The implementation of technologies such as aluminum powder metallurgy (P/M) can be used in the automobile industry to have potential economic and environmental advantages. This technology to produce vehicle components can offer the combination of weight savings due to the low density of aluminum and material and machining savings via near net shape processing attributes. In an effort to expand the scope of application for aluminum P/M, considerable research has emphasized the development of new alloys and composites. One such alloy is P/M 2324, an aluminum-copper-magnesium alloy developed to have increased mechanical properties over the standard aluminum P/M alloys of the AC2014 type. The objective of this work was to undertake a comprehensive study on the effects of hot deformation on the emerging alloy P/M 2324 as well as the alloy with a SiC addition. Here, a forgeability study of these alloys and its wrought counterpart AA2024 was completed. To

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A dissertation submitted to the Faculty of Engineering, University of the Witwatersrand, Johannesburg, in fulfilment of the requirements for the degree of Master of Science in Engineering. ,Department of Metallurgy and Materials Engineering University of the Witwatersrand Johannesburg, 1990. / An instrumented hot deformation simulator was desLgned, cons'.:ructedand commissioned at Iscor's Pilot Plant. A modified servohydraulic machine, using plane strain compression, simulated industrial plate rolling schedules. The simulation test included induction heating, multiple pass plane strain compression and either air cooling or quenching. The movement of the specimen between the different test stages was computer controlled. Accurate control of specimen temperature, strain atrain rate and interpass hold times was achieved by means of sophisticated data acquds i+Lon equipment. A comput er programme was written to simulate the hot. rolling of plate in t erms of roll sepa ratIng f.orces, ffiE.\tallurgical changes during deformation as well as the final microstructure and mechanical properties of SGa carbon manganese steel. Multiple linear regression was pe.rformed on the results obtained from mUlti-pass plane strain compression tests. It was found that themical composition, finish temperature and finish strain were the most important process parameters affecting yield strength and impact energy of air cooled place. A computer model was developed to simulate the temperature distribution in the deformation zone of a plane strain compressLon specimen at any point during or after a mUlti-pass test.

The hot working behavior of AISI 1018 steel was studied by hot-compression deformation tests on the Gleeble 1500 thermo-mechanical simulator at true strain values of -0.143 and -0.405, true strain rate values of 0.01 and 0.1, and working temperatures of 900°C and 1000°C. The tests show that a lower working temperature and lower true strain value results in a greater maximum compressive force. The apparent activation energy Qapp was calculated by using the Zener-Hollomon parameter combined with the low stress law. Qapp ­was calculated to be 311 kJ mol-1 K-1.

The formability of Mg alloy sheet in the as-hot rolled condition depends on the microstructure developed during hot rolling. In general, the formability of Mg alloys is improved by finer grain sizes. 'Microalloying' levels of calcium (Ca), strontium (Sr), and cerium (Ce) have been found to refine the as-cast structure, but there is no information as to whether this effect will be reflected in the as-hot worked structure and formability. Thus, in this work, the effects of microalloying levels of calcium (Ca), strontium (Sr), and cerium (Ce) on the microstructures (from as-cast to as-hot rolled) and subsequent hot deformation behavior of AZ31, nominally 3% Al, 1% Zn, and 0.3%Mn, were systematically investigated. / To include the effect of solidification rate these alloys were cast in different moulds (preheated steel mould, Cu-mould, and water cooled Cu-mould). One-hit compression testing at temperatures between 250°C ∼ 400 °C, strain rates of 0.001, 0.01, 0.1 s-1 and strains from 0.2 up to 1.0, was performed to investigate the basic hot compression behavior, while two-hit compression testing was conducted to determine the static softening behavior. Hot rolling of the microalloyed AZ31 alloys was then carried out to study the effects of microalloying on as-hot rolled structure under two sets of rolling schedules. To investigate the formability of these microalloyed sheets, tensile tests were completed over a temperature range between ambient and 450°C, at strain rates between 0.1 and 0.0003 s-1. / Results show that Ca and Sr act to refine the as cast grain size and the second phases, consistently promoting fine and uniform as-hot rolled grain structure. With regard to grain refinement, calcium has the strongest effect, whereas Ce is most effective for second phase refinement. In addition, microalloying retards grain growth during hot tensile testing. Multiple alloying presents a combined and complementary effect. / A refined and uniform grain structure combined with well dispersed and thermally stable second phases significantly improves the hot formability of AZ31 sheets by promoting dynamic recrystallization (DRX) in the matrix, resisting grain coarsening, and retarding the development of cavitation and necking. Under the superplastic condition of 450°C and 0.0003 s -1, the elongation was improved by 17% with Ca only, 26% with Ca and Ce, 51% with Ca and Sr, and 59% with Ca, Sr and Ce.

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Co-20Cr-15W-10Ni alloy (L-605) is a cobalt-based superalloy combining high strength with keeping high ductility, biocompatible and corrosion resistant. It has been used successfully for heart valves for its chemical inertia, and this alloy is a good candidate for stent elaboration. Control of grain size distribution can lead to significant improvement of mechanical properties: in one hand grain refinement enhance the material strength, and on the other hand large grains provide the ductility necessary to avoid the rupture in use. Therefore, tailoring the grain size distribution is a promising way to adapt the mechanical properties to the targeted applications. The grain size can be properly controlled by dynamic recrystallization during the forging process. Therefore, the comprehension of the recrystallization mechanism and its dependence on forging parameters is a key point of microstructure design approach. The optimal conditions for the occurrence of dynamic recrystallization are determined, and correlation between microstructure evolution and mechanical behavior is investigated. Compression tests are carried out at high-temperature on Thermec-master Z and Gleeble forging devices, followed by gas or water quench. Mechanical behavior of the material at high temperature is analyzed in detail, and innovative methods are proposed to determine the metallurgical mechanisms at stake during the deformation process. Mechanical properties of the material after hot-working and annealing treatments are investigated. The grain growth kinetics of L-605 alloy is determined, and experimental results are compared with the static recrystallization process. Microstructures after hot deformation are evaluated using SEM-EBSD and TEM. Significant grain refinement occurs by dynamic recrystallization for high temperature and low strain rate (T≥1100 ◦ C, strain rate < 0.1s−1), and at high strain rate (strain rate > 10s−1). Dynamic recrystallization is discontinuous and takes place from the grain boundaries, leading to a necklace structure. The nucleation mechanism is most likely to be bulging from grain boundaries and twin boundaries. A new insight of the modeling of dynamic recrystallization taking as a starting point the experimental data is proposed. By combining the results from the mechanical behavior study and microstructure observation, the recrystallization at steady-state is thoroughly analyzed and provides the mobility of grain boundaries. The nucleation criterion for the bulging from grain boundaries is reformulated to a more general expression suitable for any initial grain size. Nucleation frequency can be deduced from experimental data at steady-state through modeling, and is extrapolated to any deformation condition. From this point, a complete analytical model of the dynamic recrystallization is established, and provides a fair prediction on the mechanical behavior and the microstructure evolution during the hot-working process.

Although the austenitic stainless steels 304 and 321 are often treated nominally as equivalents in their hot rolling characteristics, the question remains whether any subtle differences between the two allow further optimisation of their respective hot rolling schedules. The hot workability of these two types of austenitic stainless steels was compared through single-hit Gleeble simulated thermomechanical processing between 800℃ and 􀀄􀀅00℃ while the strain rate was varied between 0.00􀀄s􀀈􀀉 and 5s􀀈􀀉. It was found that the constants for the hyperbolic sinh equation for hot working of AISI 321 steel are Q = 465 kJ/mol, 􀀖􀀗 = 􀀘.􀀙6 􀀚 􀀄0􀀉􀀛 􀀜􀀝􀀞􀀈􀀉􀀟􀀈􀀉, 􀀠 = 0.00􀀘 􀀜􀀝􀀞􀀈􀀉 and 􀀡 = 6.􀀄 while for 304 steel the constants are Q = 446 kJ/mol, 􀀖􀀗 = 􀀅.􀀄4 􀀚 􀀄0􀀉􀀛 􀀜􀀝􀀞􀀈􀀉􀀟􀀈􀀉, 􀀠 = 0.008 􀀜􀀝􀀞􀀈􀀉and 􀀡 = 6.􀀄. It is shown that the occurrence of dynamic recrystallisation starts when the Zener-Hollomon parameter 􀀢 􀀣 6.4 􀀚 􀀄0􀀉􀀛s􀀈􀀉 for both steels but that the differences in the values of Q and A3 (the structure factor) between the two steels does lead to consistently lower steady state stresses for the steel 321 than is found in the steel 304 at the same Z values. This may, therefore, offer some scope for further optimisation of the hot rolling schedules and in particular in the mill loads of these two respective steels. A modelled constitutive equation derived from hot working tests to predict hot rolling mill loads is proposed and validated against industrial hot rolling data for AISI 321 stainless steel. Good correlation is found between the predicted Mean Flow Stress, the Zener-Hollomon Z parameter and actual industrial mill load values from mill logs if allowances are made for differences in Von Mises plane strain conversion, friction and front or back end tension. The multipass hot working behaviour of this steel was simulated through Gleeble thermomechanical compression testing with the deformation temperature varying between 1200℃ down to 800℃ and the strain rate between 0.001s-1 and 5s-1. At strain rates greater than 0.05s-1, dynamic recovery as a softening mechanism was dominant, increasing the dynamic recrystallisation to dynamic recovery transition temperature DRTT to higher temperatures. This implies that through extrapolation to typical industrial strain rates of about 60s-1,most likely no dynamic recrystallisation in plant hot rolling occurs in this steel but only dynamic recovery. Grain refinement by DRX is, therefore, unlikely in this steel under plant hot rolling conditions. Finally, mill load modelling using the hot working constitutive constants of the near-equivalent 304 instead of those specifically determined for 321, introduces measurable differences in the predicted mill loads. The use of alloy-specific hot working constants even for near-equivalent steels is, therefore, recommended. / Thesis (PhD)--University of Pretoria, 2014. / lk2014 / Materials Science and Metallurgical Engineering / PhD / unrestricted

The focus of this thesis is to develop a simulation model for predicting ductile fractures during hot working at Alleima. The main fracture mechanism in these conditions is ductile fracture by void coalescence. The ductile fractures are caused by the linking of voids that appear when there is large plastic deformation near second-phase particles. The chosen method to simulate these was to use a Ductile Fracture Criterion (DFC), which builds on using FE models with a damage parameter. Two criteria were selected to be tested. The austenitic stainless-steel alloy 316L was selected as material for this work. Using the Gleeble 3500 system, hot tension and compression experiments were performed to gather data needed for the simulation models as well as inducing ductile fractures. Rupture occurred for all the hot tension samples and cracks were found for only one of the hot compression experiments. Using data from the Gleeble tests, a separate simulation model for each of the setups were created using the finite element software Marc/Mentat. A flow stress model for 316L was developed. Results from the simulations show that both selected DFCs can be used to predict ductile fractures. Particularly for hot tension. It was shown that it is important to model the temperature gradient in the sample accurately. For hot compression, it was difficult to conclude if the criterions were able to predict fracture since only one data point was available. The thesis concludes that there could be of interest with continued work using DFCs at Alleima.