It is well known that diamond wears out rapidly (within several metres of cutting length) when machining low carbon ferrous alloys and pure iron. The past few years have seen a growing interest in the field of elliptical vibration-assisted machining (EVAM) due to it being successful in the micromachining of difficult-to-cut materials including steel. During EVAM, a cutting tool is prescribed an oscillatory motion perpendicular to the direction of cutting, thereby causing the tool to be relieved intermittently from chemical and physical contact with the workpiece. This phenomenon serves as a guideline to develop the simulation test bed for studying EVAM in this work to compare it with conventional cutting. The pilot implementation of the EVAM came as a quasi-3-dimensional (Q3D) elliptical cutting model of body-centred cubic (BCC) iron with a diamond cutting tool using molecular dynamics (MD) simulation. The developed MD model supplemented by the advanced visualization techniques was used to probe the material removal behaviour, the development of the peak stress in the workpiece and the way the cutting force evolves during the cutting process. One of the key observations was that the cutting chips of BCC iron during conventional cutting underwent crystal twinning and became polycrystalline, while EVAM resulted in cutting chips becoming highly disordered, leading to better viscous flow compared to conventional cutting.
Although a lot of work has been done to understand both major mechanisms of hot corrosion, namely type I (high-temperature hot corrosion) and type II (low temperature hot corrosion), there is very little information available on more representative cyclic performance in these regimes. This work addresses this by assessing the performance of isothermal (type I and type II) hot corrosion tests against combined (short and long) cyclic corrosion tests. Single-crystal alloy PWA 1484 and directionally solidified alloy MAR-M247 were assessed in all test regimes. Pre- and post-exposure dimensional metrology was used to quantify the corrosion damage and characterised using SEM/EDX. This paper highlights that the results of short cycle test conditions are more damaging compared to long cycle and standard isothermal type I and II test conditions. The cast nickel-based alloy MAR-M247 was found to be a better performer compared to PWA 1484 single-crystal alloy.
Although evidence exists of the potential impact of stress, co-incident with corrosive environments at high temperature, for single crystal turbine blades, the mechanism responsible is not fully understood. This work explores the effect of CaSO4, Na2SO4 and sea salt on the scale formation and crack initiation of CMSX-4 at 550°C in 50 ppm of SO2 and synthetic air under a static stress of 800 MPa. The cross-sectional analysis showed that the CaSO4 and the Na2SO4 salted specimens did not undergo a significant degree of corrosion degradation and no cracks were detected after 400 hours of exposure. However, sea salt caused significant degradation to the scale and cracks were detected by X-ray CT scanning after 400 hours of exposure. The findings from this study suggests that the sulfation of chlorine containing species in sea salt led to the formation, vaporisation and re-oxidation of metal chlorides and this mechanism was found to play a key role in the formation of a non-protective scale. An active oxidation mechanism has been proposed to interpret the results. In conclusion, it is hypothesized that due to the synergistic effect of stress and the formation of a non-protective scale, fast diffusion paths for sulfur, oxygen and chlorine ingress were formed. Further work is currently being undertaken to understand the effect of these species on the local embrittlement of CMSX-4 that ultimately led to the initiation of cracks in the specimen.
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