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    PM Lecture 03

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    Sheikh Sabbir Sarforaz

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    PM Lecture 03

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    25 views72 pages

    PM Lecture 03

    Uploaded by

    Sheikh Sabbir Sarforaz

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    © All Rights Reserved
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    of 72

    MSE 3107

    Course Conducted By:


    PHYSICAL METALLURGY Fatema Tuz Zahra
    LECTURE 03 Azmery Akter
    Superalloys
     A Superalloy is an alloy which can be used at high temperatures,
    often in excess of 0.7 of the absolute melting temperature (Tm).
    There are 4 main Criteria for Superalloys:
    1. Ability to withstand loading at high temperature.
    2. Dimensional Stability
    3. Corrosion resistant
    4. FCC crystal structure-Why?
    Properties of Superalloys
     A Superalloy or high-performance alloy exhibits several key characteristics such as:
    1. High temperature resistance (>1300°C)
    2. Stable chemical composition
    3. Ability to remain solidified even at 80-90 % of normal melting point
    4. Excellent mechanical strength
    5. Resistance to thermal creep deformation
    6. Good surface stability
    7. Resistance to corrosion or oxidation
    8. High fracture toughness
    9. High fatigue resistance.
    Examples: Haste alloy, Inconel, Waspalloy, Rene alloys, Haynes alloy, CMSX Single
    crystal, MP98T, Incoloy etc.
     Why Superalloys?
    Initially Austenitic Stainless Steels were used for high temperature applications. But working in the
    range of 450ºC-850ºC , sensitisation occurs due to depletion of Chromium in the grain boundary
    region which makes it susceptible to cracking. So Superalloys were developed.
     There are three types of Superalloys on the basis of the predominant elements present in the
    alloy.
    Ni Based Superalloy
    • Most Ni based alloy contain 38-76% Ni, 10-20% Cr, up to 8% Al and Ti,
    5-10% Co, and small amounts of B , Zr and C

    • Other common additions are molybdenum, niobium, and tungsten, all of


    which play dual roles as strengthening solutes and carbide formers.

    • Chromium and aluminium improves surface stability through the


    formation of Cr2O3 and Al2O3

    • Some of the common type of nickel based alloys are Nimonic, Hastelloy
    and Inconel. These are the most common types of Superalloy which are
    widely used in turbine blades.
    Fe-Ni or Fe Based Superalloy
    • Most Fe-Ni based alloy contain 9-38 % nickel, 15-22 % chromium, 32-
    67 % iron

    • Iron based Super alloys are characterized by high temperature as well


    as room temperature strength.

    • Apart from this, it will have good resistance to creep , oxidation,


    corrosion and wear

    • Oxidation resistance increases with chromium content

    • Common type of Iron based alloy is Incoloy series.


    Co Based Superalloy
    • Most Co based alloy contain up to 35% nickel, 19-30 % chromium, 30-
    65 % cobalt

    • Cobalt based Super alloys have their origin in the stellite alloys

    • Cobalt alloys have higher melting points than nickel alloys

    • Cobalt based alloys can retain their strength at high temperature but
    they are not as strong as nickel based alloys

    • Cobalt alloys show superior thermal fatigue resistance and


    weldability over the nickel alloys
    Microstructures of Superalloys
    Major Phases in Ni Based Superalloy

    • Gamma matrix, γ
    • Gamma prime, γ'
    • Gamma double prime, γ''
    • Carbides
    • Topologically close-packed (TCP) type phases
    Gamma matrix, γ
    • The continuous matrix (called gamma) is an face-centered-cubic (FCC) nickel-
    based austenitic phase that usually contains a high percentage of solid-solution
    elements such as Co, Cr, Mo, and W.

    • Alloying elements found in most commercial Ni-based alloys are, C, Cr, Mo, W,
    Nb, Fe, Ti, Al, V, and Ta

    • No phase transformation upto Tm


    Gamma prime, γ'
    Gamma double prime, γ''
    Carbides

    M6C : Complex cubic structure. Stable form of carbide due to the presence of
    W/Mo. Stable upto temperature range 815-980˚C. Commercially important due
    to presence of stable carbides as grain boundary precipitates during the
    processing of wrought alloys.
    Topologically close-packed (TCP) type phases
    Heat Treatments
    Strengthening Mechanism of
    Ni Based Superalloy
    Fe Based Superalloy
    Co Based Superalloy
    Process Development of Superalloys
    Processing of Superalloys
    Applications of Superalloys
    Ultra High Strength Steels(UHSS)
    • UHSS are the steels that have very high strength, such as over 700 or 780 MPa.
    They are also called Advanced High-Strength Steel (AHSS). This allows for weight
    reduction of and design freedom for different types of structural reinforcements and
    crash components.

    • UHSS/AHSS are complex, sophisticated materials, with carefully selected chemical


    compositions and multiphase microstructures resulting from precisely controlled
    heating and cooling processes. Various strengthening mechanisms are employed to
    achieve a range of strength, ductility, toughness, and fatigue properties.

    • Ultra-high strength steel grades for automotive applications, such as HyperForm®,


    are lightweight and offer design freedom for complex parts and offer very high
    strength and optimised formability.

    • Their high yield and ductility ensure shape accuracy and tolerancing, which enable
    maintained in-service performance for difficult-to-form parts.
    Why UHSS?
    • High strength to weight ratio – Gauge reduction – Mass, Material and Fuel
    Saver. Stronger than conventional steels

    • Offer high work-hardening rates & bake hardening capability, which allows
    increased formability.

    • Greater part complexity - Fewer individual parts - Time, mass and cost
    effective.

    • Steel is the most recycled material – Used in new automotive or other


    products.

    • Improved crash performance – Improved passenger safety.


    •
    • Leave minimum carbon footprint – Environment friendly

    • When considering UHSS application benefits for vehicles, the steel industry
    has adopted the acronym given below :
    • SAFE—for crash protection (Safety), for Affordability and cost, for Fuel
    efficiency, and for the Environment.
    Dual Phase(DP) Steel: 𝜶+M
    Inter critical heat treatment
    • Dual Phase steels offer an outstanding combination of strength and
    drawability as a result of their microstructure, in which a hard martensitic
    phase is dispersed in a soft ferritic matrix.

    • Alloy additions- Si, P strengthen the steel, but must be balanced for
    weldability, while Mn, Cr, V, Nb increase the hardenability.

    • The most common way of producing DP steels is by cold rolling of low alloy
    (LA) steels followed by inter critical annealing in a continuous annealing line,
    referred to as CAL and finally followed by quenching.
    Dual Phase(DP) Steel: 𝜶+M
    Inter critical heat treatment
    Austforming Steels
    Maraging Steels
    • Extra-low-carbon, high nickel, iron base alloy

    • Maraging steels are characterized with superior strength combined with


    excellent toughness properties and weldability. without loss of malleability.

    • Maraging steels are carbon free iron-nickel alloys with additions of


    cobalt, molybdenum, titanium and aluminium.

    • The term maraging is derived from the strengthening mechanism, which


    is transforming the alloy to martensite with subsequent age hardening.
    (Martensite + Ageing)

    • Extra ordinary combination of structural strength and fracture toughness, at


    the same time , readily weldable and easy to heat treat

    • Special class of steel contain No-carbon but provides “ultrahigh-strength”

    • Their strength comes from precipitation of intermetallic compounds like


    (Mo, Ti & Al)Ni3 “NOT FROM CARBON”.
    Microalloyed Steel
    • Microalloyed steel is a type of alloy steel that contains small amounts
    of alloying elements (0.05 to 0.15%),
    including niobium, vanadium, titanium, molybdenum, zirconium, boron,
    and rare-earth metals. They are used to refine the grain microstructure or
    facilitate precipitation hardening.

    • In these steels, small amounts of niobium or vanadium or titanium were added


    and significant grain refinement was obtained due to retarding
    the recrystallization by precipitates of carbon-nitrides of these microelements.

    • The precipitation process of carbon-nitride Nb(C,N) strongly influences the


    final microstructure and properties of products. Precipitates inhibit the
    recrystallization of austenite, which leads to reduction of the size of
    the ferrite grains after transformation of nonrecrystallized austenite. A new
    generation of steels called high strength low alloyed (HSLA) steels was
    developed on this basis.
    High Strength Low Alloy(HSLA) Steels
    High Strength Low Alloy(HSLA) Steels
    • HSLA steels are hardened by a combination of precipitation and grain size
    refining, resulting in high strength with low alloy content. This enhances
    weldability and choice of coatings, since these steels exhibit neither weld
    zone softening nor grain coarsening.
    • The mechanical properties of hot rolled HSLA steels and their excellent
    cold forming performance and low temperature brittle fracture resistance
    support cost-effective solutions for many parts and sub-assemblies for
    which weight, thickness and size reduction are sought, such as: Chassis
    components; wheels; side rails; cross members.
    Properties of HSLA Steels
    Applications of HSLA Steels
    Thermo Mechanical Treatment
    Comparison Between Heat Treatment
    &Thermo Mechanical Treatment
    Objectives of Thermo Mechanical Treatment
    Grain Refinement

    Effect of strain rate and temperature on grain size


    TMT Processing on Steel
    DP Steel Sheet Production
    TMT Bars
    • Thermo mechanically treated steel known as TMT steel can be described as a new-
    generation-high-strength steel having superior properties such as weldability, strength,
    ductility and bendability meeting highest quality standards at international level.
    • Under thermo mechanical treatment of bars, the steel bars are made to pass through a
    specially designed water cooling system where these are kept for such a period that
    outer surface of bars becomes colder while the core remains hot.
    • This creates a temperature gradient in the bars.
    • When the bars are taken out of the cooling system, the heat flows from the core to the
    outer surface causing further tempering of steel bars thereby helping them in attaining
    higher yield strength of steel.
    TMT Bars
    Processing of TMT Bars
    Properties of TMT Bars
    Advantages of TMT Bars
    • TMT Bars comes with better strength & superior Elongation than any other
    type of steel bars

    • It saves up to 17% of steel

    • The cost of TMT Bar are lower than other types of steel bar

    • For better Ductility & Bendability it is easy to use for any type of construction
    structure and saves time as well

    • TMT Bars are Resistant to Fire and Corrosion that is why worldwide the
    demand of TMT Steel Bars are higher

    • The fatigue strength in TMT Bar is higher so, during the construction it can
    bend as per the requirement
    Applications of TMT Bars

    • Thermo mechanical treatment makes Steel bars superior construction


    purposes. It is important to choose only Thermo mechanically Treated Bars
    (TMT Bars) for construction purpose.
    Control of Texture
    • Texture is the distribution of crystallographic orientations of
    a polycrystalline sample.
    • A sample in which these orientations are fully random is said to have no distinct
    texture.
    • If the crystallographic orientations are not random, but have some preferred
    orientation, then the sample has a weak, moderate or strong texture.
    • The degree is dependent on the percentage of crystals having the preferred
    orientation.
    • Texture is seen in almost all engineered materials, and can have a great influence
    on materials properties.
    • The sheet manufacturing process, which involves various solid-state
    transformations such as phase transformations, plastic deformation and
    thermally activated recovery processes, determines the texture of steel and
    aluminium sheet.
    • The conventional process of flat rolling and annealing only offers limited
    degrees of freedom to modify the texture of the final product.
    Controlling Texture
    Thermo Mechanical Processes
    Hot Rolling
    Temperature in rolling mill for sequencing is used between 1200 – 1300°C.
    High Strength & Ductility comes into the steel for Thermo mechanical
    treatment.
    Steel turns into ferrite pearlite structure that means the outer core becomes
    strong and inside remain soft.
    Hot Forging
    Hot Extrusion
    Effect of Extrusion Ratio on Microstructure

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