Effect of high-pressure rolling followed by laser processing on mechanical properties, microstructure and residual stress distribution in multi-pass welds of 304L stainless steel

Multi-pass fusion welding by a filler material (wire) is normally carried out to join thick steel sections used in most engineering applications. Multiple thermal cycles from a multi-pass weld resulted in a variable distribution of residual stress field across the weld and through the thickness. Presence of tensile residual stresses can be detrimental to the integrity and the service behaviour of the welded joint. In addition to a complex distribution of residual stress state, multi-pass welds also form dendritic grain structure, which are repeatedly heated, resulting in segregation of alloying elements. In this research, microstructural refinement with modification of residual stress state was attempted by applying post-weld cold rolling followed by laser processing and then cold rolling. The residual stress was determined non-destructively by using neutron diffraction. Post-weld cold rolling followed by laser processing was carried out to induce recrystallization of the cold rolled grains. Microstructural characterisation indicates a significant grain refinement near the capping pass. However, post-weld cold rolling followed by laser processing reinstates the lock-in stress. In this study, it was demonstrated that a complete recrystallized microstructure with compressive state of stress can be formed when a further cold rolling is applied on the laser processed, recrystallized microstructure

Computer-aided analysis and design of the shape rolling process for producing turbine engine airfoils

Mild steel (AISI 1018) was selected as model cold-rolling material and Ti-6Al-4V and INCONEL 718 were selected as typical hot-rolling and cold-rolling alloys, respectively. The flow stress and workability of these alloys were characterized and friction factor at the roll/workpiece interface was determined at their respective working conditions by conducting ring tests. Computer-aided mathematical models for predicting metal flow and stresses, and for simulating the shape-rolling process were developed. These models utilize the upper-bound and the slab methods of analysis, and are capable of predicting the lateral spread, roll-separating force, roll torque and local stresses, strains and strain rates. This computer-aided design (CAD) system is also capable of simulating the actual rolling process and thereby designing roll-pass schedule in rolling of an airfoil or similar shape. The predictions from the CAD system were verified with respect to cold rolling of mild steel plates. The system is being applied to cold and hot isothermal rolling of an airfoil shape, and will be verified with respect to laboratory experiments under controlled conditions

Computer-aided analysis and design of the shape rolling process for producing turbine engine airfoils

Mild steel (AISI 1018) was selected as model cold rolling material and Ti-6A1-4V and Inconel 718 were selected as typical hot rolling and cold rolling alloys, respectively. The flow stress and workability of these alloys were characterized and friction factor at the roll/workpiece interface was determined at their respective working conditions by conducting ring tests. Computer-aided mathematical models for predicting metal flow and stresses, and for simulating the shape rolling process were developed. These models utilized the upper bound and the slab methods of analysis, and were capable of predicting the lateral spread, roll separating force, roll torque, and local stresses, strains and strain rates. This computer-aided design system was also capable of simulating the actual rolling process, and thereby designing the roll pass schedule in rolling of an airfoil or a similar shape

Evaluation and control of mechanical degradation of austenitic stainless 310S steel substrate during coated superconductor processing

The superconductor industry considers cold-rolled austenitic stainless 310S steel a less expensive substitute for Hastelloy X as a substrate for coated superconductor. However, the mechanical properties of cold-rolled 310S substrate degrade significantly in the superconductor deposition process. To overcome this, we applied hot rolling at 900 A degrees C (or 1000 A degrees C) to the 310S substrate. To check the property changes, a simulated annealing condition equivalent to that used in manufacturing was determined and applied. The effects of the hot rolling on the substrate were evaluated by analyzing its physical properties and texture.Web of Science24345444

The effects of cold rolling on the notched and unnotched tensile properties of type 310 stainless steel at plus 75 deg F, minus 320 deg F and minus 423 deg F

Effects of cold rolling on notched and unnotched tensile properties of type 310 stainless stee

Research, development and application of the innovational technology of high quality pump-compressor pipes production from sections

The innovational technology of high-strength, cold- and corrosion-resistant pump-compressor pipes from sections was developed. It includes the reduction process inside three-high stand of screw rolling before piercing in the «80» pipe-rolling mill line in OAO SinTZ. The special attention is paid to the questions of fine-grained steel production and final tubes quality. It is shown that new technology is efficient from the point of tube production of high level mechanical properties

Lubrication in cold rolling: Elasto-plasto-hydrodynamic lubrication

A model has been developed with respect to hydrodynamic lubrication in cold rolling. The basic model describes the configuration of a rigid, perfectly plastic sheet rolled by a rigid work roll. The governing equations have been solved throughout the complete contact area, i.e. the inlet, the work zone and the outlet zone. Multi-level techniques have been applied to solve these equations together with boundary conditions, resulting in an algorithm solving the problem in O(n) operations. This means that the distribution of the pressure and the traction force in the lubricant film, and the shape of this film, as well as the plastic deformation of the sheet, can be accurately calculated for a large number of nodal points on a minicomputer. Subsequently elastic deformation, work hardening and dynamic behaviour of the flow stress have been incorporated in the model. It will be shown that the influence of these effects on the film thickness or the pressure distribution is considerable

Comparative study of evolution of residual stress state by local mechanical tensioning and laser processing of ferritic and austenitic structural steel welds.

Complex thermal stresses generated in welded structures are undesirable but inevitable in fusion welding. The presence of residual stresses can be detrimental to the integrity of a welded joint. In this research, redistribution of residual stress magnitude and profile was studied and compared in two multi-pass welded structural alloys (API X100 and 304L stainless steel) after cold rolling and laser processing. The residual stress field was studied by neutron diffraction using the SALSA strain scanner at their reactor neutron source at ILL, Grenoble. In addition to a complex distribution of residual stress state, multi-pass welds also forms dendritic grain structure, which are repeatedly heated, resulting in segregation of alloying elements. Dendritic grain structure is weaker and segregation of alloying elements may result in formation of corrosion microcells as well as reduction in overall corrosion prevention due to depletion of alloying elements in certain areas. The modification of as-welded residual stress state was done by cold rolling which was followed by laser processing to create a recrystallized microstructure to minimise segregation. The main objective of this study is to understand the suitability of this novel manufacturing technique to create a stress free weldment with recrystallised grain structure. Hardness evolution in the welded structures was scanned following welding, post weld cold rolling and cold rolling followed by laser processing. Hardness distribution in both the structural alloys showed a significant evidence of plastic deformation near the cap pass of the weld metal. Residual stress redistribution was observed up to 4 mm from the capping pass for ferritic steel, while in austenitic steel weld, post weld cold rolling was effective in modifying the residual stress redistribution throughout the entire thickness. Laser processing in both cases reinstated the as-welded residual stress distribution and resulted in softening of the strained area

On the Aging and Precipitation of Al-Ag and Al-Zn Alloys

Polycrystalline specimens of Al-30wt % Ag and Al-30wt % Zn alloys, which were quenched into water from the temperature of solution heat treatment, were annealed at L.T. aging temperatures or reversion temperatures so as to make them contain zones of nearly equal radii for each alloy and various concentrations of solute element in zones. These specimens were cold rolled exactly to 50%, and then annealed at L. T. aging temperatures for varying time. The state of zones and precipitates were investigated by X-ray small-angle scattering photographs. The results obtained were as follows: (1) The precipitation ofγ'-phase began earlier in the specimens of Al-Ag alloy annealed at L. T. aging temperature before cold rolling than in those specimens annealed at reversion temperatures before cold rolling when annealed at L. T. aging temperatures after cold rolling. (2) The rate of precipitation of Zn solid solution in Al-Zn alloy did not depend upon the annealing temperature before cold rolling when cold rolled specimens were annealed at L. T. aging temperature. (3) In Al-Ag alloy, the rate of disappearance of G. P. zones at L. T. aging temperature depends mainly upon the annealing temperature before cold rolling. On the other hand, in Al-Zn alloy, the rate of disappearance of G. P. zones at L. T. aging temperature does not depened upon the annealing temperature before cold rolling. (4) These results may be explained without contradiction considering the relation of structures between matrix and precipitates and the deformation stacking faults