The welding of cemented carbide to tool steel is a challenging task, of scientific and industrial relevance, as it combines the high level of hardness of cemented carbide with the high level of fracture toughness of steel, while reducing the shaping cost and extending the application versatility, as its tribological, toughness, thermal and chemical properties can be optimally harmonised. The already existing joining technologies often impart either insufficient toughness or poor high-temperature strength to a joint to withstand the ever-increasing severe service condition demands. In this paper, a novel capacitor discharge welding (CDW) process is investigated for the case of a butt-joint between a tungsten carbide-cobalt (WC-Co) composite rod and an AISI M35 high-speed steel (HSS) rod. The latter was shaped with a conical-ended projection to promote a high current concentration and heat at the welding zone. CDW functions by combining a direct current (DC) electric current pulse and external uniaxial pressure after a preloading step, in which only uniaxial pressure is applied. The relatively high heating and cooling rates promote a thin layer of a characteristic ultrafine microstructure that combines high strength and toughness. Morphological analysis showed that the CDW process: (a) forms a sound and net shaped joint, (b) preserves the sub-micrometric grain structure of the original WC-Co composite base materials, via a transitional layer, (c) refines the microstructure of the original martensite of the HSS base material, and (d) results in an improved corrosion resistance across a 1-mm thick layer near the weld interface on the steel side. A nano-indentation test survey determined: (e) no hardness deterioration on the HSS side of the weld zone, although (f) a slight decrease in hardness was observed across the transitional layer on the composite side. Furthermore, (g) an indication of toughness of the joint was perceived as the size of the crack induced by processing the residual stress after sample preparation was unaltered.
A new dual-scale instrumented indentation test (DualS-IIT) methodology is here proposed to determine the yield stress (in a tensile-like sense). The methodology involves measuring the bulk yield radius, as defined by the expansion cavity model (ECM), induced by a Vickers macro-indentation in a medium plane cross-section. The bulk yield radius is measured by means of a subsurface nano-hardness survey along the load direction in correspondence to the transition interface between the hemispherical strain hardened region and the surrounding elastic region. The methodology has been applied to an AlLi (A2198-T3) alloy and a yield stress of 297 MPa has been measured (in agreement with a tensile test); moreover, anomalous plastic deformation behaviour has appeared under indentation. The combination of macro-and nano-indentation tests in one single experiment, as in the proposed methodology, offers a unique experimental basis to directly correlate the mechanical properties of a material at two different scales, which at present is an open issue in the research on indentation.
The use of metal foams as permanent cores in casting products is a promising strategy. It aims to improve the properties of the cast components by adding certain foam features (e.g., lightweight, high specific stiffness, impact energy/ vibration absorption ability, and good acoustic insulation properties). The use of permanent cores eliminates the steps of removal, treatment, and compulsory recycling for the traditional temporary sand cores. Herein, aluminum metals foams, in the form of bars with a dense continuous outer skin, are inserted in the die of a gravity casting experiment with an Al-Si-Cu-Mg alloy (EN AB.46400). Foams and cast objects are characterized by means of optical emission spectrometry (OES), optical microscopy (OM), scanning electron microscope equipped with energy dispersive spectroscopy (SEM-EDS), image analysis, and computed tomography (CT).
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