Influence of the microstructure on fatigue and fracture toughness properties of large heat-treated mold steels

The standard ISO 1.2738 medium-carbon low-alloy steel has long been used to fabricate plastic molds for injection molding of large automotive components, such as bumpers and dashboards. These molds are usually machined from large pre-hardened steel blooms. Due to the bloom size, the heat treatment yields mixed microstructures, continuously varying from surface to core. Negative events (such as microcracks due to improper weld bed deposition or incomplete extraction of already formed plastic objects) or too large thermal/mechanical stresses can conceivably cause mold failure during service due to the low fracture toughness and fatigue resistance typically encountered in large slack quenched and tempered ISO 1.2738 steel blooms. Alternative steel grades, including both non-standard microalloyed steels, designed for the same production process, and precipitation hardening steels, have recently been proposed by steelworks. However, the fracture toughness and the fatigue properties of these steels, and hence their response during the service, are not well known. Results of an experimental campaign to assess the fracture toughness and fatigue properties, as well as the basic mechanical properties, of a microalloyed and a precipitation hardening plastic mold steel blooms are presented and commented, also in respect to the results previously obtained by two commercial ISO 1.2738 ones. Experimental results show that these steels generally exhibit low fracture toughness values; in the traditional quenched and tempered bloom steels the brittleness may be caused both by the presence of mixed microstructures and by grain boundaries segregation, while in the precipitation hardened one the brittleness probably stems from the precipitation phenomena. This study suggests that microalloyed and precipitation hardening steels may be used to produce large plastic mold, yet the fracture toughness still remains the most critical propert

Fracture toughness and fatigue crack growth rate properties in wire + arc additive manufactured Ti-6Al-4V

This paper presents an experimental investigation of the fracture and fatigue crack growth properties of Ti-6Al-4V produced by the Wire + Arc Additive Manufacture (WAAM) process. First, fracture toughness was measured for two different orientations with respect to the build direction; the effect of wire oxygen content and build strategy were also evaluated in the light of microstructure examination. Second, fatigue crack growth rates were measured for fully additive manufactured samples, as well as for samples containing an interface between WAAM and wrought materials. The latter category covers five different scenarios of crack location and orientation with respect to the interface. Fatigue crack growth rates are compared with that of the wrought or WAAM alone conditions. Crack growth trajectory of these tests is discussed in relation to the microstructure characteristic

A new method for determining the fracture toughness of main pipeline steels

One of the fundamental aims of fracture mechanics is to define fracture toughness KIC of a material. Hence, the ASTM E399 standard was developed. However according to the standard, large-sized specimens are required to determine the fracture toughness of low alloy carbon steels. ASTM E1921 standard was developed on the fracture toughness of ferritic steels. In this study, a new method was proposed to determine the fracture toughness of ferritic steels. The purpose of the present paper is to compare the results of the method with the experimental results. Two steels that are used in gas and oil main pipelines were investigated in this study. © 2013 Wiley Publishing Ltd