Development of Induction Heating System Ensuring Increased Heating Efficiency of the Charge Material in a Forging

This study performs a complex analysis and review of the currently applied methods of inductively heating the charge material in hot die forging processes, as well as elaborates and verifies a more effective heating method. On this basis, a device for inductive heating using variable frequency inductors was designed and constructed, which made it possible to reduce the scale and decarburization with respect to the heater used so far. In the first place, the temperature distributions in the heater in the function of time were modeled with the use of the CEDRAT FLUX software. The aim of the research was to analyze the temperature gradient and value diversification on the surface and in the material core, as well as to determine the process stability. The following stage was designing and constructing a heater with an automatic system of loading and positioning of the charge on the exit, as well as with a possibility of working in a fully automated system adjusted to the work center. The last stage of investigations was the verification of the elaborated effective heating method on the basis of a short production series and a continuous work for the period of 8 h, both in the quantitative and qualitative aspect (reduced oxidation and decarburization as well as a gradient between the core and the surface). The obtained results confirm the effectiveness of the proposed solution referring to heating the charge material, especially in the aspect of stability and repeatability of the process, as well as a significant reduction in oxidation and decarburization of the material surface.     

Wear Analysis of Forging Tools Used in an Industrial Production Process—Hot Forging in Closed Dies of the “Head-Disk” of an Engine Valve Forging

The article performs an analysis of the durability of punches applied in the process of producing a valve forging from chromium-nickel steel. A forging of this type is made in two operations: coextrusion of a long shank, followed by finishing forging in closed dies of the valve head. The product obtained in this way (after other additional finishing procedures) constitutes the key element of the combustion engine (resistant to high pressures and temperatures) in motor trucks. Unfortunately, a significant problem in this production process is a relatively low durability of the forging tools, especially the punch used in the second forging operation. The key element at this stage, deciding about the punch’s further operation, is the area of the so-called “calotte”. The short-term life of the tools results from very hard performance conditions present during the forging process (periodical high mechanical and thermal loads, long path of friction). The latter cause intensive abrasive wear as well as high adhesion of the forging material to the tool surface. Based on the performed studies, including the following: technology analysis, numerical modelling, macro analyses combined with 3D scanning of tool sections as well as microstructural tests and hardness measurements, it was established that it is crucial to properly select the process parameters (charge and tool temperature, tribological conditions), as even slight changes introduced into them significantly affect the operation time of the forging tools. Mastering and proper implementation of the analyzed forging technology requires numerous further studies and tests, which will enable its perfection and thus increase the durability of the tools as well as the quality of the produced items.     

Wear Mechanisms of the Forging Tool Used in Pre-Forming in a Double Forging System of Truck Parts

Tool life in plastic forming processes is a problem of the utmost importance as it significantly affects the cost of production. Hot forging with hammers and mechanical presses is an example of the technological process in which the load on tools is extremely high and, consequently, the lifetime of tools is short. Considering, additionally, that this applies to large-scale production, from an economic point of view, the key issue will be to extend the tool life, make an accurate prediction of the number of parts that can be forged before the replacement of dies is necessary, and develop a system for quick tool changeover. Initially, however, it is necessary to understand the causes of excessive tool wear, which may lie in phenomena occurring at the level of microstructure. The aim of this article was to outline an example of the coexistence of multiple wear mechanisms in hot forging dies. For the modified chemical composition, the microstructure examinations were performed in selected areas of the tool. The research has revealed the causes of cracks in tools and some irregularities in the preparation of tools for production process.     

The Impact of the Lubricant Dose on the Reduction of Wear Dies Used in the Forging Process of the Valve Forging

The paper presents the results of research on the influence of the settings of lubrication and cooling system parameters (solenoid valve opening time and lubricant feed pressure in terms of its quantity) in order to select the optimal lubricating conditions and thus reduce the wear of the dies used in the first forging operation of the valve forging made of high-nickel steel. Based on the observation of lubrication in the industrial process, it was found that a significant part of the lubricant fails to reach the die cavity, reaching the outside of it, which causes die wear due to seizure resulting from adhesion of the forging material to the tool surface as well as high lubricant consumption and dirt in the press chamber. The authors proposed their own mobile lubricating and cooling system, which allows for a wide range of adjustments and provided with automatic cleaning procedures of the entire system, unlike the fixed lubrication system used so far in the industrial process. First, tests were carried out in laboratory conditions to determine the highest wettability and the lubricant remaining inside the tool cavity. These tests determined the lubrication system parameter settings that ensured that the greatest amount of lubricant remains in the cold die cavity without the forging process. Then, to verify the obtained results, tests were carried out in the industrial process of hot die forging of valve forgings for short production runs of up to 500 forgings. The results were compared with the measurement of changes in the geometry of tools and forgings based on 3D scanning and surface topography analysis with the use of SEM (Scanning Electron Microscope). For the best results (the variant of the setting of the dose and the time of exposure to lubricant), the forging process was carried out with the use of a new tool up to the maximum service life.     

Modeling of the Closure of Metallurgical Defects in the Magnesium Alloy Die Forging Process

The article discusses the impact of hot forging elongation operations on the closure of metallurgical discontinuities such as middle porosity in selected magnesium alloys (AZ91) depending on the shape of the input used. Numerical modeling was carried out using the Forge^®NxT 2.1 program based on the finite element method and laboratory modeling in order to bring about the closure of defects of metallurgical origin in deformed forging ingots. On the basis of the conducted research, optimal values of the main technological parameters of forging and appropriate groups of anvils to be used in individual stages of forging were proposed in order to eliminate metallurgical defects.     

Wear Improvement of Tools in the Cold Forging Process for Long Hex Flange Nuts

Cold forging has played a critical role in fasteners and has been widely used in automotive production, manufacturing, aviation and 3C (Computer, Communication, and Consumer electronics). Despite its extensive use in fastener forming and die design, operator experience and trial and error make it subjective and unreliable owing to the difficulty of controlling the development schedule. This study used finite element analysis to establish and simulate wear in automotive repair fastener manufacturing dies based on actual process conditions. The places on a die that wore most quickly were forecast, with the stress levels obtained being substituted into the Archard equation to calculate die wear. A 19.87% improvement in wear optimization occurred by applying the Taguchi quality method to the new design. Additionally, a comparison of actual manufacturing data to simulations revealed a nut forging size error within 2%, thereby demonstrating the accuracy of this theoretical analysis. Finally, SEM micrographs of the worn surfaces on the upper punch indicate that the primary wear mechanism on the cold forging die for long hex flange nuts was adhesive wear. The results can simplify the development schedule, reduce the number of trials and further enhance production quality and die life.     

On the Stability of Complex Concentrated (CC)/High Entropy (HE) Solid Solutions and the Contamination with Oxygen of Solid Solutions in Refractory Metal Intermetallic Composites (RM(Nb)ICs) and Refractory Complex Concentrated Alloys (RCCAs)

In as-cast (AC) or heat-treated (HT) metallic ultra-high temperature materials often “conventional” and complex-concentrated (CC) or high-entropy (HE) solid solutions (sss) are observed. Refractory metal containing bcc sss also are contaminated with oxygen. This paper studied the stability of CC/HE Nb_ss and the contamination with oxygen of Nb_ss in RM(INb)ICs, RM(Nb)ICs/RCCAs and RM(Nb)ICs/RHEAs. “Conventional” and CC/HE Nb_ss were compared. “Conventional” Nb_ss can be Ti-rich only in AC alloys. Ti-rich Nb_ss is not observed in HT alloys. In B containing alloys the Ti-rich Nb_ss is usually CC/HE. The CC/HE Nb_ss is stable in HT alloys with simultaneous addition of Mo, W with Hf, Ge+Sn. The implications for alloy design of correlations between the parameter δ of “conventional” and CC/HE Nb_ss with the B or the Ge+Sn concentration in the Nb_ss and of relationships of other solutes with the B or Ge+Sn content are discussed. The CC/HE Nb_ss has low Δχ, VEC and Ω and high ΔS_mix, |ΔH_mix| and δ parameters, and is formed in alloys that have high entropy of mixing. These parameters are compared with those of single-phase bcc ss HEAs and differences in ΔH_mix, δ, Δχ and Ω, and similarities in ΔS_mix and VEC are discussed. Relationships between the parameters of alloy and “conventional” Nb_ss also apply for CC/HE Nb_ss. The parameters δ_ss and Ω_ss, and VEC_ss and VEC_alloy can differentiate between types of alloying additions and their concentrations and are key regarding the formation or not of CC/HE Nb_ss. After isothermal oxidation at a pest temperature (800 ^oC/100 h) the contaminated with oxygen Nb_ss in the diffusion zone is CC/HE Nb_ss, whereas the Nb_ss in the bulk can be “conventional” Nb_ss or CC/HE Nb_ss. The parameters of “uncontaminated” and contaminated with oxygen sss are linked with linear relationships. There are correlations between the oxygen concentration in contaminated sss in the diffusion zone and the bulk of alloys with the parameters Δχ_Nbss, δ_Nbss and VEC_Nbss, the values of which increase with increasing oxygen concentration in the ss. The effects of contamination with oxygen of the near surface areas of a HT RM(Nb)IC with Al, Cr, Hf, Si, Sn, Ti and V additions and a high vol.% Nb_ss on the hardness and Young’s modulus of the Nb_ss, and contributions to the hardness of the Nb_ss in B free or B containing alloys are discussed. The hardness and Young’s modulus of the bcc ss increased linearly with its oxygen concentration and the change in hardness and Young’s modulus due to contamination increased linearly with [O]^2/3.     

The Transverse Bearing Characteristics of the Pile Foundation in a Calcareous Sand Area

Reviewing literature revealed that the studies on the bearing characteristics of pile foundations mainly focuses on clay, ordinary sand, loess, saline soil, and other areas. However, few studies on the bearing characteristics of the pile foundation in calcareous sand were conducted. Besides, existing traditional studies ignored the variation of soil compression modulus with depth, and the effect of void ratio on the transverse bearing characteristics of the pile foundation in a calcareous sand area were not well understood. In response of these problems, this study conducted a theoretical investigation on the transverse bearing characteristics of the pile foundation in a calcareous sand area. The transverse bearing characteristics of the pile foundation were derived based on the Pasternak foundation model and the Winkler foundation model, incorporating the heterogeneous distribution of compressive modulus with buried depth. The calculation results of the Pasternak foundation model are closer to the observed results than the Winkler foundation model. Therefore, the following research on the transverse bearing characteristics of the pile foundation in the calcareous sand area adopts the Pasternak foundation model. Then, the effects of the pile length, pile diameter, pile elastic modulus, horizontal load, bending moment, and void ratio on the transverse bearing characteristics of the pile foundation in a calcareous sand area were thoroughly analyzed. Furthermore, the difference between the transverse bearing characteristics of the pile foundation in a calcareous sand area and a quartz sand area was discussed. Results show that the horizontal displacement of the pile top in a calcareous sand area is greater than the quartz sand area under the same conditions.     

Experimental Investigation of the Performance of a Hybrid Self-Healing System in Porous Asphalt under Fatigue Loadings

Self-healing asphalt, which is designed to achieve autonomic damage repair in asphalt pavement, offers a great life-extension prospect and therefore not only reduces pavement maintenance costs but also saves energy and reduces CO₂ emissions. The combined asphalt self-healing system, incorporating both encapsulated rejuvenator and induction heating, can heal cracks with melted binder and aged binder rejuvenation, and the synergistic effect of the two technologies shows significant advantages in healing efficiency over the single self-healing method. This study explores the fatigue life extension prospect of the combined healing system in porous asphalt. To this aim, porous asphalt (PA) test specimens with various healing systems were prepared, including: (i) the capsule healing system, (ii) the induction healing system, (iii) the combined healing system and (iv) a reference system (without extrinsic healing). The fatigue properties of the PA samples were characterized by an indirect tensile fatigue test and a four-point bending fatigue test. Additionally, a 24-h rest period was designed to activate the built-in self-healing system(s) in the PA. Finally, a damaging and healing programme was employed to evaluate the fatigue damage healing efficiency of these systems. The results indicate that all these self-healing systems can extend the fatigue life of porous asphalt, while in the combined healing system, the gradual healing effect of the released rejuvenator from the capsules may contribute to a better induction healing effect in the damaging and healing cycles.     

Order-Induced Selectivity Increase of Cu60Pd40 in the Semi-Hydrogenation of Acetylene

The two structural modifications of Cu₆₀Pd₄₀ were synthesized as bulk powders and tested as unsupported model catalysts in the semi-hydrogenation of acetylene. The partly ordered low-temperature modification (CsCl type of structure) showed an outstanding ethylene selectivity of >90% over 20 h on stream while the disordered high-temperature modification (Cu type of structure) was 20% less selective, indicating an influence of the degree of order in the crystal structure on the catalytic properties. The results are supported by XRD and in situ XPS experiments. The latter suggest the existence of partly isolated Pd sites on the surface. In situ PGAA investigations proved the absence of metal hydride formation during reaction. Quantum chemical calculations of the electronic structure of both modifications using the CPA-FPLO framework revealed significant differences in their respective density of states, thus still leaving open the question of whether the degree of structural order or/and the electronic hybridization is the decisive factor for the observed difference in selectivity.     

The Effect of the β-Al5FeSi Phases on Microstructure,Mechanical and Fatigue Properties in A356.0 Cast Alloys with Higher Fe Content without Additional Alloying of Mn

Secondary-cast aluminum alloys have increasing industrial applications. Their biggest deficiency is their impurity content, especially Fe, which has low solubility in Al and almost all the content creates intermetallic phases. This work examines the effect of higher Fe content on the microstructure and properties of A356.0 alloy. At the same time, no other possibility existed to affecting the brittleness of the formation of the β phases. The calculation of Fe_crit, ratio of Mn/Fe, quantitative and computed tomography analysis of porosity and Fe plate-like phases, measurement of mechanical and fatigue properties, and fractography analysis were performed in this study. The results show that gravity die casting into a sand mold, and the non-usage of Mn addition or heat treatment, do not have a negative effect on increasing the size of the Fe-rich plate-like phases. The longest Fe-rich phases have limited the pore growth and ratios, but their higher thickness led to greater porosity formation. The mechanical and fatigue properties correlate with the Fe_crit level and the highest were for the experimental alloy with 0.454 wt.% of Fe. The experimental results confirmed the fact that if the Fe plate-like phases have a length of up to 50 µm, the fatigue properties depend more on the size of porosity. If the length of the Fe needles is more than 50 µm, then the properties are mainly affected by the length of these Fe phases.