Heat treatment can be defined as a combination of heating and cooling operations applied to a metal or alloy in solid state. It is an important manufacturing process, which controls the mechanical properties of metals, therefore contributes to the product quality. Computerized Heat Treatment Planning System for Quenching and Tempering (CHT-q/t), a windows based stand alone software, is developed to assist the heat treatment process design. The goal of CHT-q/t is to predict the temperature profile of load in batch as well as continuous furnace during heating, quenching and tempering of steel, then to predict the mechanical properties as Quenched & Tempered, and finally to optimize the heat treatment process design. The thesis reviews existing heat treating simulation software and identifies the industrial need of a software tool which integrates part load and furnace model with heat treating process. The thesis discusses cooling curve of specimen and Time Temperature Transformation (TTT) diagram to determine the microstructure evolution and subsequently the mechanical properties of steel after quenching. An extensive database has been developed to support the various function modules. The thesis focuses mainly in the TTT and quenchant database development, property prediction after quenching and tempering and the implementation of software. The properties determined in the thesis are hardness, ultimate tensile strength, yield strength, toughness and percentage elongation. Hardness has been predicted by the use of some well known analytical equations and the TTT database, finally regression analysis has been used to give the value as a function of carbon percentage and volume fraction of martensite. The other mechanical properties are calculated based on a relation of hardness and volume fraction of martensite. Various case studies were performed to show the application of CHT-bf and CHT-cf at Bodycote Thermal Processing, Worcester & Waterbury. The objective behind the case studies was to study the effect of change in load arrangement, production rate and cycle time on the heat treated parts and finally to give recommendations in order to save energy and improve productivity and quality.

This research extended the knowledge of the solid phase transformation and the resulting influence on impact toughness and pitting corrosion resistance in super austenitic stainless steel (SASS) SANICRO® 35. A time-temperature-transformation diagram (TTT diagram) was assembled by performing isothermal heat treatments in the temperature range of 650-1050 °C for different periods of time, ranging from 5 min to 500 min. Microstructural analysis via LOM-DIC, SEM-EDS shows that the nose temperature of dominating σ phase is located in between 900-950 °C. Minor nitrides including π phase and Cr2N with the nose temperature of 900 °C and 850 °C, respectively, were detected after prolonged heat treatment times. Area fraction of precipitates was calculated by analyzing micrographic images in the software ImageJ. Charpy impact tests indicate that the impact toughness degrades with increasing area fraction of precipitates but at a higher rate at the early stage of precipitation. Despite a much-lessened area fraction, fine precipitates decorating the grain boundaries in a continuous pattern impose significant negative effect on impact toughness. Pitting corrosion resistance was indicated by critical pitting temperature (CPT) as per ASTM G150mod (3M MgCl2). Pitting corrosion resistance deteriorated with increasing amount of σ phase due to the Cr- and Mo-depleted surrounding area, but it is more dependent on the distribution pattern of precipitates, as well as the secondary phase type. The lowest CPTs were measured after heat treatment for 500 min at 800 °C and 850 °C where nitrides including Cr2N and π phase were formed and the small precipitates were distributed on grain boundaries continuously. Auxiliary simulation of TTT diagram via TC PRISMA shows drastic variation from experimental results in regard of time scale. The enhancement pre-factor for the interfacial mobility and interfacial energy can be modified to approach the experimental results. / Detta arbete utfördes för att undersöka fasomvandlingar och dess inflytande på slagsegheten och gropfrätningsmotståndet för det superaustenitiska rostfria stålet (SASS) SANICRO® 35. Ett tid-temperatur-transformationsdiagram (TTT-diagram) har tagits fram genom att utföra isotermiska värmebehandlingar mellan 650-1050 °C med olika hålltider från 5-500 minuter. Mikrostrukturanalys genom LOM-DIC, SEM-EDS undersökning visar att nosen för den dominerande σ-fasen ligger mellan 900-950 °C. Mindre nitrider, som π-fas och Cr2N, med nosarna vid 900 °C respektive 850 °C observerades vid längre hålltider. Areafraktionen av utskiljningar beräknades genom analys av mikrobilder med programmet ImageJ. Slagprovning visade att slagsegheten minskar med ökande fraktion utskiljningar men med en tydligare försämring i början av fastransformationen. Trots att de utgör en betydligt mindre areafraktion så kan mindre utskiljningar som följer korngränserna också påverka materialet signifikant negativt. Gropfrätningsmotståndet testades genom att mäta Critical Pitting Temperature (CPT) enligt ASTM G150mod (3M MgCl2). CPT minskade med ökande andel σ-fas p.g.a. den Cr- och Mo-utarmade zon som omger de utskilda partiklarna. Det finns även en stark koppling mellan lägre CPT och distributionen av utskiljningarna samt andra typer av faser. Lägst CPT uppmättes efter 500 minuter vid 800 °C och 850 °C då små nitrider inklusive Cr2N och π-fas bildats längs med stora delar av korngränserna. Simulering av TTT-diagram i TC PRISMA visade en drastisk skillnad i tiden till utskiljning/mängden utskiljningar jämfört med de experimentella resultaten. Diffusionförstärkningsfaktorn (eng. “mobility enhancement pre-factor”) och ytenergin kan minskas för att bättre överensstämma med de experimentella resultaten.

Military aircraft that require high maneuverability, durability, ballistic protection, reparability, and energy efficiency require structural alloys with low density, high toughness, and high strength. Also, repairs to these aircraft demand a production process that has the flexibility to be relatively in-situ with the same high-performance output. Materials produced by the cold spray process, a thermo-mechanical powder consolidation technique, meet many of the requirements. In accordance with President Obama’s 2011 Materials Genome Initiative, the focus of this effort is to design customized aluminum alloy powders which exploit the unique behavior and properties of the materials created by the cold spray process. Analytical and computational models are used to customize microchemistry, thermal conditioning, and solidification behavior of the powders by predicting equilibrium and non-equilibrium microstructure and resulting materials properties and performance. Thermodynamic, kinetic, and solidification models are used, including commercial software packages Thermo-Calc, Pandat™, and JMatPro®, and TC-PRISMA. Predicted powder properties can be used as input into a cold spray process impact model to determine the consolidated materials’ properties. Mechanical properties of powder particles are predicted as a function of powder particle diameter and are compared to experimental results.

This research focused on a comprehensive microstructural and mechanical property characterisation study of the Ni-Fe-Cr alloys 718 and 945X. The aim of the project was to better understand the relationship between performance and microstructure of existing (Alloy 718) and newly developed (Alloy 945X) high strength nickel alloys focusing on downhole applications. The main difference between the two alloys is that alloy 945X has lower Nb content than alloy 718, which may minimise the tendency to form delta when combined with correct processing. Previous studies have related the hydrogen embrittlement in alloy 718 with the collection of hydrogen by delta phase. Microstructural characterisation of the new alloy 945X after long term isothermal exposure up to 120 hours in the temperature range 650◦C to 900◦C was conducted with scanning electron microscopy (SEM), to generate a time-temperature-transformation (TTT) diagram. The TTT diagram was used as a road map for designing two isothermal heat treatments of alloy 945X on tensile specimens. Then, the effect of hydrogen charging on the tensile properties and microstructure of the 'as-received' and these two variant heat treatments was investigated. Fractographic analysis showed that, in the presence of hydrogen, intergranular fracture occurred for all the heat treatments, regardless the presence of delta phase at grain boundaries. There was no simple correlation between the volume fraction of delta-phase and susceptibility to hydrogen assisted embrittlement. Rather, it was demonstrated that the morphology and distribution of delta-phase along grain boundaries plays a key role and the other precipitate phases also have an influence through their effect on the ease of strain localisation. This study also examined the hydrogen embrittlement sensitivity of nickel alloy 718 given four different heat treatments to obtain various microstructural states. Each heat treatment leads to differences in the precipitate morphologies of γ', γ'' and delta phases. Material characterisation and fractography of the examined heat treatments were performed using a high resolution FEG-SEM. Three specimens of each condition were pre- charged with hydrogen and tensile properties were compared with those of non-charged specimens. It was observed that hydrogen embrittlement was associated with intergranular and transgranular microcrack formation, leading to an intergranular brittle fracture. delta phase may assist the intergranular crack propagation, and this was shown to be particularly true when this phase is coarse enough to produce crack initia- tion, but this is not the only factor determining embrittlement. Other microstructural features play a role, as does the strength of the material. Finally, the evolution of delta-(Ni3Nb) phase in alloy 718 from the early stages of precipitation, with a particular focus on identifying the grain boundary characteristics that favour precipitation of grain boundary delta phase was investigated. Results showed that delta phase was firstly formed on Σ3 boundaries after 5 hours at the examined temperature (800◦C). Increasing ageing time at 800◦C was observed to lead to an increase in size and precipitation of phases γ'-γ''-delta, an increase in fraction of the special CSL boundaries and an evolution in the morphology of twins and the growth of grains.