Browse Topic: Ferrous metals

Items (13,119)
Austenitic stainless steel (AISI 316L) is highly valued in various industries for its properties, especially related to wear and corrosion resistances. There are several applications of austenitic stainless steel in the automotive industry. This study investigates the effects of porosity of SS316L samples fabricated using powder metallurgy (uniaxial pressure). Two different compaction pressures, 300 MPa, and 600 MPa, were applied to analyze their influence on the material’s density, porosity, microstructure, hardness, and abrasion responses. The SS316L samples were sintered at 1120 °C for 30 min. The microstructural analysis revealed that the sample pressed at 600 MPa exhibited higher density and lower porosity (18.9%) compared to the sample pressed at 300 MPa (29.2%). This increased compaction pressure led to a more uniform microstructure with smaller grain sizes and a more consistent distribution of circular pores. Consequently, the hardness of the 600 MPa sample was significantly
Tahanzadeh, SamiraSeriacopi, VanessaRodrigues, DanielMachado, Izabel Fernanda
The development of advanced high-strength steels has become essential in the production of lightweight, safe, and more economical vehicles within the context of the automotive industry. Among the advanced high-strength steels, complex phase steels stand out, characterized by their high formability and high energy absorption and deformation capacity. Laser welding is a technique that applies laser using high energy density as a heat source. It has the advantages that the high welding speed and low heat input compared to other welding methods cause a decrease in deformation, and the narrow width of the weld bead and heat-affected zone allows for the welding of complex parts that would be difficult for other welding methods. Based on a study of a complex phase steel, an analysis was made of the microstructures observed by optical microscopy, the grain boundaries and certain phases contained in this microstructure, as well as the microstructures of each area in the laser welding region
Dias, Erica XimenesReis de Faria Neto, AntonioCastro, Thais SantosMartins, Marcelo SampaioSantos Pereira, Marcelo
This study focuses on machining automobile parts such as drive shafts and axles made of low alloy steel AISI 4140. The influence of cutting inserts geometrical parameters, viz., relief angle (RIA), rake angle (RAA), and nose radius (NA) are studied by designing experiments using Taguchi’s methodology. Numerical simulation is conducted using DEFORM-2D; a suitable L9 orthogonal array (OA) is considered for this work for varying combinations of inputs, and the resultant cutting force, maximum principal stress, and tool life are determined. Adopting a signal-to-noise (S/N) ratio minimizes the outputs for better machining conditions and achieves high-quality components with precision, tolerance, and accuracy. The ideal conditions obtained from the S/N ratio are RAA of 6°, RIA of 3°, and NR of 0.6 mm. Analysis of variance presents that the NR influences the resultant cutting force, wear depth, and work piece damage 73.51%, RAA following by 23.99%, and RIA by 2.03% achieved with a R2 value of
Senthilkumar, N.
In this study, an investigation was conducted on friction stir spot-welded AA7075 aluminum alloy with mild steel. Fusion welding of these two materials presents challenges because of differences in melting points and metallurgical incompatibility. To overcome these challenges, friction stir spot welding was employed for joining these materials. Trial runs were conducted based on a central composite rotatable design matrix, which encompassed four factors at five levels: tool rotational speed, plunge rate, dwell time, and tool diameter ratio. Shear tests were conducted to evaluate the joint strength, and subsequently, an empirical equation was developed via analysis of variance. Notably, a joint fabricated under specific conditions demonstrated exceptional strength, with the highest fracture load of 9.56 kN. These optimal parameters included the tool rotational speed, plunge ratio, dwell time and diameter ratio of 1000 rpm, 4 mm/min, 5 sec and 3.0. This achievement underscores the
Salman, Riyam Abd AlrazaqMohammed, Khidhair JasimRajan, Rajthilak KrishnanSmaisim, Ghassan FadhilSiva Subramanian, R.
The properties of organic nitrate ester that inhibit scale formation were investigated in order to acquire a better understanding of ferrous carbide precipitation from supersaturated solutions. When the scale inhibitor was present, precipitation rates were much lower than when it was missing, even at very low concentrations. When the temperature and time are increased simultaneously, more scale is deposited. The effect of nitrate ester on scale deposition demonstrates that the inhibitory dosage is relatively low at low temperatures but rapidly increases when exposed to high temperatures. The inhibitor is thought to alter the shape of the first crystals by binding to dynamic growth sites and inhibiting the threshold level of development
Sandeep, ChSrinivasan, V. P.Raja Kumar, G.Anandan, R.Shanthi, C.Selvarajan, L.
This research introduces a Detailed Digital Fuel Indicator (DDFI) system to enhance fuel monitoring accuracy in automobiles using advanced infrared (IR) sensor technology for precise fuel level detection. The innovative system includes a secondary tank, meticulously calibrated to the volumetric ratio of the primary tank, to ensure consistent and accurate readings. The DDFI system provides real-time data on fuel levels with an impressive accuracy of ±5%, a notable improvement over the traditional methods. Key components of the system include an IR sensor, a programmable integrated circuit (IC), and a secondary tank fabricated from galvanized iron (GI) sheet metal, ensuring durability and reliability in various environmental conditions. The system is designed to be user-friendly, offering an intuitive interface for drivers to monitor fuel levels effortlessly. Additionally, the DDFI system integrates seamlessly with existing vehicle systems, allowing for easy installation and minimal
Mallieswaran, K.Nithya, R.Rajendran, ShurutiArulaalan, M.
This research investigates the impact of friction stir welding (FSW) used to join micro-alloyed steel, on the material and its mechanical characteristics. FSW increases the metallurgical and mechanical qualities of joints made from micro-alloyed steel. However, Friction Stir Welding has produced only modest improvements in connecting steels. Automobile chassis, offshore platforms, oil and gas pipelines, mining, shipbuilding and railroad carriages, pressure vessels, bridges, and storage tanks are just some of the many places and find micro-alloyed steels employed. Frictional heat and tool movement over the joint cause micro defects occurred. Tungsten carbide tools are used in this investigation. Welding shares the same process characteristics, such as the tool's rotating speed (900 rpm) and axial force (10 kN). The table's traverse speed options are available, including 50 mm/min, 60 mm/min, and 70 mm/min. Vickers microhardness testing machines and tensile testing machines are used to
Rajan, C. SakthiKumar, N. MathanKumar, K. VetrivelKannan, S.Soundararajan, S.
The figures in this SAE Information Report illustrate the principle that, regardless of composition, steels of the same cross-sectional hardness produced by tempering after through hardening will have approximately the same longitudinal1 tensile strength at room temperature. Figure 1 shows the relation between hardness and longitudinal tensile strength of 0.30 to 0.50% carbon steels in the fully hardened and tempered, as rolled, normalized, and annealed conditions. Figure 2 showing the relation between longitudinal tensile strength and yield strength, and Figure 3 illustrating longitudinal tensile strength versus reduction of area, are typical of steels in the quenched and tempered condition. Figure 3 shows the direct relationship between ductility and hardness and illustrates the fact that the reduction of area decreases as hardness increases, and that, for a given hardness, the reduction of area is generally higher for alloy steels than for plain carbon steels. It is evident from
Metals Technical Committee
To meet light-weighting and safety target of automotive vehicles, different Aluminium alloys are used in various body parts. Apart from conventional manufacturing process of gravity die casting (GDC), advanced manufacturing process such as low pressure die casting (LPDC), high pressure die casting (HPDC) and extrusion processes are also used to form complex automotive body parts. Steel parts are majorly used in automotive applications across world. However, steel has limitations with respect to light-weighting. To achieve light-weighting, now a days, there is trend to use these complex Aluminium parts in automotive industry to replace steel and integrate multiple parts into a single one. Aluminium has emerged as great potential for light-weighting and reducing complexity of handling multiple parts at an automotive plant. There is a challenge to identify suitable etchant for microstructural characterization of Aluminium alloy parts that can be made through various manufacturing
Deshmukh, MansiJain, VikasMisal, SwapnaliPaliwal, Lokesh
To meet the corrosion target of automotive vehicles, different coated steel sheets are used in various parts of the body in white (BIW), chassis, and powertrain. Hot dip galvanized (GI) and hot hip galvannealed (GA) are the two most commonly used steel sheets worldwide. Other coatings, such as Zn-Ni, Al-Si, Zn plating, and electro-galvanized zinc coating, are application-specific coatings that are used suitably to meet different performance requirements. To meet the robust corrosion and performance requirements, there is a trend of increasing the use of coated steel sheets in automotive vehicles. While different coated steels have different corrosion performance, they also exhibit different joining and paint adhesion performance. Spot welding is one of the most common technique used for joining automotive parts. Joint strength majorly depends on steel base material grade, chemistry and properties. However, coating on base material also influence joining performance. Major challenge is
Jain, VikasMisal, SwapnaliDeshmukh, MansiPaliwal, Lokesh
Since the inception of battery driven electric vehicles in the automotive world, there has been a constant challenge in maximizing the range of an electric vehicles through various means including battery technology, vehicle weight optimization, low drag coefficients etc. The tires being a viscoelastic composite material have now become a vital to the range performance of an EV. The rolling resistance of a tire is now become a hotter topic than ever. The rolling resistance coefficient (RRC) is the measure of energy loss during rolling due to viscoelastic dissipation in the tire. The viscous dissipation in tire arises due to hysteresis in the various components of a tire including tread, sidewall, inner liner, apex etc rubber compounds. The internal friction between layers of body ply, steel belts and tread crown ply also contribute to the internal heat generation. Therefore, the development of ultra-low RRC tires is a serious challenge for tire engineers. Nevertheless, the recent
Mishra, NitishSingh, Ram Krishnan
This specification covers an aircraft-quality, low-alloy steel in the form of sheet, strip, and plate
AMS E Carbon and Low Alloy Steels Committee
This specification covers established inch/pound manufacturing tolerances applicable to carbon steel bars ordered to inch/pound dimensions. These tolerances apply to all conditions, unless otherwise noted. The term “excl” applies only to the higher figure of the specified range
AMS E Carbon and Low Alloy Steels Committee
This specification covers an aircraft-quality, low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock
AMS E Carbon and Low Alloy Steels Committee
This specification covers an aircraft-quality nitriding grade low-alloy steel in the form of bars, forgings, mechanical tubing, and forging stock
AMS E Carbon and Low Alloy Steels Committee
This specification covers a carbon steel in the form of sheet and strip
AMS E Carbon and Low Alloy Steels Committee
This SAE Information Report summarizes the characteristics of carburized steels and factors involved in controlling hardness, microstructure, and residual stress. Methods of determining case hardenability are reviewed, as well as methods to test for freedom from non-martensitic structures in the carburized case. Factors influencing case hardenability are also reviewed. Methods of predicting case hardenability are included, with examples of calculations for several standard carburizing steels. A bibliography is included in 2.2. The references provide more detailed information on the topics discussed in this document
Metals Technical Committee
ABSTRACT Barriers to the introduction of composite materials for ground vehicle applications include material property selection and cost effective material processing. Advancements in processing of thermoplastic composites for use in applications for semi structural and structural applications have created opportunities in “Out of Autoclave” processing utilizing preconsolidated unidirectional reinforced tapes. Traditional tooling for the bending formation of high temperature reinforced structural thermoplastic laminates typically involves matched metal tooling consisting of steel or aluminum and are costly and heavy. In this research, a comparative analysis was performed to evaluate the use of a large scale 3D printed forming tool in comparison to a traditional metallic mold. Material processing considerations included the development of a technique for localized laminate heating to achieve optimized energy input in the forming process. Considerations in tooling development included
Erb, DavidDwyer, BenjaminRoy, JonathanYori, WilliamLopez-Anido, Roberto A.Smail, AndrewHart, Robert
ABSTRACT Two relevant materials found in ground vehicle underbody armor/hull designs are Aluminum 2139-T8 and RHA Steel (Class I). These are 2 very important materials that need a thorough understanding of their high-strain rate behavior. The Johnson-Cook Deformation (JC-D) model at this time is the most preferred constitutive material model to utilize for high-strain (large deformation) blast simulations. The JC-D Model contains five empirically-based input parameters which can be determined traditionally through a series of uniaxial laboratory tests where each target parameter is isolated, while the remaining parameters are held constant. There are many criticisms and problems with this approach. The objective of this two part paper is to present and adopt a more accurate approach with less criticism to the determination of these five input parameters through both a sensitivity study to determine which input parameters are the most sensitive to a particular chosen response which in
Hause, TerrySheng, Jianping
ABSTRACT Survivability of a welded vehicle hull is directly tied to the performance of the grade of steel armor used. Selecting the highest performing grade of armor that can be welded into a specific location on a vehicle will improve survivability. While rolled homogeneous armor is the simplest to weld, challenges in welding high hard, and especially ultra high hard, are well known. Preventative measures to avoid weld cracking in vehicle structures can lead to increased costs during fabrication. Cracking of welds, both seen and unseen, in deployed vehicles directly impacts the survivability of the vehicle. Weld cracking during deployment further magnifies repair costs and leads to non-mission capable status. This analysis examines the weldability, ballistic/blast performance, and underlying metallurgy of Flash® Processed steels that have been tested by Army, Academia, and Industry. Citation: G. Cola, “Flash® 600 Ultra High Hard: Room-Temp ER120S-1 Weldability Tekken, H-Plate
Cola, Gary M
ABSTRACT α-β titanium alloys are used in armor plate applications due to their capability to defend against ballistic threats while having a 40% lower density than steel. ATI 425® was developed as a cold-deformable alternative to Ti-6Al-4V with similar ballistic properties and improved blast performance owing to the alloy’s higher damage tolerance. ATI Titan 27™ is an evolutionary step forward on ATI 425® Alloy, and is being developed as a higher-performance titanium armor alloy owing to its greater than 10% improvement in strength with similar ductility and formability. Recent work has demonstrated a novel deformation mechanism that explains the improved cold deformation observed in both alloys over Ti-6Al-4V. This mechanism, a twinning of α-phase coinciding with slip in the β-phase, is unique among high-strength titanium alloys. Moreover, twinning is well known to be suppressed with high oxygen content, and ATI Titan 27™ Alloy has one of the highest oxygen targets across high
Foltz, JohnRuiz-Aparicio, LuisBerry, DavidPorter, Rick
ABSTRACT This paper reviews research that has been conducted to develop inductively assisted localized hot forming bending technologies, and to use standardized welding tests to assess the practicality and potential benefits of adopting stainless based consumables to weld both existing and evolving armor alloys. For the titanium alloy Ti6Al4V it was determined that warming the plate to circa 600°F would improve the materials ductility (as measured by reduction of area) from ~18 to 40% without exposing the material to a temperature at which atmospheric contamination would be significantly deleterious. For the commercial alloy BB and class 1 armor alloy it was found that there was little effect on the charpy impact toughness and the proof strength as a result of processing at 900 °F with either air cool or water quench and there was an added benefit of lower residual stresses in the finished bends compared to cold formed bends. Heating “alloy BB” to 1600 °F followed by water quench
Lawmon, JohnAlexandrov, BoianDuffey., MatthewNgan., Tiffany
ABSTRACT FeMnAlC alloys exhibit lower density (6.5-7.2 g/cm3) than traditional military steels (7.9 g/cm3) while maintaining similar energy absorption capabilities. Material substitutions in legacy systems must meet existing form/fit/function requirements, limiting opportunities for lightweighting of existing designs. This study examines production and material properties of thick plate with a nominal chemistry of 30% Mn, 9%Al and 1%C, in the wrought condition. Due to the high aluminum and carbon content, there are unique challenges to large scale (45+ ton heat) production versus typical armor steel chemistries. Lab-scale wrought and production material are characterized, comparing microstructure, and mechanical properties. Processing practices including teeming flux and rolling temperature are discussed. The high manganese content of this alloy presents challenges for welding and machining practices, such as limited compatibility of weld wires and substantial work hardening during
Sebeck, KatherineToppler, IanRogers, MattLimmer, KristaCheeseman, BryanHowell, RyanHerman, William
ABSTRACT A bainite phase-based alloy and associated thermomechanical process were developed to produce (2.5 to over 5 cm) thick armor-grade steel with uniform through-thickness high hardness and strength. The alloy composition and the final-critical (austenite to bainite) isothermal transformation step were specifically designed to utilize a simple and versatile air-cool/quench method to keep a low upfront capital cost and to provide the ability to continuously control the cooling rate in real time, in order to produce maximum volume fraction of bainite phase, and promote uniformly distributed strength and hardness. Final thickness of 1.9 cm and 5.7 cm steel plates were fabricated for characterization, testing and evaluation and found to possess uniform through-thickness hardness between 53 to 55 HRC and dynamic compressive strength of up to 2 GPa
Chu, Henry S.Lillo, Thomas M.Anderson, Jeffrey A.Zagula, Thomas A.
ABSTRACT A newly developed structural adhesive demonstrates a unique combination of high strength (43 ± 2 MPa) and displacement (4.7 ± 1.2 mm) in aluminum lap joint testing. Bulk material characterization of the prototype adhesive reveals its extreme ductility, with nearly 80% shear strain before failure and a 2.5-fold increase in strain energy density as compared to commercial structural adhesives. The prototype adhesive is found to maintain 67 to 82% of its initial strength under extreme environmental conditions, including at high temperatures (71°C), after high humidity (63°C hot water soak, 2 weeks), and after corrosive conditions (B117 salt spray, 1000 hours). The prototype structural adhesive is shown to also generate high strength bonds with multiple substrates, including steel, carbon fiber, and mixed material joints, while also providing galvanic isolation
Pollum, MarvinKriley, JosephNakajima, MasaTan, Kar TeanStalker, JeffreyFleischauer, RichardRearick, Brian
ABSTRACT This paper addresses candidate technologies for attaching steels to selected lightweight materials. Materials of interest here include aluminum and titanium alloys. Metallurgical challenges for the aluminum-to-steel and titanium-to-steel combinations are first described, as well as paths to overcome these challenges. Specific joining approaches incorporating these paths are then outlined with examples for specific processes. For aluminum-to-steel joining, inertia, linear, and friction stir welding are investigated. Key elements of success included rapid thermal cycles and an appropriate topography on the steel surface. For titanium-to-steel joining, successful approaches incorporated thin refractory metal interlayers that prevented intimate contact of the parent metal species. Specific welding methods employed included resistance mash seam and upset welding. In both cases, the process provided both heat for joining and a relatively simple strain path that allowed significant
Gould, Jerry E.Eff, MichaelNamola, Kate
ABSTRACT Corrosion damage to military ground vehicles costs the U.S. Army around $1.6B per year. A large part of that cost is related to keeping vehicles like the Stryker at their full fighting capability. Corrosion damage has been a common finding on Stryker vehicles and even light corrosion damage, which often reaches 10% of the body thickness or more, can degrade its armor protection rating and require replacement. Recently, cold spray deposition has been shown to be capable of restoring the full ballistic resistance of corrosion damaged high hard steel armor panels. These repairs can be done on-vehicle in depot facilities, using mobile high-pressure cold spray systems. This repair capability can reduce the number of entire side, roof, and floor panels that need to be cut out and re-welded in, which is the only currently approved repair operation for corrosion damage that exceeds allowable depths. Citation: V.K. Champagne, C.A. Widener, A.T. Nardi, G.D. Ferguson, “Structural Repair
Champagne, Victor K.Widener, Christian A.Nardi, Aaron T.Ferguson, Gehn D.
Abstract The United State Army employs several advanced armored combat vehicles, in a wide array of different environments, and applications. Armor steels are hard and are required to meet certain conditions to stay within the military’s specifications for armored steels. Vehicle armor is typically joined using arc welding methods. Joining via arc welding degrades armor material below specification, so alternate joining methods are being explored like Friction Stir Welding (FSW). FSW is a solid-state joining technique that utilizes a rotating pin to stir plasticized material and use a tool shoulder to forge the material into the joint. The advantages come from the reduction in peak temperature, an increase in mechanical performance, and a decrease in possible defects that occur. In this study FSW parameters were developed and used to weld Wrought Homogenous Armor (HRA) steel. The welds were subject to hardness indention, and metallographic analysis to observe an early prediction of
Evans, WilliamRamirez, AntonioMcDonnell, MartinEff, Mike
ABSTRACT The US Army TARDEC has been researching an alternative to current armor steel that is both tough, and light-weight. The studied alloy is based on the Fe-Mn-Al-C system. This study was conducted to investigate and quantify this alloy’s susceptibility to hot cracking phenomena related to casting and welding. Very little research has been done on general weldability of this alloy system, so the results of these tests will be compared to other high Mn steels, and alloys that have undergone cast pin tear testing. Testing will be conducted utilizing button melting tests, autogenous spot welds, and cast pin tear testing. The cast pin tear testing was conducted to measure this alloys susceptibility to weld solidification cracking. The spot welds were used to quantify the susceptibility of the weld heat affected zone (HAZ) to liquation cracking, as well as to observe the solidification structure of the fusion zone. The testing results showed that the FeMnAl system in its current form
Evans, WilliamRamirez, Antonio J.Sebeck, Katherine
ABSTRACT Flash® Bainite Processing employs rapid thermal cycling (<10s) to strengthen commercial off the shelf (COTS) steel sheet, plate, and tubing into Ultra Hard 600 Armor, High Hard 500 Armor, and advanced high strength steel (AHSS). In a continuous process, induction technology heats a narrow segment of the steel cross section in just seconds to atypically high temperature (1000-1300°C). Quenching substantially immediately follows. A report by Benet Labs and Picatinny Arsenal, investigating a less mature flash technology in 2011, surmised that the novel flash bainite process for steels has the potential to reduce cost and weight while also enhancing mechanical performance [1]. Receiving five financial grants, the US Dept of Energy has greatly matured flash technology in the last few years and its metallurgical understanding in collaboration with Oak Ridge National Lab and others. DOE has named Flash Bainite as the “SBIR Small Business of the Year” in May 2018 and awarded a Phase 3
Cola, Gary M
ABSTRACT The U.S. Army - GVSC Materials Characterization and Failure Analysis team conducted a preliminary study in FY18 to address the issue of galvanic and pitting corrosion of U.S. Army ground vehicle system (GVS) structural surfaces. The objective of this study was to develop a permanent coating solution to supplement the existing corrosion protective coating of zinc rich primer and CARC paint, and extend the lifecycle of the armor. Twenty-five permanent, 0.1 inch layer, additively manufactured (AM) coated coupons of deposited Stellite 6 cobalt alloy on MIL-STD-46100 High Hard (HH) armor steel blocks were produced for cyclic testing using an un-optimized set of parameters. These coupons were subjected to a twenty-four week study in accelerated corrosive conditions of a fog spray chamber alongside primer-CARC coated and uncoated coupons. The resulting study showed no signs of pitting corrosion in the surface of the AM coated coupons, and minimal galvanic corrosion. Citation: I
Toppler, Ian JSchleh, Daniel CRomero, Claudio Gutierrez
ABSTRACT With the increase in electric power on military ground vehicle platforms, electrically driven accessories are replacing existing hydraulic, belt, and gear-driven loads. Permanent Magnet Synchronous Machines (PMSM) are often selected to drive these accessories, and are under consideration for the main engine generator, due to their torque density and efficiency being among the highest available. To maximize the efficiency of a PMSM, accurate knowledge of its parameters is required across the entire operating range. Efficient control of the onboard electric drives will help reduce fuel consumption in the ground vehicle fleet. This paper presents the effects of iron saturation on the performance of a PMSM drive. Iron saturation depends on the amount of current injected into the motor and it restricts the amount of flux linkage that can be generated. PMSMs are controlled using a two axis space vector representation. Ideally, the control is decoupled, such that the flux linkage
Cintron-Rivera, Jorge G.Foster, Shanelle N.Zanardelli, Wesley G.Strangas, Elias G.
ABSTRACT V-shaped hulls for vehicles, to mitigate buried blast loads, are typically formed by bending plate. Such an approach was carried out in fabricating small test articles and testing them with buried-explosive blast load in Southwest Research Institute’s (SwRI) Landmine Test Fixture. During the experiments, detailed time dependent deflections were recorded over a wide area of the test article surface using the Dynamic Deformation Instrumentation System (DDIS). This information allowed detailed comparison with numerical simulations that were performed with LS-DYNA. Though in general there is good agreement on the deflection, in the specific location of the bends in the steel the agreement decreases in the lateral cross section. Computations performed with empirical blast loads developed by SwRI and by more computationally intensive ALE methods in LS-DYNA produced the same results. Computations performed in EPIC showed the same result. The metal plate was then bent numerically so
Walker, James D.Chocron, SidneyMoore, Thomas Z.Bradley, Joseph H.Carpenter, Alexander J.Weiss, CarlGerlach, Charles A.Grosch, Donald J.Grimm, MattBurguess, Victor W.
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