Abstract:The aim of the study was to determine the microstructure and residual stress changes which appears in the S235 steel (which is designed for operating in elevated temperatures) during cold rolling. The changes of orientation, both morphological and crystallographic, are occurring as a result of the rolling process. Analysis of the results allowed to determine the change in grain morphology (size, shape), determination of grain morphology of the rolling direction and determination of crystallographic texture. Th… Show more
“…Skutkuje to ograniczeniem głębokości wnikania prądów w stali ferromagnetycznej do kilkuset mikrometrów, czyli w zakresie grubości warstw hartowanych. Podobne badania, z zastosowaniem prądów wirowych prowadzono także w zakresie oceny stopnia uszkodzenia zmęczeniowego [1,2], stanu składowych naprężenia resztkowych [3], czy też grubości warstw hartowanych [4,5]. Z kolei metoda szumów Barkhausena wykorzystywana była przez autorów m in.…”
“…Skutkuje to ograniczeniem głębokości wnikania prądów w stali ferromagnetycznej do kilkuset mikrometrów, czyli w zakresie grubości warstw hartowanych. Podobne badania, z zastosowaniem prądów wirowych prowadzono także w zakresie oceny stopnia uszkodzenia zmęczeniowego [1,2], stanu składowych naprężenia resztkowych [3], czy też grubości warstw hartowanych [4,5]. Z kolei metoda szumów Barkhausena wykorzystywana była przez autorów m in.…”
“…It was identified that quality check results are mostly requested from the sugar industry, while a precise specification of the final product is hardly requested [13]. Several destructive/non-destructive techniques are reported in literature, focusing on the major causes that lead to defective production, such as magnetic particle testing [14], ultrasonic testing [15], crystallographic testing [16] and scanning electron microscopy (SEM). The in-depth porosity effect on the fatigue life of the A319 alloy was discussed by Zhang et al [17].…”
The sugar mill roller shaft is one of the critical parts of the sugar industry. It requires careful manufacturing and testing in order to meet the stringent specification when it is used for applications under continuous fatigue and wear environments. For heavy industry, the manufacturing of such heavy parts (>600 mm diameter) is a challenge, owing to ease of occurrence of surface/subsurface cracks and inclusions that lead to the rejection of the final product. Therefore, the identification and continuous reduction of defects are inevitable tasks. If the defect activity is controlled, this offers the possibility to extend the component (sugar mill roller) life cycle and resistance to failure. The current study aims to explore the benefits of using ultrasonic testing (UT) to avoid the rejection of the shaft in heavy industry. This study performed a rigorous evaluation of defects through destructive and nondestructive quality checks in order to detect the causes and effects of rejection. The results gathered in this study depict macro-surface cracks and sub-surface microcracks. The results also found alumina and oxide type non-metallic inclusions, which led to surface/subsurface cracks and ultimately the rejection of the mill roller shaft. A root cause analysis (RCA) approach highlighted the refractory lining, the hot-top of the furnace and the ladle as significant causes of inclusions. The low-quality flux and refractory lining material of the furnace and the hot-top, which were possible causes of rejection, were replaced by standard materials with better quality, applied by their standardized procedure, to prevent this problem in future production. The feedback statistics, evaluated over more than one year, indicated that the rejection rate was reduced for defective production by up to 7.6%.
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