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Chen, Z., Peng, R. L., Zhou, J., M'Saoubi, R., Gustafsson, D. & Moverare, J. (2019). Effect of Machining Parameters on Cutting Force and Surface Integrity when High-Speed Turning AD730™ with PCBN Tools. The International Journal of Advanced Manufacturing Technology, 100(9-12), 2601-2615
Open this publication in new window or tab >>Effect of Machining Parameters on Cutting Force and Surface Integrity when High-Speed Turning AD730™ with PCBN Tools
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2019 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 100, no 9-12, p. 2601-2615Article in journal (Refereed) Published
Abstract [en]

The novel wrought nickel-based superalloy, AD 730™, is a good candidate material for turbine disc applications at high temperatures beyond 650 °C. The present study focuses on the machining performance of this newly developed alloy under high-speed turning conditions with advanced PCBN tools. Meanwhile, the machined surface integrity as influenced by cutting speed and feed rate was also investigated. The surface integrity was thoroughly characterized in terms of surface roughness and morphology, machining-induced plastic deformation, white layer formation, and residual stresses. It has been found that the cutting speed and feed rate had a strong effect on the cutting forces and resultant surface integrity. The cutting forces required when machining the alloy were gradually reduced with increasing cutting speed, while at 250 m/min and above, the flank tool wear became stronger which led to increased thrust force and feed force. A higher feed rate, on the other hand, always resulted in higher cutting forces. Increasing the cutting speed and feed rate in general deteriorated the surface integrity. High cutting speeds within the range of 200–250 m/min and a low feed rate of 0.1 mm/rev are preferable in order to implement more cost-effective machining without largely reducing the surface quality achieved. The formation of tensile residual stresses on the machined AD 730™, however, could be of a concern where good fatigue resistance is critical.

Place, publisher, year, edition, pages
Springer London, 2019
Keywords
Nickel-based superalloy, High-speed turning, Cutting forces, Surface integrity, AD730, Cubic boron nitride (CBN) tool
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-153292 (URN)10.1007/s00170-018-2792-1 (DOI)000458310400032 ()2-s2.0-85055531180 (Scopus ID)
Available from: 2018-12-10 Created: 2018-12-10 Last updated: 2019-03-05Bibliographically approved
Wärner, H., Calmunger, M., Chai, G., Johansson, S. & Moverare, J. (2019). Thermomechanical Fatigue Behaviour of Aged Heat Resistant Austenitic Alloys. International Journal of Fatigue (127), 509-521
Open this publication in new window or tab >>Thermomechanical Fatigue Behaviour of Aged Heat Resistant Austenitic Alloys
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2019 (English)In: International Journal of Fatigue, ISSN 0142-1123, E-ISSN 1879-3452, no 127, p. 509-521Article in journal (Refereed) Published
Keywords
Thermomechanical fatigue, austenitic alloys, pre-ageing
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-159644 (URN)10.1016/j.ijfatigue.2019.06.012 (DOI)
Available from: 2019-08-14 Created: 2019-08-14 Last updated: 2019-08-14
Palmert, F., Moverare, J. & Gustafsson, D. (2019). Thermomechanical fatigue crack growth in a single crystal nickel base superalloy. International Journal of Fatigue, 122, 184-198
Open this publication in new window or tab >>Thermomechanical fatigue crack growth in a single crystal nickel base superalloy
2019 (English)In: International Journal of Fatigue, ISSN 0142-1123, E-ISSN 1879-3452, Vol. 122, p. 184-198Article in journal (Refereed) Published
Abstract [en]

Thermomechanical fatigue crack growth in a single crystal nickel base superalloy was studied. Tests were performed on single edge notched specimens, using in phase and out of phase thermomechanical fatigue cycling with temperature ranges of 100-750°C and 100-850°C and hold times at maximum temperature ranging from 10s to 6h. Isothermal testing at 100°C, 750°C and 850°C was also performed using the same test setup. A compliance-based method is proposed to experimentally evaluate the crack opening stress and thereby estimate the effective stress intensity factor range ΔKeff for both isothermal and nonisothermal conditions. For in phase thermomechanical fatigue, the crack growth rate is increased if a hold time is applied at the maximum temperature. By using the compliance-based crack opening evaluation, this increase in crack growth rate was explained by an increase in the effective stress intensity factor range which accelerated the cycle dependent crack growth. No significant difference in crack growth rate vs ΔKeff was observed between in phase thermomechanical fatigue tests and isothermal tests at the maximum temperature. For out of phase thermomechanical fatigue, the crack growth rate was insensitive to the maximum temperature and also to the length of hold time at maximum temperature. The crack growth rate vs ΔKeff during out of phase thermomechanical fatigue was significantly higher than during isothermal fatigue at the minimum temperature, even though the advancement of the crack presumably occurs at the same temperature. Dissolution of γ′ precipitates and recrystallization at the crack tip during out of phase thermomechanical fatigue is suggested as a likely explanation for this difference in crack growth rate.

Place, publisher, year, edition, pages
Elsevier, 2019
Keywords
single crystal superalloy, thermomechanical fatigue, crack growth, crack closure
National Category
Materials Engineering Applied Mechanics Manufacturing, Surface and Joining Technology Metallurgy and Metallic Materials Infrastructure Engineering
Identifiers
urn:nbn:se:liu:diva-154074 (URN)10.1016/j.ijfatigue.2019.01.014 (DOI)000462110100017 ()
Note

Funding agencies: Siemens Industrial Turbomachinery AB in Finspang, Sweden; Swedish Energy Agency, via the Research Consortium of Materials Technology for Thermal Energy Processes [KME-702]

Available from: 2019-01-28 Created: 2019-01-28 Last updated: 2019-04-08
Wärner, H., Calmunger, M., Chai, G. & Moverare, J. (2018). Creep-Fatigue Interaction in Heat Resistant Austenitic Alloys. In: EDP Sciences (Ed.), MATEC Web of Conferences 165 , 05001 (2018): . Paper presented at Fatigue 2018 , 12th International Fatigue Congress, 27 May-1 June 2018, Poitiers, France. EDP Sciences, 165
Open this publication in new window or tab >>Creep-Fatigue Interaction in Heat Resistant Austenitic Alloys
2018 (English)In: MATEC Web of Conferences 165 , 05001 (2018) / [ed] EDP Sciences, EDP Sciences, 2018, Vol. 165Conference paper, Published paper (Refereed)
Place, publisher, year, edition, pages
EDP Sciences, 2018
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-148182 (URN)10.1051/matecconf/2018165505001 (DOI)
Conference
Fatigue 2018 , 12th International Fatigue Congress, 27 May-1 June 2018, Poitiers, France
Available from: 2018-06-01 Created: 2018-06-01 Last updated: 2018-11-27
Chen, Z., Zhou, J., Peng, R. L., M'Saoubi, R., Gustafsson, D., Palmert, F. & Moverare, J. (2018). Plastic Deformation and Residual Stress in High Speed Turning of AD730™ Nickel-based Superalloy with PCBN and WC Tools. In: Procedia CIRP 71 (2018) pp 440-445: . Paper presented at The 4th CIRP Conference on Surface Integrity, 11th-13th July, Tianjin, China (pp. 440-445). Elsevier, 71
Open this publication in new window or tab >>Plastic Deformation and Residual Stress in High Speed Turning of AD730™ Nickel-based Superalloy with PCBN and WC Tools
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2018 (English)In: Procedia CIRP 71 (2018) pp 440-445, Elsevier, 2018, Vol. 71, p. 440-445Conference paper, Published paper (Refereed)
Abstract [en]

A higher gas turbine efficiency can be achieved by increasing the operating temperature in hot sections. AD730™ is a recently-developed wrought/cast nickel-based superalloy which can maintain excellent mechanical properties above 700 ℃. However, machining of AD730™ could be a difficult task like other nickel-based superalloys. Therefore, studies are needed with respect to the machinability of this new alloy.

In this paper, high-speed turning was performed on AD730™ using polycrystalline cubic boron nitride (PCBN) tools and coated tungsten carbide (WC) tools at varied cutting speeds. The surface integrity was assessed in two important aspects, i.e., surface and sub-surface plastic deformation and residual stresses. The PCBN tools generally showed better performance compared with the WC tools since it led to reduced machining time without largely compromising the surface integrity achieved. The optimal cutting speed was identified in the range of 200-250 m/min when using the PCBN tools, which gives rise to a good combination of machining efficiency and surface integrity. The further increase of the cutting speed to 300 m/min resulted in severe and deep plastic deformation. Meanwhile, a continuous white layer was formed at the machined surface. When turning with the WC tools, the increased cutting speed from 80 m/min to 100 m/min showed very little effect with respect to the plastic deformation on the machined surface. It was found that tensile residual stresses were developed on all machined surfaces no matter when the PCBN or WC tools were used, and the surface tension was generally increased with increasing cutting speed. The tensile layer might need to be modified by e.g., post-machining surface treatments such as shot peening, if taking good fatigue performance into consideration.

Place, publisher, year, edition, pages
Elsevier, 2018
Keywords
plastic deformation, residual stress, nickel-based superalloy, AD730TM, high-speed turning
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-148484 (URN)10.1016/j.procir.2018.05.051 (DOI)
Conference
The 4th CIRP Conference on Surface Integrity, 11th-13th July, Tianjin, China
Available from: 2018-06-12 Created: 2018-06-12 Last updated: 2018-07-03
Calmunger, M., Chai, G., Eriksson, R., Johansson, S. & Moverare, J. J. (2017). Characterization of austenitic stainless steels deformed at elevated temperature. Metallurgical and Materials Transactions. A, 48A(10), 4525-4538
Open this publication in new window or tab >>Characterization of austenitic stainless steels deformed at elevated temperature
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2017 (English)In: Metallurgical and Materials Transactions. A, ISSN 1073-5623, E-ISSN 1543-1940, Vol. 48A, no 10, p. 4525-4538Article in journal (Refereed) Published
Abstract [en]

Highly alloyed austenitic stainless steels are promising candidates to replace more expansive nickel-based alloys within the energy-producing industry. The present study investigates the deformation mechanisms by microstructural characterisation, mechanical properties and stress-strain response of three commercial austenitic stainless steels and two commercial nickel-based alloys using uniaxial tensile tests at elevated temperatures from 400 C up to 700 C. The materials showed different influence of temperature on ductility, where the ductility at elevated temperatures increased with increasing nickel and solid solution hardening element content. The investigated materials showed planar dislocation driven deformation at elevated temperature. Scanning electron microscopy showed that deformation twins were an active deformation mechanism in austenitic stainless steels during tensile deformation at elevated temperatures up to 700 C.

Place, publisher, year, edition, pages
Springer-Verlag New York, 2017
Keywords
Austenitic stainless steel, Nickel-based alloy, Microstructural characterization, Deformation twinning, Stress-strain response
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-122942 (URN)10.1007/s11661-017-4212-9 (DOI)000408884300012 ()
Note

Previous status of this publication was manuscript

Funding agencies: AB Sandvik Materials Technology in Sweden; Swedish National Energy Administration through the Research Consortium of Materials Technology for Thermal Energy Processes [KME-701]; AFM Strategic Faculty Grant SFO-MAT-LiU at Linkoping University [2009-00971]

Available from: 2015-11-30 Created: 2015-11-30 Last updated: 2017-09-22Bibliographically approved
Norman, V., Skoglund, P., Leidermark, D. & Moverare, J. (2017). Damage Mechanisms in Silicon-Molybdenum Cast Irons Subjected to Thermo-mechanical Fatigue. International Journal of Fatigue, 99(2), 258-265
Open this publication in new window or tab >>Damage Mechanisms in Silicon-Molybdenum Cast Irons Subjected to Thermo-mechanical Fatigue
2017 (English)In: International Journal of Fatigue, ISSN 0142-1123, E-ISSN 1879-3452, Vol. 99, no 2, p. 258-265Article in journal (Refereed) Published
Abstract [en]

The damage mechanisms active in silicon-molybdenum cast irons, namely EN-GJS-SiMo5-1 and SiMo1000, under thermo-mechanical fatigue and combined thermo-mechanical and high-cycle fatigue conditions have been investigated. The studied load conditions are those experienced at critical locations in exhaust manifolds of heavy-vehicle diesel engines, namely a temperature cycle of 300–750 °C with varied total mechanical and high-cycle fatigue strain ranges. It is established that oxide intrusions are formed in the early life from which macroscopic fatigue cracks are initiated close to the end-of-life. However, when high-cycle fatigue loading is superimposed, small cracks are preferentially initiated at graphite nodules within the bulk. In addition, it is found that both the oxidation growth rate and casting defects located near the surface affect the intrusion growth.

Place, publisher, year, edition, pages
Elsevier, 2017
Keywords
Cast iron, Thermo-mechanical fatigue, High-cycle fatigue, Enviromental assisted fatigue, Fatigue crack growth
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-137287 (URN)10.1016/j.ijfatigue.2017.01.014 (DOI)000400718300007 ()2-s2.0-85017123996 (Scopus ID)
Note

Funding agencies: Scania CV AB; Swedish Governmental Agency for Innovation Systems [FFI-2012-03625]; Swedish Foundation for Strategic Research [SM12-0014]; Strategic Faculty Grant AFM (SFO-MAT-LiU) at Linkoping University [2009-00971]

Available from: 2017-05-10 Created: 2017-05-10 Last updated: 2018-02-13Bibliographically approved
Chen, Z., Peng, R. L., Zhou, J., Bushlya, V., Saoubi, R. M., Johansson, S. & Moverare, J. (2017). Effect of Cutting Conditions on Machinability of AD 730 TM during High Speed Turning with PCBN Tools. In: : . Paper presented at EUROMAT17, Thessaloniki 17-21 September 2017,Greece (pp. 1-1).
Open this publication in new window or tab >>Effect of Cutting Conditions on Machinability of AD 730 TM during High Speed Turning with PCBN Tools
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2017 (English)Conference paper, Oral presentation with published abstract (Refereed)
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-143973 (URN)
Conference
EUROMAT17, Thessaloniki 17-21 September 2017,Greece
Available from: 2018-01-01 Created: 2018-01-01 Last updated: 2018-08-02Bibliographically approved
Lundberg, M., Saarimäki, J., Moverare, J. & Peng, R. L. (2017). Effective X-ray Elastic Constant of Cast Iron. Journal of Materials Science, 53(4), 2766-2773
Open this publication in new window or tab >>Effective X-ray Elastic Constant of Cast Iron
2017 (English)In: Journal of Materials Science, ISSN 0022-2461, E-ISSN 1573-4803, Vol. 53, no 4, p. 2766-2773Article in journal (Refereed) Published
Abstract [en]

X-ray diffraction is a non-destructive method used for strain measurements in crystalline materials. Conversion of strain to stress can be achieved using the X-ray elastic constants (XEC), s1 and ½s2. The sin2ψ method was used during in situ loading to determine XEC for flake, vermicular, and spherical graphite iron. A fully pearlitic steel was used as reference. Uniaxial testing was conducted on the cast iron to create a homogeneous strain field, as well as four-point bending in both tension and compression due to the tension/compression asymmetry. The commonly used XEC value ½s2 = 5.81 × 10−6 MPa−1 is theoretically derived from an α-Fe single crystal. When investigating materials that contain ferrite, such as polycrystalline cast iron, this value is not accurate. Determination of an effective XEC for polycrystalline cast iron yields a better correlation between the measured microstrains and the properties observed on a macroscopic scale. The need for an effective XEC is evident, especially when it comes to model validation of, for example, casting simulations. Effective XEC values have been determined for flake, vermicular, and spherical graphite iron. The determined value is lower than the theoretical value.

National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-141980 (URN)10.1007/s10853-017-1657-6 (DOI)000416544500040 ()2-s2.0-85031402118 (Scopus ID)
Note

Funding agencies: Agora Materiae, graduate school, the Swedish Government Strategic Research Area in Materials Science on Functional Materials at Linkoping University [2009-00971]; Volvo Trucks; Vinnova FFI, Scania

Available from: 2017-10-16 Created: 2017-10-16 Last updated: 2018-08-30Bibliographically approved
Calmunger, M., Eriksson, R., Chai, G., Johansson, S. & Moverare, J. (2017). Influence of Cyclic Oxidation in Moist Air on Surface Oxidation-Affected Zones. In: : . Paper presented at EUROMAT17, Thessaloniki 17-21 September 2017,Greece (pp. 1-1).
Open this publication in new window or tab >>Influence of Cyclic Oxidation in Moist Air on Surface Oxidation-Affected Zones
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2017 (English)Conference paper, Oral presentation with published abstract (Refereed)
National Category
Materials Engineering
Identifiers
urn:nbn:se:liu:diva-143972 (URN)
Conference
EUROMAT17, Thessaloniki 17-21 September 2017,Greece
Available from: 2018-01-01 Created: 2018-01-01 Last updated: 2018-01-16Bibliographically approved
Organisations
Identifiers
ORCID iD: ORCID iD iconorcid.org/0000-0002-8304-0221

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