TY - JOUR A1 - El-Batahgy, A. A1 - Saiyah, A. A1 - Khafagi, S. A1 - Gumenyuk, Andrey A1 - Gook, S. A1 - Rethmeier, Michael T1 - Shielded metal arc welding of 9%Ni steel using matching ferritic filler metal N2 - Motivated by the tensile strength loss of 9%Ni steel arc welded joints made using Ni-based austenitic filler metals, the feasibility of maintaining the tensile strength using matching ferritic filler metal has been demonstrated. In comparison with shielded metal arc welded joint made using Ni-based austenitic electrode ENiCrMo-6, higher tensile strength comparable to that of the base metal was obtained using matching ferritic electrode. Besides, sufficient impact toughness energies with much lower mismatch were obtained for weld metal and heat-affected zone. Welded joint with a lower mechanical mismatching is of considerable importance for achieving acceptable combination of tensile strength and impact toughness.Abetter combination of These mechanical properties is ensured by applying a post weld heat treatment. KW - Mechanical mismatching KW - Mechanical properties KW - Microstructure KW - Austenitic welding electrode KW - Matching ferritic welding electrode PY - 2020 DO - https://doi.org/10.1080/13621718.2020.1846936 SN - 1362-1718 SP - 1 EP - 7 PB - Taylor & Francis AN - OPUS4-51835 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Kempf, A. A1 - Hilgenberg, Kai T1 - Influence of sub-cell structure on the mechanical properties of AlSi10Mg manufactured by laser powder bed fusion N2 - AlSi10Mg is one of the most applied alloys for laser powder bed fusion (LPBF) technology, due to its great possibilities for implementing new lightweight concepts such as in automotive industries. For the component design it is necessary to know about the mechanical properties and the mechanical behaviour. The many published strength properties of LPBF processed AlSi10Mg show significant differences up to approximately 225 MPa in ultimate tensile strength (UTS) and 195 MPa in yield strength (YS). To understand these varying properties, a ring trial was carried out manufacturing specimens on 6 LPBF machines with different parameters and build-up strategies. They were studied in the as-built (AB) condition and after heat treatment at 300 °C for 30 min, respectively. For examining the mechanical properties, tensile tests and hardness measurements were carried out. The microstructure was characterized by optical light microscopy (OM), field emission scanning electron microscopy (SEM), energy dispersive X-ray spectroscopy (EDX), X-ray diffraction (XRD) and electron backscatter diffraction (EBSD). The identified differences in strength properties were discussed based on the 4 strengthening mechanism known for metallic materials and at the background of material defects. It was found that the size of the typical sub-cell structure of LPBF AlSi10Mg affected substantially the mechanical properties in the AB condition, in which with decreasing sub-cell size strength increased. If heat treatment was applied, the strength properties decreased and did not differ anymore. Since annealing led to coarsened sub-cells, whereas the grains itself did not change in size, the influence of sub-cell structure on strength was further confirmed. In addition, acicular precipitates in the AB condition were observed at specimens from one LPBF machine showing the lowest tensile elongation. KW - Laser powder bed fusion KW - AlSi10Mg KW - Mechanical properties KW - Microstructure PY - 2020 DO - https://doi.org/10.1016/j.msea.2020.138976 VL - 776 SP - Paper 138976, 12 PB - Elsevier B.V. AN - OPUS4-50316 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Sonego, M. A1 - Madia, Mauro A1 - Eder, M. A1 - Fleck, C. A1 - Pessan, L. A. T1 - Microstructural features influencing the mechanical performance of the Brazil nut (Bertholletia excelsa) mesocarp N2 - Brazil nut (Bertholletia excelsa) fruits are capable of resisting high mechanical forces when released from trees as tall as 50 m, as well as during animal dispersal by sharp-teethed rodents. Thick mesocarp plays a crucial part in seed protection. We investigated the role of microstructure and how sclereids, fibers, and voids affect nutshell performance using compression, tensile and fracture toughness tests. Fractured specimens were analyzed through scanning electron microscopy (SEM) and microtomography (microCT). Mesocarp showed high deformability (strain at max. stress of ~30%) under compression loading, a critical tensile strength of ~24.9 MPa, a Weibull modulus of ~3, and an elastic modulus of ~2 GPa in the tensile test. The fracture toughness, estimated through the work of fracture of SENB tests, reached ~2 kJ/m2. The thick and strong walls of mesocarp cells, with a weaker boundary between them (compound middle lamella), promote a tortuous intercellular crack path. Several toughening mechanisms, such as crack deflection, breaking of fiber bundles, fiber pullout and bridging as well as crack branching, occur depending on how fiber bundles and voids are oriented. KW - Toughening mechanisms KW - Brazil nut Mesocarp KW - Microstructure KW - Mechanical properties PY - 2021 DO - https://doi.org/10.1016/j.jmbbm.2020.104306 VL - 116 SP - 104306 PB - Elsevier Ltd. AN - OPUS4-52081 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Gook, S. A1 - Midik, A. A1 - Biegler, M. A1 - Gumenyuk, Andrey A1 - Rethmeier, Michael T1 - Joining 30 mm Thick Shipbuilding Steel Plates EH36 Using a Process Combination of Hybrid Laser Arc Welding and Submerged Arc Welding N2 - This article presents a cost-effective and reliable method for welding 30 mm thick sheets of shipbuilding steel EH36. The method proposes to perform butt welding in a two-run technique using hybrid laser arc welding (HLAW) and submerged arc welding (SAW). The HLAW is performed as a partial penetration weld with a penetration depth of approximately 25 mm. The SAWis carried out as a second run on the opposite side. With a SAWpenetration depth of 8 mm, the weld cross-section is closed with the reliable intersection of both passes. The advantages of the proposed welding method are: no need for forming of the HLAW root; the SAW pass can effectively eliminate pores in the HLAWroot; the high stability of the welding process regarding the preparation quality of the weld edges. Plasma cut edges can be welded without lack of fusion defects. The weld quality achieved is confirmed by destructive tests. KW - Shipbuilding steel KW - Hybrid laser arc welding KW - Submerged arc welding KW - Hardness KW - Bending test KW - Two-run welding technique KW - Microstructure PY - 2022 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-556090 DO - https://doi.org/10.3390/jmmp6040084 SN - 2504-4494 VL - 6 IS - 4 SP - 1 EP - 11 PB - MDPI CY - Basel AN - OPUS4-55609 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Fu, B. A1 - Shen, J. A1 - Suhuddin, U. A1 - Pereira, A. A1 - Maawad, E. A1 - dos Santos, J. A1 - Klusemann, B. A1 - Rethmeier, Michael T1 - Revealing joining mechanism in refill friction stir spot welding of AZ31 magnesium alloy to galvanized DP600 steel N2 - The application of magnesium (Mg) inevitably involves dissimilar welding with steel. A novel solid state spot welding method, refill friction stir spot welding (refill FSSW), was utilized to weld AZ31 Mg alloy to galvanized DP600 steel. Although Mg/Fe is an immiscible alloy system, defect-free welds with high strength were successfully obtained in a wide parameter window. The results of microstructure, interfacial reactions, and mechanical properties are reported to reveal the underlying joining mechanism. Due to the melting of Zn coating and subsequent Mg-Zn reactions, Mg-Zn eutectic and intermetallic compounds were detected within welds. Heterogeneous interfacial reactions occur along Mg/steel interface, and the relationship between interfacial structure and fracture behavior was investigated. The joining mechanism is associated with Zn coating and Fe-Al layer: 1) the presence of Zn coating is beneficial for achieving high-quality welding between Mg and steel, it protects the interface from oxidation and contributes to brazing of the weld; 2) the Al present in Mg alloy reacts with Fe, resulting in the growth of Fe-Al layer, which contributes to the diffusion bonding in the interface. The overall results clearly show that Refill FSSW is a competitive welding method for joining Mg and galvanized steel. KW - Refill friction stir spot welding KW - Multi-materials joining KW - Magnesium alloy KW - Galvanized steel KW - Mechanical properties KW - Microstructure PY - 2021 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-536878 DO - https://doi.org/10.1016/j.matdes.2021.109997 SN - 0264-1275 VL - 209 SP - 109997 PB - Elsevier Ltd. AN - OPUS4-53687 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - El-Batahgy, A. A1 - Elkousy, M. A1 - Al-Rahman, A. A1 - Gumenyuk, Andrey A1 - Rethmeier, Michael A1 - Gook, S. T1 - Retaining Mechanical Properties of GMA-Welded Joints of 9%Ni Steel Using Experimentally Produced Matching Ferritic Filler Metal N2 - Motivated by the loss of tensile strength in 9%Ni steel arc-welded joints performed using commercially available Ni-based austenitic filler metals, the viability of retaining tensile strength using an experimentally produced matching ferritic filler metal was confirmed. Compared to the austenitic Ni-based filler metal (685 MPa), higher tensile strength in gas metal arc (GMA) welded joints was achieved using a ferritic filler metal (749 MPa) due to its microstructure being similar to the base metal (645 MPa). The microstructure of hard martensite resulted in an impact energy of 71 J (-196 °C), which was two times higher than the specified minimum value of _>34 J. The tensile and impact strength of the welded joint is affected not only by its microstructure, but also by the degree of its mechanical mismatch depending on the type of filler metal. Welds with a harder microstructure and less mechanical mismatch are important for achieving an adequate combination of tensile strength and notched impact strength. This is achievable with the cost-effective ferritic filler metal. A more desirable combination of mechanical properties is guaranteed by applying low preheating temperature (200 °C), which is a more practicable and economical solution compared to the high post-weld heat treatment (PWHT) temperature (580 °C) suggested by other research. KW - 9%Ni steel KW - Ni-based austenitic filler metal KW - Mechanical mismatching KW - Microstructure KW - Post-weld heat treatment KW - Preheating KW - Matching ferritic filler metal PY - 2022 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-564610 DO - https://doi.org/10.3390/ma15238538 SN - 1996-1944 VL - 15 IS - 23 SP - 1 EP - 14 PB - MDPI AN - OPUS4-56461 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Buzolin, R.H. A1 - Richter, Tim A1 - Pixner, F. A1 - Rhode, Michael A1 - Schröpfer, Dirk A1 - Enzinger, N. T1 - Microstructure and texture characterisation of friction stir welded CoCrNi and CoCrFeMnNi multi-principle element alloys N2 - This work investigates the microstructure formed in friction stir welds of FCC alloys, focused on two multiprincipal alloys: a CoCrFeMnNi high-entropy alloy (HEA) and a CoCrNi medium-entropy alloy (MEA). A commercial stainless steel AISI 304 is used for comparison. The largest nugget was formed in the MEA, while the smallest was formed in the HEA. Grain refinement occurs in the stirred zone in all welds. Discontinuous dynamic recrystallisation is the predominant restoration mechanism during friction stir welding of the three investigated alloys. A sharp decrement in the Σ3 boundary fraction occurs in the stirred zone of the AISI 304 and HEA welds, while comparable values with the base metal are found for the MEA weld. The peak in the maximum index of crystallographic texture is observed on the advancing side of the stirred zone of the AISI 304 weld. A strong <001> θ-fibre texture is formed in the advancing side of the nugget in the AISI 304 from a well-established {123} <634> S-type texture in the base metal. Multiple crystallographic texture components without specific fibres are identified in most regions of the welds, indicating the complex shear path history during friction stir welding. KW - Microstructure KW - Multiple principal element alloy KW - Friction stir welding KW - Electron backscattered diffraction KW - Crystallographic texture PY - 2023 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-572987 DO - https://doi.org/10.1016/j.mtcomm.2023.105870 VL - 35 SP - 1 EP - 14 PB - Elsevier Ltd. CY - Amsterdam (NL) AN - OPUS4-57298 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Üstündag, Ö. A1 - Gook, S. A1 - Gumenyuk, Andrey A1 - Rethmeier, Michael T1 - Hybrid laser arc welding of thick high-strength piepline steels of grade X120 with adapted heat input N2 - The influence of heat input and welding speed on the microstructure and mechanical properties of single-pass hybrid laser arc welded 20mm thick plates of high-strength pipeline steel X120 were presented. The heat Input was varied in the range of 1.4 kJ mm−1 to 2.9 kJ mm−1, while the welding speed was changed between 0.5m min−1 and 1.5m min−1. A novel technique of bath support based on external oscillating electromagnetic field was used to compensate the hydrostatic pressure at low welding velocities. A major advantage of this technology is, that the welding speed and thus the cooling time t8/5 can be variated in a wide parameter window without issues regarding the weld root quality. The recommended welding thermal cycles for the pipeline steel X120 can be met by that way. All tested Charpy-V specimens meet the requirements of API 5 L regarding the impact energy. For higher heat inputs the average impact energy was 144 ± 37 J at a testing temperature of −40 °C. High heat Input above 1.6 kJ mm−1 leads to softening in the weld metal and heat-affected-zone resulting in loss of strength. The minimum tensile strength of 915 MPa could be achieved at heat inputs between 1.4 kJ mm−1 and 1.6 kJ mm−1. KW - High-strength low-alloy steel KW - Hybrid laser-arc welding KW - Mechanical-technological properties KW - Microstructure KW - Toughness KW - Pipeline steel of grade X120 PY - 2020 DO - https://doi.org/10.1016/j.jmatprotec.2019.116358 SN - 0924-0136 VL - 275 SP - 116358 PB - Elsevier B.V. AN - OPUS4-50008 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - El-Batahgy, A. A1 - Saiyah, A. A1 - Khafagi, S. A1 - Gumenyuk, Andrey A1 - Gook, Sergej A1 - Rethmeier, Michael T1 - Shielded metal arc welding of 9%Ni steel using matching ferritic filler metal N2 - Motivated by the tensile strength loss of 9%Ni steel arc welded joints made using Ni-based austenitic filler metals, the feasibility of maintaining the tensile strength using matching ferritic filler metal has been demonstrated. In comparison with shielded metal arc welded joint made using Ni-based austenitic electrode ENiCrMo-6, higher tensile strength comparable to that of the base metal was obtained using matching ferritic electrode. Besides, sufficient impact toughness energies with much lower mismatch were obtained for weld metal and heat-affected zone. Welded joint with a lower mechanical mismatching is of considerable importance for achieving acceptable combination of tensile strength and impact toughness. A better combination of These mechanical properties is ensured by applying a post weld heat treatment. KW - 9%Ni steel KW - Ni-based austenitic welding electrode KW - Matching ferritic welding electrode KW - Mechanical properties KW - Mechanical mismatching KW - Microstructure KW - SMAW PY - 2020 DO - https://doi.org/10.1080/13621718.2020.1846936 VL - 26 IS - 2 SP - 116 EP - 122 PB - Taylor & Francis AN - OPUS4-52025 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER - TY - JOUR A1 - Schröpfer, Dirk A1 - Treutler, K. A1 - Börner, Andreas A1 - Gustus, R. A1 - Kannengießer, Thomas A1 - Wesling, V. A1 - Maus-Friedrichs, W. T1 - Surface finishing of hard-to-machine cladding alloys for highly stressed components N2 - The supply and processing of materials for highly stressed components are usually cost-intensive. Efforts to achieve cost and resource efficiency lead to more complex structures and contours. Additive manufacturing steps for component repair and production offer significant economic advantages. Machining needs to be coordinated with additive manufacturing steps in a complementary way to produce functional surfaces suitable for the demands. Regarding inhomogeneity and anisotropy of the microstructure and properties as well as production-related stresses, a great deal of knowledge is still required for efficient use by small- and medium-size enterprises, especially for the interactions of subsequent machining of these difficult-to-machine materials. Therefore, investigations on these influences and interactions were carried out using a highly innovative cost-intensive NiCrMo alloy (IN725). These alloys are applied for claddings as well as for additive component manufacturing and repair welding using gas metal arc welding processes. For the welded specimens, the adequate solidification morphology, microstructure and property profile were investigated. The machinability in terms of finishing milling of the welded surfaces and comparative analyses for ultrasonic-assisted milling processes was examined focussing on surface integrity. It was shown that appropriate cutting parameters and superimposed oscillating of the milling tool in the direction of the tool rotation significantly reduce the mechanical loads for tool and workpiece surface. This contributes to ensure a high surface integrity, especially when cutting has to be carried out without cooling lubricants. KW - WAAM KW - IN725 KW - Machining KW - Ultrasonic-assisted milling KW - Residual stresses KW - Cutting forces KW - Surface integrity KW - Microstructure PY - 2021 UR - https://nbn-resolving.org/urn:nbn:de:kobv:b43-524872 DO - https://doi.org/10.1007/s00170-021-06815-y VL - 114 IS - 5-6 SP - 1427 EP - 1442 PB - Springer AN - OPUS4-52487 LA - eng AD - Bundesanstalt fuer Materialforschung und -pruefung (BAM), Berlin, Germany ER -