Effect of Microstructural Characteristics of Thick Steel Plates on Residual Stress Formation and Cracking during Flame Cutting

Jokiaho, Tuomas; Santa-aho, Suvi; Järvinen, Henri; Honkanen, Mari; Peura, Pasi; Vippola, Minnamari

doi:10.1520/mpc20170083

Cited by 4 publications

(19 citation statements)

References 19 publications

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“…It was also reported that plates with an increased amount of alloying elements tend to produce harder and broader HAZ. In addition, in an earlier study, [9] it was confirmed that the flame cutting process creates three types of microstructural regions in the HAZ: a martensite region, two-phase region (mixture of newly formed martensite and tempered original structure), and tempered original structure. The region closest to the cut edge is fully austenized during the flame cutting, and during cooling, it transforms into martensite.…”

Section: Introductionmentioning

confidence: 70%

“…Flame cutting creates an HAZ in the cut edge of thick wear-resistant steel plates with three distinct microstructural regions: a martensite region, two-phase region, and tempered original structure. [9] In addition, preheated samples had similar microstructural regions as samples that were flame cut without preheating. The region closest to the cut edge is fully austenized during flame cutting and forms martensite during rapid cooling.…”

Section: Resultsmentioning

confidence: 94%

“…Commonly cracks are formed in the horizontal (sheet) plane, but they may also propagate in the vertical direction. In an earlier study [9] by the current author, it was found that cracks are often formed just beneath the flame cut surface and for that reason they are difficult to detect. The cracking probability has been noticed [12] to enhance with increasing plate hardness and thickness.…”

Section: Introductionmentioning

confidence: 84%

“…[16] The residual measuring method is described in more detail in previous studies. [9,13,14] The examination locations and directions of the residual stress measurements are described in Figure 1. As shown in the figure, measurements were performed at the centerline of the samples (where the cracks are mostly formed during flame cutting) in two perpendicular measurement directions: the rolling direction (0 deg) and the thickness direction (90 deg).…”

Section: Methodsmentioning

confidence: 99%

“…The combination of preheating and low cutting speed produced the most beneficial residual stress state with the most compressive stress and the lowest tensile stress peak. To obtain further knowledge of the flame cut process and cracking behavior, another study [9] was made to investigate the microstructural characteristics related to this topic. It was shown that a higher residual stress state was caused by elongated prior austenite grains compared to an equiaxed prior austenite grain structure.…”

Section: Introductionmentioning

confidence: 99%

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Role of Steel Plate Thickness on the Residual Stress Formation and Cracking Behavior During Flame Cutting

Jokiaho

Santa-aho

Peura

et al. 2019

Metall Mater Trans A

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Thick wear-resistant steel plates are utilized in challenging applications, which require a high hardness and toughness. However, utilization of the thick plates is problematic as they often have nonuniform mechanical properties along the thickness direction due to the manufacturing-induced segregations. In addition, the processing of thick plates commonly involves flame cutting, which causes several challenges. Flame cutting forms a heat-affected zone and generates high residual stresses during the cutting process. In the worst case, flame cutting causes cracking of the cut edge. The aim of this study is to investigate the role of plate thickness on the residual stress formation and cracking behavior when utilizing flame cutting. Residual stress profiles are measured by X-ray diffraction, plates and cut edges and are mechanically tested and characterized by electron microscopy. The results show that thicker plates generate more unfavorable residual stress state during flame cutting. Thick plates also contain segregations, which have decreased mechanical properties. The combination of high residual tensile stresses and segregations increase the risk of cracking during flame cutting. To prevent the cracking, the residual stresses should be lowered by lower cutting speeds and preheating. In addition, manufacturing practices should be aimed at lowering segregation formation in thick plates.

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Section: Introductionmentioning

confidence: 70%

Section: Resultsmentioning

confidence: 94%

Section: Introductionmentioning

confidence: 84%

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Role of Steel Plate Thickness on the Residual Stress Formation and Cracking Behavior During Flame Cutting

Jokiaho

Santa-aho

Peura

et al. 2019

Metall Mater Trans A

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Cracking and Failure Characteristics of Flame Cut Thick Steel Plates

Jokiaho

Santa-aho

Peura

et al. 2020

Metall Mater Trans A

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The manufacturing of thick wear-resistant steel plates commonly leads to a layered structure and non-uniform properties in the thickness direction which makes the processing and utilization of the plates problematic. The processing steps of thick plates include flame cutting, which generates a heat-affected zone and high residual stresses into the cut edge. In the worst case, the cutting causes cracking. However, the residual stress level alone is not high enough to break a wear-resistant steel plate that behaves normally. Therefore, high-tensile stress also requires a microstructurally weak factor for crack initiation. For this reason, the main objective of this study is to reveal the main microstructural reasons behind the cracking of plates in flame cutting. To achieve this, plate samples containing cracks are mechanically tested and analyzed by electron microscopy. The results show that cracks are commonly formed horizontally into the tempered region of the heat-affected zone. Cracks initiate in the segregations, which typically have a higher amount of impurity and alloying elements. Increased impurity and alloying content in the segregations decreases the cohesion of the prior austenite grain boundaries. These weakened grain boundaries combined with high-residual tensile stress generate the cracks in the flame-cutting process.

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Residual stresses of MAG-welded ultrahigh-strength steel rectangular hollow sections

Keränen,

Pylvänäinen,

Kaijalainen

et al. 2024

Engineering Structures

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Effect of Microstructural Characteristics of Thick Steel Plates on Residual Stress Formation and Cracking during Flame Cutting

Cited by 4 publications

References 19 publications

Role of Steel Plate Thickness on the Residual Stress Formation and Cracking Behavior During Flame Cutting

Role of Steel Plate Thickness on the Residual Stress Formation and Cracking Behavior During Flame Cutting

Cracking and Failure Characteristics of Flame Cut Thick Steel Plates

Residual stresses of MAG-welded ultrahigh-strength steel rectangular hollow sections

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