Mechanical properties and microstructures of forged large blanks of low-carbon steel without necessary incoming ultrasound test have been studied. The examination was performed to find out the reasons for product defects. Abnormalities in structure and disagreement of metal plasticity with standard requirements are revealed. On the basis of the results obtained it is assumed that the reasons for the defects could be deviations from standard chemical composition and irregularities in hot forging

Fuhrmeister, Thomas

Nitzsche, G.

Rex, Stephan

Richter, W.

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Imaging polarimeter with high angle resolution

Apasov, А. М.

Valuyev, D. V.

Danilov, V. I.

Electronic archive of Tomsk Polytechnic University

81Introduction«Yurmash» metallurgical industry is one of the fewin Russia which can produce forgings with mass up to17,5 tons. From this point of view it is economically andtechnically attractive both for domestic and foreignconsumers. However, this circumstance puts on highresponsibility for the quality of production especially innew conditions of economical activity.At the same time, by 2000, the situation at a factoryis so that the inplant defect at large finding manufacturing exceeds 7 %. Ingots more often crack at normalization and heating for hot forging or are not upset in theprocess of blacksmith redistribution. The most part offinished product is not undergone the required incoming ultrasound test (UST).The external causes of such condition are stipulated bydegradation of the enterprise raw material base and the internal ones – by high wearing of the equipment and significant expansion of a number of the produced steel grades. Itis enough only to mention that at present, the plant meltsnot only domestic low and mediumcarbon steels but alsosome grades by German standards, specifically St52,3N [1].The main way of these defects elimination is in strictobservance of procedures discipline and timely sciencebased correction of production flow sheets. The latter isnot possible without thorough comparative investigations of the structure and mechanical properties of waste and conditional blanks.2. Materials and techniques of investigation The crosscut template of steel St52,3N which was cutof the blank that had not been undergone the requiredUST was used as the material of the investigations. The diameter of the blank is 430 mm. The required chemicalcomposition of the given steel is presented in Table 1. Theplace of template cutting was in the area of two broachingmacro defects with the diameters of 5...8,5 and 8...10 mm,found out by UST at a depth of 210 and 200...230 mm,correspondingly. The template was undergone checking bythe method of magnetic particle test before samples production for the mechanical and structural examinationsthat allowed detecting the crack parallel to the blank axis.The samples for the mechanical examination and metallographic investigations were cut of the template part thatabutted straight to the crack. The structure of metal samples of conditional blank was investigated for comparison.Table 1. The standard required chemical composition of steelSt52,3N, wt. %The uniaxial tension mechanical examinations werecarried out at the universal testing machine Instron1185. Strain rate was 1,67.10–4 s–1 (1mm/min) at temperature 300 K. Flat samples with test portion sizes100×10×3 mm were fabricated for tension by SS149784. Longitudinal axis of the samples was normal toforging axis. Impact strength by SS 15242042 was determined at pendulum impact testing machine МК 30Аwith maximal impact energy 300 J at temperature 300 Kwith standard samples with Ustress concentrate.Metallographic investigations were carried out atmicroscope Neophot21. Mechanical buffing, mechaC Mn Al P SSi,notmoreCr,notmoreMo,notmoreNi,notmore0,16...0,22 1,0...1,6 0,02...0,06 0,035 0,035 0,55 0,4 0,1 0,4Power engineeringUDC 620.18:669.14ON POSSIBLE REASONS FOR DEFECTS IN LARGE BLANKS OF LOWCARBON MANGANESE STEEL AT «YURMASH»A.M. Apasov, D.V. Valuyev, V.I. Danilov*Yurga Institute of Technology (branch) of TPUEmail: mchmyti@rambler.ru*RAS SD Institute of Physics of Strength and Material Science, TomskEmail: dvi@ispms.tsc.ruMechanical properties and microstructures of forged large blanks of lowcarbon steel without necessary incoming ultrasound test havebeen studied. The examination was performed to find out the reasons for product defects. Abnormalities in structure and disagreementof metal plasticity with standard requirements are revealed. On the basis of the results obtained it is assumed that the reasons for thedefects could be deviations from standard chemical composition and irregularities in hot forging.nical polishing with diamond paste ASM 10/7 NVL,chemical etching in 4 % alcoholic solution HNO3 wereused at crosscut microsection manufacturing.3. Results of the investigations and their analysis According to the results of mechanical testing thetype of deformative diagrams was analyzed and standardstrength and plastic properties were determined. Onlyone of five tested samples on deformative curves (Fig. 1,Curve 1) had yield drop and plateau typical for lowcarbon steel in normalize and annealed state. Therefore theconventional (σ0,2) but not physical yield strength wascalculated [2]. The typical loading diagram is presentedin Fig. 1, Curve 2. The fact of a little nonstationary deformation in a collar may be noticed. The mechanicalcharacteristics are presented in Table 2.Fig. 1. The diagram of steel St52,3N samples loadingIt follows from Table 2 that δ is rather higher than εtotso the process of deformation localization in the collar isof a great importance. Sample № 5 was fractured on thefirst mark near the tensile machine grip therefore δ andψ were not determined and the data of this sample wereignored when calculating average strength properties.Besides it is seen that if the strength parameters correspond to the maximum requirement level the plasticity is more than 40 % lower. In total correspondence withthe type of deformative curve samples contraction infracture collar ψ which did not exceed 20 % turned outto be very small. At the same time steel impact strengthat temperature 300 K turned out to be at rather satisfactory level and formed 70 J/cm2.Table 2. Mechanical characteristics of waste blank materialσu is the ultimate strength, εtot is the magnitude of a sample plasticdeformation at breaking moment, calculated by the deformativecurves, δ is the extension strain at breaking measured by conventional method at a base of 50 mm, KCU is the impact strength attemperature 300 K; ψ is the contractionFractures formed both at impact and quasi statictests turned out to be typical. According to the classification proposed in [3], they may be determined as heterogeneousfibrous ones with tears. Separate areas ofcrystal chips are observed between the fibers. Fibersform the layers parallel to the forging axis. Such type offracture appears owing to heterogeneity of the initialcast structure and insufficient degree of deformation atshaping [3].Metallographic analysis allows revealing that the researched steel is ferritepearlite one with the followingsizes of constituents: the diameter of pearlitic grains is25...40 mkm and pearlitic colonies one is 10...15 mkm(Fig. 2, a). The fact that pearlitic colonies are settled inchains, evidently, along the boundaries of «old» austenitic grains seems to be significant (Fig. 2, a, b). Very coarse substructure of pearlitic colonies is noticed. In mostcases pearlite represents the transition modification fromlaminar to grained. In those cases when pearlite structure is closer to the laminar one it turns out to be possibleto measure interlamellar distance which exceeds 2 mkm.Besides, pearilite content in steel is 25...30 % thatcorresponds to carbon concentration >0,25 wt. %,which exceeds appreciably the required one by standard(Table 1). Light polyhedral extractions of secondaryphases are noticed in considerable quantities in ferritegrains (Fig. 2, b). Their sizes reach 0,5 mkm.The second disadvantage of the researched samples isplenty of pores which sizes reach to 100 mkm. In a numberof cases pores rise on the free surface of a blank. As a ruleσ0,2,MPаσu, MPа KCU,J/cm2 εtot, % δ, % ψ, %Sample 1 293 501 76 11,6 13 14Sample 2 287 500 68 12,0 12,8 14Sample 3 270 480 66 9,7 10,6 20Sample 4 256 422,5 – 5,8 7,0 15Sample 5 253 411 – 6,1 – – Average 270±18 463±45 70±5 9±2,9 10,8±2,7 15,7±2,8ТStandardrequirements≥275 450...630 ≥50 – ≥17 –Bulletin of the Томsк Pоlytеchnic University. 2007. V. 310. № 382Fig. 2. Microstructure of steel St52,3N of waste blank: а) general view of microstructure, pores are indicated with arrows; b) finestructure of pearlite colony, chain of pores is indicated with arrows; c) pores in pearlite colony?      ?    ?а b cthey are mainly located in pearlitic colonies often forminga continuous chains (Fig. 2, a, b). Very large pores capturepearlitic colonies totally (Fig. 2, c). It is seen that ferrite grains surrounding them are weakly etched (Fig. 2, c). The peculiar aureole around a pore is formed where evidently alloy and carbon segregation is concentrated.Let us emphasize that these peculiarities are distinguished more clearly when comparing with conditionalmetal sections (Fig. 3).Fig. 3. Microstructure of steel St52,3N of conditional product:а) general view of microstructure; b) fine structure ofpearlitic colonyStructural element sizes in conditional material arethe same as in the defective one but the pearlitic colonies are located stochastically and do not form the chains.Total pearlite is 20...25 % and corresponds to the gradechemical composition of steel (Table 1). Besides, thepearlitic colonies structure is more dispersed and itsmodification is close to the grained one (Fig. 3, b). There are relatively less extractions of secondary phases inside ferrite grains (Fig. 3).4. Conclusion and summary According to the data of mechanical tests andphractographic analysis steel St52,3N of the defectiveblank does not possess sufficient plasticity. The considerable areas of brittle failure are revealed on fractures.Such fractures appear at insufficient deformation degree at hot shaping.Metal microstructure is not optimal. Pearlitic colonies morphology is coarsely dispersed, close to laminar.Pearlitic colonies are located in chains along the boundaries of «old» austenitic grains. As a rule pores are located in pearlitic colonies. A large number of secondaryphase extractions is observed in ferrite grains solid. Apart of pearlite relative to ferrite is higher than thatwhich should be according to the standard chemicalcomposition of steel. Hence it follows:1. Carbon content in steel St52,3N of defective blankswas higher than permissible.2. Steel contains a high proportion of large pores andsecondary phase extractions in ferrite grains whichmay serve as the sources of thermal cracks.3. According to the fractures state it may be concludedthat deformation degree at hot forging was insufficient and cast metal was considerably heterogeneousin its chemical composition.4. Electron microscopic investigations of metal deflected mode, nature of secondary phase extractions andferrite grains fine structure and pearlite colonies arerequired for technological process correction.a     ?a b Power engineering83REFERENCES1. Vegst K., Vegst M. Key to steels. Translation from German ed. byE.Yu. Kolpishon. – SaintPetersburg: Professiya, 2006. – 760 p.2. Metallurgy and steel thermal treatment. Reference book. V. I. Book 2.Methods of the examination and investigation / Ed. by M.L. Bernshtein,A.G. Rahshtadt. – Moscow: Metallurgiya, 1991. – 462 p.3. Ezhov A.A., Gerasimova L.P., Katok A.M. Fractures of structuralsteels // Metallovedeniye i Termicheskaya Obrabotka. – 2004. –№ 4. – P. 34–38.Received 22.12.2006

On possible reasons for defects in large blanks of low-carbon manganese steel at "YURMASH"

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On possible reasons for defects in large blanks of low-carbon manganese steel at "YURMASH"

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