of crystals formed in the coating and, consequently, the nickel coating morphology. The authors used sodium, potassium, and calcium chlorides in the same molar concentration to be additives. During the electrodeposition of coating samples, the substrate nature and the electrolysis regimes changed. The deposition was carried out in the stationary mode of electrodeposition within one or two stages of electrolysis. The authors studied the obtained samples by scanning electron microscopy methods using X-ray diffraction analysis. The study identified that chlorides can significantly change the coating surface morphology. Depending on chloride concentration and deposition regimes, the surface morphology of nickel coatings changes from the three-dimensional cone-shaped structures to the lamellar habit. Chlorides allow forming crystals with pentagonal symmetry as well. The addition of chlorides affects the growth of crystals in certain crystallographic directions (111), which may be the result of their inhibitory effect. The obtained nickel coatings have a regular microrelief.

Frontier Materials & Technologies. 2022;(1):40-48
pages 40-48 views

The comparison of the main time-frequency transformations of spectral analysis of acoustic emission signals

Rastegaeva I.I., Rastegaev I.A., Agletdinov E.A., Merson D.L.

Abstract

Due to the intensive development of spectroscopic techniques for detecting acoustic emission signals, the problem of providing the best time-frequency resolution through the application of specific time-frequency transformation algorithms comes to the fore. The Short-Time Fourier Transform, the Wavelet Transform, the Smoothed Pseudo Wigner Distribution, the Choi-Williams Distribution, and the Hilbert-Huang Transform are currently the main time-frequency transformations used or integrated into the acoustic emission method. However, today in the literature, there is not enough information that allows evaluating time-frequency transformations regarding the effectiveness of their application to specify the features of discrete and continuous acoustic emission signals. On this basis, the authors carried out an experimental comparison of synthetic and actual model signals to determine the efficiency of specified time-frequency transformations. The synthetic model signals were a chirp signal, ideal sinusoids, and a Dirac delta function. The actual signals were a discrete acoustic emission signal from the Hsu Nelson source decomposed into dispersion modes in the acoustic channel and a continuous acoustic emission signal from the air outflow through a calibrated hole. The analysis shows that only the Fourier transform and the Wavelet transform can define all control features of model signals at the frequency components’ energy gap of about 25 dB. Wigner Distribution, Choi-Williams Distribution, and Hilbert-Huang Transform demonstrated higher time-frequency resolution did not identify frequency components of low energy. Therefore, the authors recommend using them to identify spectral changes in the resonance and discrete signals but in the narrow energy range. The Fourier transform and the Wavelet transform demonstrated the best result to analyze continuous acoustic emission. However, to use the latter, the procedure of selection of the optimal basis function is necessary. The study determined that the Hilbert-Huang transform allows identifying the frequency fluctuations, but it is necessary to develop ways to increase sensitivity and extract basic information from the spectrograms to enhance the validity of its results.

Frontier Materials & Technologies. 2022;(1):49-60
pages 49-60 views

Special aspects of structure formation of a transition zone in a layer composite produced by explosion welding

Rozen A.E., Kharina I.L., Gudenko A.S., Pryshchak A.V., Khorin A.V., Batrashov V.M., Guskov M.S., Rozen A.A., Kozlov D.V.

Abstract

The paper presents the research on special aspects of structure formation in the transition zones of a layer metal material made of structural carbon and alloy stainless steels with an internal protector. The authors specify the order of layers arrangement. As an industrial method of producing such a material, the explosion welding technology was selected, which ensures the production of three-, four- and six-layer materials with one and two internal protectors per one explosion. The selection of optimal process parameters was carried out using computer modeling in the LS-DYNA software product. By calculation, the authors determined the main technological parameters of the process, which provide in the contact zone at each interlayer boundary the ratio of the amplitude of the generated waves to their length in the range from 0.3 to 0.5. Mechanical tests of multilayer workpieces were carried out. The shear strength of layers was from 320 to 410 MPa, the ultimate tensile strength of the main layer was from 520 to 710 MPa, the impact resistance was from 290 to 740 kJ/m2, and the bending angle under static loading was 140 degrees and higher. The authors determined the phase composition and characteristics of the crystallographic structure of transition zones of a layer metal material with an internal protector. The study identified the presence of γ-Fe with a face-centered crystal lattice, two cubic structures, one hexagonal, and one orthorhombic. On the samples with artificial pitting, the authors determined their influence on the rate of anodic dissolution of a protective layer when contacting with an aggressive environment. The study shows that the interlayer boundaries with a homogeneous structure and minimal thickness have the highest corrosion resistance.

Frontier Materials & Technologies. 2022;(1):61-72
pages 61-72 views

Forming an edged cubic texture in band substrates made of (Cu+Ni)–Me (Me=Mo, Mn, Nb) alloys for high-temperature second-generation superconductors

Suaridze T.R., Khlebnikova Y.V., Egorova L.Y.

Abstract

After cold-rolling reduction with the shrinkage of more than 97 % and recrystallization annealing, the edged cubic texture develops in some fcc lattice metals with the high and medium values of stacking fault energy such as Ni, Cu, Al, Pt, and some alloys on their base. The extended bands of metals and fcc lattice alloys can be used to apply multilayer functional compositions. The authors studied the structure and crystallographic texture in bands of three-component copper-nickel-based alloys. The study showed the crucial possibility of creating multi-component alloys based on the Cu+40% Ni binary alloy doped with such elements as Mo or Nb. The paper considers the formation of an edged cubic texture in bands of Cu–Ni–Mn, Cu–Ni–Nb, and Cu–Ni–Мо alloys produced through cold deformation with rolling and recrystallization annealing performed at different temperatures. The study identified that annealing during one hour at 1050 °С was an optimal recrystallization annealing mode when on the surface of bands made of (Cu+40 % Ni)–Me alloys (where Me=Mn, Mo, Nb) deformed at ~99 %, the most perfect cubic texture was realized. According to the data obtained, after such annealing mode, from 94% to 98% of grains with orientation {001}<100> developed in the Cu–40% Ni–1.3% Mn, Cu–40% Ni–0.8% Mo, and Cu–40% Ni–0.5% Nb alloys. It opens the prospect of using these alloys as epitaxial substrates in the technology of high-temperature second-generation superconductors. The evaluation of mechanical characteristics showed that alloying contributed to an increase in the yield strength of Cu–40% Ni–1.3% Mn, Cu–40% Ni–0.8% Mo, and Cu–40% Ni–0.5% Nb alloys by 3–4 times compared with the yield strength value of a textured copper band.

Frontier Materials & Technologies. 2022;(1):73-81
pages 73-81 views

The influence of aging on phase composition and mechanical properties of vanadium-alloyed high-nitrogen steel

Tumbusova I.A., Maier G.G.

Abstract

Complex solid solution hardening of austenitic chrome-manganese steels by nitrogen and carbon is one of the most effective ways of production of high-nitrogen austenitic steels (HNS) without using special casting methods. To enhance the solubility of interstitials in the metal liquid state and suppress undesired secondary phases of Cr2N and Cr23C6, the carbide-forming elements (for instance, vanadium) are added to the HNS composition. By now, there are no experimental works on the age-hardening of ultrahigh-interstitial vanadium steels (more than 1 % wt.). In the present work, the authors used the X-ray structure analysis method, electron microscopy, and the uniaxial static tensile tests to study the effect of temperature (600 °С and 700 °С) and duration (0.5 h, 5 h) of age-hardening on the structure and mechanical properties of ultrahigh-interstitial vanadium-containing Cr–Mn steel (Fe–22Cr–26Mn–1.3V–0.7C–1.2N, N+C=1.9 % wt.). The experiments demonstrated that due to the complex decomposition (by intermittent and continuous mechanisms) of austenite saturated by interstitials, the aging at 600 °С and 700 °С is accompanied by a solid-solution hardening of the austenitic phase by carbonitrides Cr2(N, С) and (V,Cr)(N,С). The study identified that the increased temperature and prolongation of age-hardening stimulate the movement of intermittent decomposition front from the boundaries to the center of austenitic grains. (V,Cr)(N,С) particles formed by the continuous decomposition in the austenitic grains hinder the propagation of the reaction front, meanwhile, the large spherical (V,Cr)(N,C) and Cr2(N,C) particles, not dissolved after quenching, have little effect on its movement. At the chosen age-hardening modes, the yield strength of steel increases, and the fracture elongation decreases.

Frontier Materials & Technologies. 2022;(1):82-90
pages 82-90 views

The analysis of changes in microhardness, creep rate, and morphology of the VT1-0 titanium fracture surface deformed under the action of the constant magnetic field of 0.3 T

Shlyarov V.V., Zagulyaev D.V., Serebryakova A.A.

Abstract

Today, a promising research area is the study of the behavior of the materials’ technological and physical characteristics under the external energy effects, such as constant magnetic fields. It is caused by the emergence of multifactorial scientific and industrial problems arising because of the introduction of high technologies into production. One of the directions is the production of new equipment, devices, and machines that somehow form electromagnetic fields around them. Therefore, an umbrella approach to studying the influence of magnetic field effects on the deformation characteristics of metals and alloys contributes to a deeper understanding of the physical nature of this effect. As an object for the research, the authors selected commercially pure titanium of VT1-0 grade. The work aims to study the influence of a constant magnetic field of 0.3 T on microhardness, creep rate, and fracture surface of commercially pure VT1-0 titanium. The results show that under the influence of a constant magnetic field of 0.3 T, the relative value of VT1-0 titanium microhardness decreases by 2–5 %, followed by relaxation to the initial value. The creep rate of titanium increases by approximately 31 % when applying a field of 0.3 T induction during the test (without field applying, the creep rate is 2.4 %/h, in the magnetic field is 3 %/h). The fracture surface analysis using scanning electron microscopy (SEM) shows that titanium specimens undergo ductile fracture. Numerous equiaxial destruction pits characterize the fracture surface. It should be noted that pits with the stretched areas are present mainly on the samples destroyed under the creep conditions in a constant magnetic field of 0.3 T.

Frontier Materials & Technologies. 2022;(1):91-100
pages 91-100 views

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