Microstructure and mechanical properties of Ni-Cu alloys fabricated using wire arc additive manufacturing

Ni-Cu alloys, also known as Monel alloys, are widely used in marine industry due to their high corrosion resistance and good mechanical properties. Submarine propeller shafts, diesel engine piston rods and centrifugal pump shafts are examples of application of these alloys. Despite their good mechanical and corrosion resistant properties, Ni-Cu components may fail in operation via sliding wear, galling and pitting corrosion. Since the Ni-base alloys are expensive, repair is often an economic choice than replacement. A possibility to use wire arc additive manufacturing (WAAM) technology for fabrication of new and repair of used Ni-Cu components was assessed in this thesis. Two Ni-Cu wires with various Ti, Mn, Al and C contents were deposited on a Ni-Cu substrate with a wide range of welding parameters (travel speed, wire feed rate). The solute atom concentrations and particle number density values were modified using various post processing heat treatment schedules. A comprehensive study of the microstructure, mechanical properties, wear and corrosion resistance of the Ni-Cu alloy components fabricated using WAAM has been conducted. Microstructure characterisation, in particular a detailed study of the precipitate’s parameters (size, number density and chemical composition) was carried out using optical, scanning, transmission and atomic resolution electron microscopy. Mechanical properties were assessed using hardness, tensile testing to fracture, wear and corrosion resistance

Effect of chemical composition on microstructure, strength and wear resistance of wire deposited Ni-Cu alloys

Two Ni-Cu alloys (Monel K500 and FM 60) having various Mn, Fe, Al, Ti and C contents were deposited on a Monel K500 plate at three different speeds using wire arc additive manufacturing technique. Microstructure characterisation, in particular a detailed study of precipitates, was carried out using optical and scanning electron microscopy. Mechanical properties were assessed using hardness, tensile and wear testing. For similar deposition conditions, Monel K500 has exhibited smaller secondary dendrite arm spacing and higher number density of Ti-rich particles, although the Ti concentration in FM 60 was higher. Finer microstructure and Ti precipitation led to superior hardness, tensile and wear resistance of Monel K500 compared to FM 60. The variation in microstructure-properties relationship with alloy composition is discussed

Strengthening mechanisms in thermomechanically processed NbTi-microalloyed steel

The effect of deformation temperature on microstructure and mechanical properties was investigated for thermomechanically processed NbTi-microalloyed steel with ferrite-pearlite microstructure. With a decrease in the finish deformation temperature at 1348 K to 1098 K (1075 °C to 825 °C) temperature range, the ambient temperature yield stress did not vary significantly, work hardening rate decreased, ultimate tensile strength decreased, and elongation to failure increased. These variations in mechanical properties were correlated to the variations in microstructural parameters (such as ferrite grain size, solid solution concentrations, precipitate number density and dislocation density). Calculations based on the measured microstructural parameters suggested the grain refinement, solid solution strengthening, precipitation strengthening, and work hardening contributed up to 32 pct, up to 48 pct, up to 25 pct, and less than 3 pct to the yield stress, respectively. With a decrease in the finish deformation temperature, both the grain size strengthening and solid solution strengthening increased, the precipitation strengthening decreased, and the work hardening contribution did not vary significantly

Superior mechanical properties of microalloyed steels processed via a new technology based on austenite conditioning followed by warm deformation

In this paper we introduce the AC2WD-technology, which stands for Austenite Conditioning – Accelerated Cooling – Warm Deformation. This technology was tested in laboratory conditions using a Gleeble thermomechanical simulator. Two microalloyed steels processed via this technology have shown a superior combination of mechanical properties, compared to those obtained via the conventional thermomechanical processing routes

New technology to produce 1 GPa low carbon microalloyed steels from cast strip

Global economy requires steel with further increasing mechanical properties and simultaneously decreasing price. In mass manufacturing three major methods can be used to increase strength: (i) increase microalloying element additions (increases cost), (ii) decrease deformation temperature and (iii) increase cooling rate after high temperature processing (both can be challenging for equipment). Thin strip casting is an effective way to reduce cost as it brings a reduction in number of deformation passes and shortens the production line. However, the mechanical properties can be missed due to insufficient microstructure development. In this article, we investigate a recently proposed technology based on Austenite Conditioning followed by Accelerated Cooling andWarm Deformation (AC2WD). Two low carbon steels microalloyed with either 0.012Ti or 0.1Mo-0.064Nb-0.021Ti (wt.%) were subjected to three processing modifications of the AC2WD-technology with two, one or no deformation of cast microstructure in the austenite temperature field. The Ti- and MoNbTi-steels exhibited 685–765 MPa and 880–950 MPa of the yield stress, 780–840 MPa and 1035–1120 MPa of tensile strength, and 20–30% and 22–24% of elongation to failure, respectively. The nature of strengthening mechanisms associated with the AC2WD-technology is discussed on the basis of detailed microstructure characterisation

Strengthening Mechanisms in Nickel-Copper Alloys: A Review

Nickel-Copper (Ni-Cu) alloys exhibit simultaneously high strength and toughness, excellent corrosion resistance, and may show good wear resistance. Therefore, they are widely used in the chemical, oil, and marine industries for manufacturing of various components of equipment, such as: drill collars, pumps, valves, impellers, fixtures, pipes, and, particularly, propeller shafts of marine vessels. Processing technology includes bar forging, plate and tube rolling, wire drawing followed by heat treatment (for certain alloy compositions). Growing demand for properties improvement at a reduced cost initiate developments of new alloy chemistries and processing technologies, which require a revision of the microstructure-properties relationship. This work is dedicate to analysis of publicly available data for the microstructure, mechanical properties and strengthening mechanisms in Ni-Cu alloys. The effects of composition (Ti, Al, Mn, Cr, Mo, Co contents) and heat treatment on grain refinement, solid solution, precipitation strengthening, and work hardening are discussed

Strengthening mechanisms in nickel-copper alloys: A review

© 2020 by the authors. Licensee MDPI, Basel, Switzerland. Nickel-Copper (Ni-Cu) alloys exhibit simultaneously high strength and toughness, excellent corrosion resistance, and may show good wear resistance. Therefore, they are widely used in the chemical, oil, and marine industries for manufacturing of various components of equipment, such as: Drill collars, pumps, valves, impellers, fixtures, pipes, and, particularly, propeller shafts of marine vessels. Processing technology includes bar forging, plate and tube rolling, wire drawing followed by heat treatment (for certain alloy compositions). Growing demand for properties improvement at a reduced cost initiate developments of new alloy chemistries and processing technologies, which require a revision of the microstructure-properties relationship. This work is dedicate to analysis of publicly available data for the microstructure, mechanical properties and strengthening mechanisms in Ni-Cu alloys. The effects of composition (Ti, Al, Mn, Cr, Mo, Co contents) and heat treatment on grain refinement, solid solution, precipitation strengthening, and work hardening are discussed

High temperature dislocation structure and NbC precipitation in three Ni-Fe-Nb-C model alloys

In this original work, the dislocation structure and NbC precipitation were investigated in three Ni-based alloys (70Ni-Fe-0.331Nb-0.040C, 70Ni-Fe-0.851Nb-0.114C and 70Ni-Fe-1.420Nb-0.157C, wt%) thermomechanically processed in the temperature range of 1250-1075 °C. The dislocation structure inhomogeneity (dislocation networks and cell walls), which we observed in the middle and high Nb+C alloys, resulted from the dislocation pile-ups in the vicinity of \u3e200 nm NbC particles. The dislocation density around \u3e200 nm particles exceeded the average values by 5-7 times, and that in the cell walls might exceed the average values by 10 times. Twins and stacking faults were observed in all alloys after solution treatment at 1250 °C, however, they were not observed after 1.2 strain at 1075 °C. The dislocation generation rate during deformation at 1075 °C varied with alloy composition and increased with an increase in the°C, the majority of particles were growing in the high Nb+C alloy, theNb+C alloy and all the particles were dissolving in the low Nb+C alloy. Deformation to 1.2 strain at 1075 °C resulted in strain-induced precipitation in all alloys andNb+C alloys

New Technology to Produce 1 GPa Low Carbon Microalloyed Steels from Cast Strip

Global economy requires steel with further increasing mechanical properties and simultaneously decreasing price. In mass manufacturing three major methods can be used to increase strength: (i) increase microalloying element additions (increases cost), (ii) decrease deformation temperature and (iii) increase cooling rate after high temperature processing (both can be challenging for equipment). Thin strip casting is an effective way to reduce cost as it brings a reduction in number of deformation passes and shortens the production line. However, the mechanical properties can be missed due to insufficient microstructure development. In this article, we investigate a recently proposed technology based on Austenite Conditioning followed by Accelerated Cooling and Warm Deformation (AC2WD). Two low carbon steels microalloyed with either 0.012Ti or 0.1Mo-0.064Nb-0.021Ti (wt.%) were subjected to three processing modifications of the AC2WD-technology with two, one or no deformation of cast microstructure in the austenite temperature field. The Ti- and MoNbTi-steels exhibited 685–765 MPa and 880–950 MPa of the yield stress, 780–840 MPa and 1035–1120 MPa of tensile strength, and 20–30% and 22–24% of elongation to failure, respectively. The nature of strengthening mechanisms associated with the AC2WD-technology is discussed on the basis of detailed microstructure characterisation

Effect of solidification rate on microstructure evolution in dual phase microalloyed steel

In steels the dependence of ambient temperature microstructure and mechanical properties on solidification rate is not well reported. In this work we investigate the microstructure and hardness evolution for a low C low Mn NbTi-microalloyed steel solidified in the cooling rate range of 1-50 Cs-1. The maximum strength was obtained at the intermediate solidification rate of 30 Cs-1. This result has been correlated to the microstructure variation with solidification rate