Non-metallic inclusions are considered undesired, yet unavoidable components of all steels and are prone to act as sources of stress that play a predominant role in crack initiation. Experiments conducted during the forging process of 30Cr2Ni4MoV steel revealed that cracks mainly originate from compound inclusions, especially intensive plastic inclusions or sliced brittle inclusions containing particles in their interior. The deformation behavior of these two types of compound inclusions was then simulated. It has been shown that the intensive plastic inclusions parallel to the applied stress result in two effects that cause additional stress and produce strain concentration, which are key factors of the union of inclusions and the origins of cracks. Tensile stress that can also lead to cracking certainly exists among intensive plastic inclusions distributed perpendicular to the applied stress. In a compound brittle inclusion, as the amount of deformation increases, areas of strain concentration first develop and then conical cracks are initiated on both sides of the interior particle. When multiple particles are distributed within a small distance, the adjacent conical cracks tend to be connected under the maximum shear stress and finally sever the sliced brittle inclusion at an angle of 45°.
Aiming at the disadvantages of low utilization ratio of steel ingot, uneven microstructure properties and long production period in the solid steel ingot forging process of heavy cylinder forgings such as reactor pressure vessel, a new shortened process using hollow steel ingot was proposed. By means of modeling of lead sample and DEFORM-3D numerical simulation, the deformation law and grain refinement behavior for 162 ton hollow steel ingot upsetting at different reduction ratios, pressing speeds and friction factors were investigated, and the formation rule of inner-wall defects in upsetting of hollow steel ingots with different shape factors was further analyzed. Simulation results show that the severest deformation occurs in the shear zone of meridian plane in the upsetting process of hollow steel ingot, and the average grain size in the shear zone is the smallest. As pressing speed increases, the forming load gradually increases and the deformation uniformity gets worse, while the average grain size decreases. An increase in friction factor can increase the peak value of effective strain, but it significantly reduces the deformation uniformity, increases the forming load and goes against grain refinement. Moreover, the four kinds of defects on the inner wall of steel ingot can be eliminated effectively by referring to the plotted defect control curve for hollow steel ingot during high temperature upsetting.
The effect of heat treatment on microstructure and hardness of internal crack healing in a low carbon steel was studied. The internal cracks were produced into the samples by a drilling and compression method. The microstructure of crack healing zone was examined using optical microscopy (OM) and scanning electron microscopy (SEM). The hardness of crack healing zone was measured using a Vickers micro-hardness testing machine (FM-800). The results show that healing temperature plays a more significant role in internal crack healing than holding time. Compared as-quenched samples with as-normalized samples under the same healing parameters, it is found that cooling speed is also an important factor for internal crack healing. The migration and enrichment of iron atoms provide material source for recrystallization and grain growth of crack healing zone. The existence of micro-voids leads to the hardness of the ferrite in the crack healing zone lower than that in the matrix.
A new model to predict the structure evolution of 30Cr2Ni4MoV steel is proposed based on the dislocation density in this research. Hot compression of 30Cr2Ni4MoV steel is carried out on Gleeble 1500 at different temperatures from 1233 K to 1473 K with a strain rate of 0.01 s-1 and the deformed samples are immediately quenched by water to frozen the austenite structure. The recrystallization kinetics model of 30Cr2Ni4MoV steel is successfully established by inverse analysis of the flow curve based on the relation between flow stress and dislocation density. In order to validate the proposed model, comparison between the predicted values and experimental values obtained by metallographic analysis is implemented. It is shown that the predicted results agree with the experimental results well.
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