Vol. 24 No. 4 2022 3 EDITORIAL COUNCIL EDITORIAL BOARD EDITOR-IN-CHIEF: Anatoliy A. Bataev, D.Sc. (Engineering), Professor, Rector, Novosibirsk State Technical University, Novosibirsk, Russian Federation DEPUTIES EDITOR-IN-CHIEF: Vladimir V. Ivancivsky, D.Sc. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Vadim Y. Skeeba, Ph.D. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Editor of the English translation: Elena A. Lozhkina, Ph.D. (Engineering), Department of Material Science in Mechanical Engineering, Novosibirsk State Technical University, Novosibirsk, Russian Federation The journal is issued since 1999 Publication frequency – 4 numbers a year Data on the journal are published in «Ulrich's Periodical Directory» Journal “Obrabotka Metallov” (“Metal Working and Material Science”) has been Indexed in Clarivate Analytics Services. We sincerely happy to announce that Journal “Obrabotka Metallov” (“Metal Working and Material Science”), ISSN 1994-6309 / E-ISSN 2541-819X is selected for coverage in Clarivate Analytics (formerly Thomson Reuters) products and services started from July 10, 2017. Beginning with No. 1 (74) 2017, this publication will be indexed and abstracted in: Emerging Sources Citation Index. Journal “Obrabotka Metallov” (“Metal Working & Material Science”) has entered into an electronic licensing relationship with EBSCO Publishing, the world's leading aggregator of full text journals, magazines and eBooks. The full text of JOURNAL can be found in the EBSCOhost™ databases. Novosibirsk State Technical University, Prospekt K. Marksa, 20, Novosibirsk, 630073, Russia Tel.: +7 (383) 346-17-75 http://journals.nstu.ru/obrabotka_metallov E-mail: metal_working@mail.ru; metal_working@corp.nstu.ru
OBRABOTKAMETALLOV Vol. 24 No. 4 2022 4 EDITORIAL COUNCIL EDITORIAL COUNCIL CHAIRMAN: Nikolai V. Pustovoy, D.Sc. (Engineering), Professor, President, Novosibirsk State Technical University, Novosibirsk, Russian Federation MEMBERS: The Federative Republic of Brazil: Alberto Moreira Jorge Junior, Dr.-Ing., Full Professor; Federal University of São Carlos, São Carlos The Federal Republic of Germany: Moniko Greif, Dr.-Ing., Professor, Hochschule RheinMain University of Applied Sciences, Russelsheim Florian Nürnberger, Dr.-Ing., Chief Engineer and Head of the Department “Technology of Materials”, Leibniz Universität Hannover, Garbsen; Thomas Hassel, Dr.-Ing., Head of Underwater Technology Center Hanover, Leibniz Universität Hannover, Garbsen The Spain: Andrey L. Chuvilin, Ph.D. (Physics and Mathematics), Ikerbasque Research Professor, Head of Electron Microscopy Laboratory “CIC nanoGUNE”, San Sebastian The Republic of Belarus: Fyodor I. Panteleenko, D.Sc. (Engineering), Professor, First Vice-Rector, Corresponding Member of National Academy of Sciences of Belarus, Belarusian National Technical University, Minsk The Ukraine: Sergiy V. Kovalevskyy, D.Sc. (Engineering), Professor, Vice Rector for Research and Academic Affairs, Donbass State Engineering Academy, Kramatorsk The Russian Federation: Vladimir G. Atapin, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Victor P. Balkov, Deputy general director, Research and Development Tooling Institute “VNIIINSTRUMENT”, Moscow; Vladimir A. Bataev, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Vladimir G. Burov, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Aleksandr N. Gerasenko, Director, Scientifi c and Production company “Mashservispribor”, Novosibirsk; Sergey V. Kirsanov, D.Sc. (Engineering), Professor, National Research Tomsk Polytechnic University, Tomsk; Aleksandr N. Korotkov, D.Sc. (Engineering), Professor, Kuzbass State Technical University, Kemerovo; Evgeniy A. Kudryashov, D.Sc. (Engineering), Professor, Southwest State University, Kursk; Dmitry V. Lobanov, D.Sc. (Engineering), Associate Professor, I.N. Ulianov Chuvash State University, Cheboksary; Aleksey V. Makarov, D.Sc. (Engineering), Corresponding Member of RAS, Head of division, Head of laboratory (Laboratory of Mechanical Properties) M.N. Miheev Institute of Metal Physics, Russian Academy of Sciences (Ural Branch), Yekaterinburg; Aleksandr G. Ovcharenko, D.Sc. (Engineering), Professor, Biysk Technological Institute, Biysk; Yuriy N. Saraev, D.Sc. (Engineering), Professor, Institute of Strength Physics and Materials Science, Russian Academy of Sciences (Siberian Branch), Tomsk; Alexander S. Yanyushkin, D.Sc. (Engineering), Professor, I.N. Ulianov Chuvash State University, Cheboksary
Vol. 24 No. 4 2022 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Dyuryagin A.A., Ardashev D.V. A study of the relationship between cutting force and machined surface roughness with the feed per tooth when milling EuTroLoy 16604 material produced by the DMD method...................... 6 Ulakhanov N.S., Tikhonov A.G., Mishigdorzhiyn U.L., Ivancivsky V.V., Vakhrushev N.V. The features of residual stresses investigation in the hardened surface layer of die steels after diffusion boroaluminizing............... 18 Rubtsov V.E., Panfi lov A.O., Knyazhev E.O., Nikolaeva A.V., Cheremnov A.M., Gusarova A.V., Beloborodov V.A., Chumaevskii A.V., Ivanov A.N. Development of plasma cutting technique for C1220 copper, AA2024 aluminum alloy, and Ti-1,5Al-1,0Mn titanium alloy using a plasma torch with reverse polarity................ 33 Amirov A.I., Moskvichev E.N., Ivanov A.N., Chumaevskii A.V, Beloborodov V.A. Formation features of a welding joint of alloy Ti-5Al-3Mo-1V by the friction stir welding using heat-resistant tool from ZhS6 alloy....... 53 EQUIPMENT. INSTRUMENTS Ardashev D.V., Zhukov A.S. Investigation of the relationship between the cutting ability of the tool and the acoustic signal parameters during profi le grinding..................................................................................................... 64 Bataev D. K-S., Goitemirov R. U., Bataeva P. D. Studies of wear resistance and antifriction properties of metalpolymer pairs operating in a sea water simulator........................................................................................................ 84 Zakovorotny V.L., Gvindjiliya V.E., Fesenko E.O. Application of the synergistic concept in determining the CNC program for turning............................................................................................................................................ 98 MATERIAL SCIENCE Sokolov R.A., Novikov V.F., Kovenskij I.M., Muratov K.R., Venediktov A.N., Chaugarova L.Z. The effect of heat treatment on the formation of MnS compound in low-carbon structural steel 09Mn2Si................................ 113 Burkov А.А., Krutikova V.O. Deposition of titanium silicide on stainless steel AISI 304 surface...................... 127 Pugacheva N.B., NikolinYu.V., BykovaT.M., Goruleva L.S. Chemical composition, structure and microhardness of multilayer high-temperature coatings..................................................................................................................... 138 Saprykina N.А., Chebodaeva V.V., Saprykin A.А., Sharkeev Y.P., Ibragimov E.А., Guseva T.S. Synthesis of a three-component aluminum-based alloy by selective laser melting............................................................... 151 Gabets D.A., MarkovA.M., Guryev M.A., Pismenny E.A., NasyrovaA.K. The effect of complex modifi cation on the structure and properties of gray cast iron for tribotechnical application..................................................... 165 Ivanov I.V., Yurgin A.B., Nasennik I.E. Kuper K.E. Residual stress estimation in crystalline phases of highentropy alloys of the AlxCoCrFeNi system........................................................................................................... 181 Korosteleva E.N., Nikolaev I.O., Korzhova V.V. Features of the structure formation of sintered powder materials using waste metal processing of steel workpieces................................................................................. 192 EroshenkoA.Yu., Legostaeva E.V., Glukhov I.A., Uvarkin P.V., TolmachevA.I., Luginin N.A., Bataev V.A., Ivanov I.V., Sharkeev Yu.P. Effect of deformation processing on microstructure and mechanical properties of Ti-42Nb-7Zr alloy............................................................................................................................................. 206 Kutkin O.M., Bataev I.A., Dovzhenko G.D., Bataeva Z.B. The study of characteristics of the structure of metallic alloys using synchrotron radiation computed laminography (Research Review)................................ 219 EDITORIALMATERIALS 243 FOUNDERS MATERIALS 255 CONTENTS
OBRABOTKAMETALLOV Vol. 24 No. 4 2022 TECHNOLOGY The features of residual stresses investigation in the hardened surface layer of die steels after diffusion boroaluminizing Nikolay Ulakhanov 1, 2, a,*, Aleksandr Tikhonov 3, b, Undrakh Mishigdorzhiyn 1, c, Vladimir Ivancivsky 4, d, Nikita Vakhrushev 4, e 1 Institute of Physical Material Science of the Siberian Branch of the RAS, 6 Sakhyanovoy str., Ulan-Ude, 670047, Russian Federation 2 East Siberia State University of Technology and Management, 40V Kluchevskaya str, Ulan-Ude, 670013, Russian Federation 3 Irkutsk National Research Technical University, 83 Lermontov str., Irkutsk, 664074, Russian Federation 4 Novosibirsk State Technical University, 20 Prospekt K. Marksa, Novosibirsk, 630073, Russian Federation a https://orcid.org/0000-0002-0635-4577, nulahanov@mail.ru, b https://orcid.org/0000-0002-4917-9916, tihonovalex90@mail.ru, с https://orcid.org/0000-0002-7863-9045, undrakh@ipms.bscnet.ru, d https://orcid.org/0000-0001-9244-225X, ivancivskij@corp.nstu.ru, e https://orcid.org/0000-0002-2273-5329, vah_nikit@mail.ru Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2022 vol. 24 no. 4 pp. 18–32 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2022-24.4-18-32 ART I CLE I NFO Article history: Received: 28 September 2022 Revised: 14 October 2022 Accepted: 03 November 2022 Available online: 15 December 2022 Keywords: Thermal-Chemical Treatment (TCT) Boroaluminizing Residual Stresses Die steel Funding The research was supported by a grant from the Russian Science Foundation (project 19-79-10163-P). Acknowledgements Research were partially conducted at core facility “Structure, mechanical and physical properties of materials”. ABSTRACT Introduction. Diffusion boroaluminizing provides improved performance properties of the die steels’ surface such as wear resistance, high hardness, and corrosion resistance. Surface hardening can significantly contribute to the occurrence of technological residual stresses (TRS) on the surface. Currently, there are no studies on the topic of the stress state of diffusion boroaluminizing. The purpose of this work is to develop a method for determining the TRS and a nature of its distribution in the diffusion layers on the surface of 5CrNiMo and 3Cr2W8V die steels after boroaluminizing by a mechanical method. The paper considers the results of experimental studies on the determination of the normal components of TRS by the mechanical method in diffusion layers of die steels. The conducted studies showed that the formation of unfavorable tensile TRS occurs along the depth of the hardened layer in the case of the investigated TCT method and types of steels. Results and discussions. The main approaches for determining the TRS in the surface layer of 3Cr2W8V and 5CrNiMo die steels after TCT are considered. Problems in the determination of TRS by the mechanical method on the UDINON-2 unit are identified, and its solution is proposed. The efficiency of using the anodic dissolution method for the continuous removal of stressed layers during the TRS study by the mechanical method on the UDION-2 unit is shown. The optimal electrolyte composition is selected for the process of anodic dissolution consisting of: NaNO3 – 60 g/l; NaNO2 – 5 g/l; Na2CO3 – 5 g/l; C3H8O3 – 15 g/l; H2O – the rest. The distributions of the normal TRS components in the diffusion layer of die steel specimens are revealed. It is established that, during the TCT of these steels predominantly tensile TRS are formed in the surface layer. Further research will be aimed at developing measures to reduce tensile TRS during diffusion boroaluminizing of die steels. For citation: Ulakhanov N.S., Tikhonov A.G., Mishigdorzhiyn U.L., Ivancivsky V.V., Vakhrushev N.V. The features of residual stresses investigation in the hardened surface layer of die steels after diffusion boroaluminizing. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2022, vol. 24, no. 4, pp. 18–32. DOI: 10.17212/1994-6309-2022-24.4-18-32. (In Russian). ______ * Corresponding author Ulakhanov Nikolay S., Junior researcher Institute of Physical Material Science of the Siberian Branch of the RAS, 6 Sakhyanovoy str., 670047, Ulan-Ude, Russian Federation Tel.: 8 (3012) 43-48-70, e-mail: nulahanov@mail.ru Introduction Chemical and thermal treatment (CTT) of metals is widely used to improve the mechanical properties of machine parts and tools [1]. Carburizing, chrome plating and nitriding are thermochemical processes that improve the wear resistance and corrosion resistance of components [2–12]. One of the effective
OBRABOTKAMETALLOV technology Vol. 24 No. 4 2022 technologies for modifying the surface layers of die steels is multicomponent CTT, such as boroaluminizing, which allows increasing significantly the wear resistance, as well as heat resistance, corrosion resistance and a number of other properties of the surface layers of machine parts and tools [13–16]. The service life of products after hardening largely depends on the distribution of technological residual stresses (TRS) in the diffusion layer and adjacent layers of the base material and on the general nature of the microstructure of the entire section changed during the CTT process [8,17–20]. Control and management of TRS is one of the most important tasks of mechanical engineering [21, 22]. Therefore, when developing Fe-Me-B coatings by diffusion alloying methods on the surface of steel products, efforts should be directed to finding TRS distributions that improve the operational properties of products. It is known that the study of the stress-strain state (SSS) of borated layers can be carried out by the methods of destructive and non-destructive testing [23–26]. In our work [27], the first data on the assessment of the stress state of boride layers were presented. In this paper, we review the methods for determining the TRS that can be used after hardening CTT, in particular, in Fe-Me-B coatings in the surface layer of carbon and alloy steels, and also consider the problems of measuring residual stresses by mechanical method and its solution. The results of experimental studies on the detection of the TRS distribution in the diffusion layers of 3Cr2W8V and 5CrNiMo tool steels after hightemperature boroaluminizing (HBA) are presented. Research methodology CTT was carried out in saturating pastes containing powders of boron carbide, aluminum and sodium fluoride as an activator of the following composition: 80 % B4C + 16% Al + 4% NaF [15]. Samples with overall dimensions of 1.8×80×60 mm (Fig. 1, a) were made of 3Cr2W8V and 5CrNiMo tool steels (see Tables 1, 2). After tamping, the molds were removed, and the resulting briquettes were dried at a temperature of 50–100 °C for two hours in a drying chamber. After that, the briquettes were loaded into a furnace preheated to the process temperature. The treatment duration was 2 hours, the temperature was 950 and 1,050 °C. The samples were cooled outside the furnace in calm air at room temperature. The sample after CTT is shown in Fig. 1, b. a b Fig. 1. Flat samples Ta b l e 1 Chemical composition of 5CrNiMo steel, wt. % С Si Mn Cr Mo Ni P S Cu 0.50–0.60 0.10–0.40 0.50–0.80 0.50–0.60 0.15–0.30 1.40–1.80 ≤ 0.03 ≤ 0.03 ≤ 0.30
OBRABOTKAMETALLOV Vol. 24 No. 4 2022 technology Ta b l e 2 Chemical composition of 3Cr2W8V steel, wt. % C Si Mn W V Cr Ni P S Cu 0.3–0.4 0.15–0.4 0.15–0.4 8.5–10.0 0.3–0.6 2.2–2.7 < 0.35 ≤ 0.03 ≤ 0.03 ≤ 0.03 Metallographic analysis was performed on an optical microscope “METAM RV-34” with a digital camera “Altami Studio”. The stress state of boride coatings after CTT was measured using an installation for determining residual stresses UDION-2 (Fig. 2), developed at IRNTU [23–27]. Elementary strip samples were cut from the initial plate samples on the Discotom-10 cutting machine (Struers, Denmark) using an abrasive disc cutting wheel with the use of abundant cooling (Fig. 3, a). The strips were cut in a mutually perpendicular direction along the X and Z axes (Fig. 3, b), the nominal length of the strips was 60 mm, width – 8 mm. After cutting out the strip samples, its geometric parameters (width b and thickness h), bend of deflection and initial mass were measured. This data is necessary for the subsequent calculation of the TRS. The sample strips were mounted in the devices of the UDION2 installation and its electrochemical etching (anodic dissolution) was carried out in the electrolyte of composition No. 3 (Table 4) with simultaneous recording of the real time sample deformation. After etching, the samples were dismounted and re-weighed; the average etching rate was determined by formula (1). The final stage was the calculation of the TRS in the XUdion software [28] and the construction of TRS distribution plots. Results and discussions The problem of research of TRS by mechanical method Let us denote the problems associated with the measurement of residual stresses by the mechanical method after strengthening thermal and chemical treatment. The determination of TRS by the mechanical method at the UDION-2 installation [23–28] is associated with the registration of elementary samples-strips motion (when measuring residual stresses in plates) during the removal of stressed layers of the material Fig. 2. Installation for measuring residual stresses by mechanical method (UDION-2) a b Fig. 3. Cutting elementary samples-strips from initial plates
OBRABOTKAMETALLOV technology Vol. 24 No. 4 2022 under study as a function of the thickness of the removed layer. Removal of stressed layers from the surface under study in this installation is realized by the means of chemical etching – gradual dissolution of the material in electrolyte solutions. Basically, the compositions of electrolytes used in chemical etching are a combination of solutions of inorganic acids with water. At the same time, in order to ensure accuracy and minimize measurement error, it is necessary to ensure the following surface quality parameters during the etching process: low roughness, absence of pitting, undercuts under the protective coating, pits, nonscratches, and, if possible, to achieve a constant etching rate throughout the process. For a stable flow of the process and the establishment of the optimal duration of the experiment, the recommended etching rate should be 0.005–0.01 mm/min. When processing products by CTT methods [1, 13–16], the surface layer of the metal acquires the following properties: – decrease in magnetic permeability; – increase in electrical resistance; – increase in torsional stiffness; – increase in hardness; – increase in wear resistance; – increase in corrosion resistance, in particular acid resistance. The latter property makes it difficult to study the TRS in products subjected to the types of CTT under consideration, at least during chemical etching in acid solutions. To confirm this, we conducted a number of studies on the chemical etching of test samples made of 3Cr2W8V steel after boroaluminizing in various compositions of acid electrolytes (Table 3). The test samples were made in the form of strips with overall dimensions of 1.7×8×60 mm. An area of 80 mm2 was etched, rubber enamel was used to protect the rest of the sample. Etching was carried out in a small volume of electrolyte, not exceeding 200 ml, in a thermostatic bath of the UDION2 installation with a control of the average rate of removal of layers (etching), calculated by the formula [29]: ∆ = ρτ etching 1000 m V S , mm/min (1) where Δm – weight of the removed material, g; S – the surface area from which the material was removed, mm2; ρ – material density, g/sm3; τ – test time (etching), min. Ta b l e 3 Electrolyte compositions, parameters, and results of chemical etching of samples after CTT Composition No. Electrolyte composition t, oC etching V , mm/min Comments 1 (g/l): HF – 30; Н2SO4 – 150; Н2O – rest 23 – There are practically no signs of poisoning 2 (g/l): HF – 120; Н2SO4 – 590; Н2O – rest 35 0.0014 The surface is dark gray with large amounts of non-etched areas (Fig. 4, a) 3 (% vol.): HF – 10; Н2SO4 – 8; HNO3 – 9; H2O – rest 35 0.0076 Black relief surface with numerous small bumps and depressions (Fig. 4, b) 4 (% vol.): HCl – 565; HNO3 – 237; NaF – 30; H2O – rest 37 0.0063 Gray wavy surface with a non-etched area in the middle (Fig. 4, c)
OBRABOTKAMETALLOV Vol. 24 No. 4 2022 TECHNOLOGY Composition No. 1 was taken as the initial electrolyte (Table 3) [29], this electrolyte showed a poor result, the surface of the sample was practically not etched. Composition No. 2 was obtained by increasing the concentration of components of composition No. 1 with an increase in the temperature of the solution. Composition No. 3 is a modification of the previous composition with the addition of nitric acid as an oxidizer. Composition No. 4 is focused on chemical dimensional processing of steels [30]. The condition of the samples surface after chemical etching is shown in Figure 4. a b c Fig. 4. The surface of specimens as a result of chemical etching of specimens made of 3Cr2W8V steel after CTT: a – composition No. 2; b – composition No. 3; c – composition No. 4 As can be seen from the experiments, chemical etching does not give acceptable results, therefore, for layer-by-layer removal of material from samples after CTT, it was proposed to use electrochemical etching, in particular anodic dissolution, when studying the TRS at the UDION-2 installation. The removal of the material during electrochemical treatment occurs under the action of an electric current in the electrolyte medium. The electrochemical treatment process is based on the phenomenon of anodic dissolution of metals. Anodic dissolution can take place in electrolytes of different compositions, including non-aggressive ones – aqueous solutions of salts that are cheap and harmless [31, 32] compared to acidic ones. Under the action of an electric current in the electrolyte, the anode material, which is the test sample, dissolves in the form of processing products. The cathode does not wear out, which is one of the positive features of the process. As a result of the reactions, hydrogen is released at the cathode, and precipitation in the form of insoluble metal hydroxide and oxygen occurs at the anode. Insoluble hydroxide clutters up the electrolyte and reduces the productivity of the process. In this regard, it is necessary to make provision for the processes of regeneration and purification of the electrolyte from the reaction products (settling, filtration, decantation). To work out the process, parameters and composition of the electrolyte, a number of studies were conducted on the anodic dissolution of 3Cr2W8V steel samples after CTT (Table 4). For this, an electrochemical cell was placed in the thermostatic bath of the UDION-2 installation (Fig. 5), a lead cathode connected to the negative output of the power source, and a sample anode connected to the positive output of the power source, was placed in the thermostatic bath. As a power source for the electrochemical circuit, a Mastech HY3010 laboratory DC power source was used with output voltage regulation in the range of 0–30 V at an output current of 0–10 A, with the function of a stabilized current source. As in the case of chemical etching during anodic dissolution, the average rate of layers removal was calculated according to the formula (1).
OBRABOTKAMETALLOV technology Vol. 24 No. 4 2022 Ta b l e 4 Electrolyte compositions; parameters, and results of electrochemical etching (anodic dissolution) of samples after CTT Composition No. Electrolyte composition t, oC Current density j, A/dm2 Voltage U, V ÒÐ V , mm/min Comments 1 (%weight.): KNO3 – 12; NaF – 2; NaCl – 1; H2O – rest 30 75 5 0.0062 The surface is dark gray, smooth, even in the center, with a slight undulation along the edges (Fig. 6, a) 2 (%weight.): H3PO4 – 49,5; Н2SO4 – 40; H2O – rest 32 100 8.5 0.007 Textured light surface with metallic luster, case of electrolytic polishing (Fig. 6, b) 3 (g/l): NaNO3 – 60; NaNO2 – 5; Na2CO3 – 5; C3H8O3 – 15; H2O – rest 30 100 10 0.0056 The surface is dark gray, matte smooth, smooth with a few minor micro-steps (Fig. 6, c) Composition No. 1 (see Table 4) [30], recommended for dimensional electrochemical machining of tool steels, generally showed good results, except for a slight surface waviness (Fig. 6, a). Composition No. 2 [29] gives a shiny, though textured, smooth surface (Fig. 6, b), but only for this type of steel. Composition No. 3 recommended for abrasiveelectrochemical machining of metals [33] showed good results, the surfaces of the samples are matte smooth gray with minimal roughness (Fig. 6, c). Preparatory studies have shown that for the layer-bylayer removal of material in the study of TRS by mechanical method in samples after diffusion boroaluminizing, the most acceptable results are obtained by the process of anodic dissolution. It should be noted that in each specific case, the selection of the electrolyte composition and the necessary electrical and temperature conditions is carried out individually for each material, taking into account the type of its treatment; this procedure is time-consuming and requires test samples for testing the process. In these studies, the composition of electrolyte No. 3 for anodic dissolution showed the best result (Table 4). This electrolyte also showed good results with anodic dissolution of the surface layer of 5CrNiMo steel samples after CTT. To control the process of anodic dissolution of the material, in particular, to establish its required speed, adjustment of the electrolyte temperature and electrical parameters of the process (voltage, anode current density) can be applied. Fig. 5. Electrochemical cell for testing the process of anodic dissolution: 1 – cathode (lead plate); 2 – anode (sample); 3 – beaker with electrolyte solution
OBRABOTKAMETALLOV Vol. 24 No. 4 2022 technology a b c Fig. 6. The surface of specimens as a result of electrochemical etching of specimens made of 3Cr2W8V steel after CTT: a – composition No. 1; b – composition No. 2; c – composition No. 3 Investigation of TRS after diffusion boroaluminizing Control samples after annealing (Fig. 7) are characterized by the presence of compression TRS on its surface: for 5CrNiMo steel sample (Fig. 7, a) the compression TRS values lie in the range of −325…−570 MPa with a sharp rise and specifying near-zero values from a depth of 0.05–0.075 mm; for 3Cr2W8V steel sample (Fig. 7, b) these values are in the range of −155…−235 MPa. Moreover, the TRS plot after annealing of the 5CrNiMo steel plate is self-balanced (Fig. 7, a). After the CTT of 5CrNiMo steel at a temperature of 950 °C (Fig. 8, a), a diffusion layer with a thickness of 400–450 µm is formed [15], in which the TRS components are tensile. On the surface of the sample, it takes values of 210 MPa, at a depth of 0.08 mm it reaches a maximum of 620–687 MPa and gradually decrease, taking zero values at a depth of 0.9 mm. The depth of the TRS in this case is estimated to be within 0.5 mm. a b Fig. 7. Diagrams of residual stresses in a plate: a – of steel 5CrNiMo after annealing at 790 °C; b – of steel 3Cr2W8V after annealing at 880 °C
OBRABOTKAMETALLOV technology Vol. 24 No. 4 2022 a b Fig. 8. Diagrams of residual stresses in a plate made of 5CrNiMo steel at a treatment temperature: a – 950 °C; b – 1,050 °C After the CTT of 5CrNiMo steel at a temperature of 1,050 °C (Fig. 8, b), layers with a thickness of 750–900 µm are formed [15], in which the components are tensile; on the surface take near-zero values. The component σZ has a maximum of 436 MPa at a depth of 0.05 mm with a further general downward trend, although with slight increases in values at depths of 0.2 and 0.375 mm. The σX component has at first a sharp rise to 250 MPa, and then a smooth rise to 330 MPa at a depth of 0.2 mm, and then a general downward trend with a slight increase in values at a depth of 0.4 mm. The depth of the TRS in this case is more than 0.8 mm. It can be noticed that the component σX does not have the first peak value, as the component σZ does, although they both have insignificant areas of increasing values with a general downward trend at almost the same depths. After the CTT of 3Cr2W8V steel at a temperature of 950 °C (Fig. 9, a) at a depth of the diffusion layer up to 130–150 mm [15], two zones are observed on the TRS plot: tensile and compressing – so it can be said that the TRS plots in this case are self-balanced. On the surface, the TRS components have values of 100 MPa and reach a maximum of 360–470 MPa at a depth of 0.025 mm, then a dropping occurs and at a depth of 0.18–0.25 mm it turns into compressive (σX = –150 MPa at a depth of 0.3 mm).The depth of the TRS is 0.3 mm. After HBA of 3Cr2W8V steel at a temperature of 1,050 °C (Fig. 9, b) in a diffusion layer with a depth of 500–600 µm [15], the components of the TRS on the surface are compressive with values of −125...−210 MPa, but abruptly turn into tensile and reach a maximum of 565 MPa at a depth of 0.03 mm. Then there is a smooth dropping of the components to zero at a depth of 0.35–0.4 mm and a transition to the a b Fig. 9. Diagrams of residual stresses in a plate made of 3Cr2W8V steel at a processing temperature: a – 950 °C; b – 1,050 °C
OBRABOTKAMETALLOV Vol. 24 No. 4 2022 technology compressive region up to −100...−130 MPa. The depth of occurrence of the TRS at the same time is more than 0.55 mm. Since the CTT processes take place in the entire volume of the material and form a flat SSS of a homogeneous type, i.e. any direction in the processing plane is the main one, the components of the TRS should be the same in all directions. Similar diffusion layers obtained on the surface of 5CrNiMo and 3Cr2W8V steels by boroaluminizing can be classified as composite layers with heterogeneous dispersed morphology of the boride crystals arrangement [35, 36]. These layers are characterized by a complex distribution of microhardness in depth, explained by the gradient distribution of B, Al and alloying elements from the base steel [15]. It was shown in [15] that as a result of CTT on 5CrNiMo and 3Cr2W8V steels at a temperature of 1,050 °C and on 5CrNiMo steel at a temperature of 950 °C, diffusion layers are formed on the surface of the steel, in which solid structural components (borides and carbides) are arranged in a matrix of plastic phases (aluminides, solid solutions of aluminum and carbon in α-Fe). The obtained properties have a positive effect on the wear resistance of the working surface, however, the nature of the TRS distribution in the diffusion layers and its dependence on the SSS obtained as a result of the strengthening CTT remains understudied. As is known, tensile properties are unfavorable and can lead to cracks and destruction of the product, increase intercrystalline corrosion, contribute to fatigue failure, especially for parts operating under shock and alternating loads. In this case, it is necessary to provide a set of measures to reduce the tensile TRS after CTT or to form favorable compression TRS. As such measures can be proposed: subsequent heat treatment (tempering), quenching with subsequent tempering, plasma or laser treatment, elaboration of modes and technologies of CTT, etc. which will be a continuation of further research. Conclusions The main methods for determining the TRS in the surface layer after strengthening by the CTT methods of tool die steels 5CrNiMo and 3Cr2W8V are considered. Problems are identified in determining the TRS by mechanical method on the UDINON-2 installation in samples after diffusion boroaluminizing, and its solution are proposed. The expediency of using the anodic dissolution method for continuous removal of stressed layers from treated samples in the study of TRS by mechanical method on the UDION-2 installation is shown. The optimal electrolyte composition for the anodic dissolution process is selected, consisting of: NaNO3 – 60 g/l; NaNO2 – 5 g/l; Na2CO3 – 5 g/l; C3H8O3 – 15 g/l; H2O – the rest. The distributions of TRS normal components in the diffusion layer of samples from die steels after boroaluminizing are revealed. It is established that the formation of predominantly tensile TRS occurs in the surface layer of the CTT of these steels. Further research will be aimed at developing technological methods to reduce the tensile forces during diffusion boroaluminizing of die steels. References 1. Voroshnin L.G., Mendeleeva O.L., Smetkin V.A. Teoriya i tekhnologiya khimiko-termicheskoi obrabotki [Theory and technology of chemical and heat treatment]. Moscow, Novoe znanie Publ., 2010. 304 p. ISBN 978-594735-149-1. 2. Gagandeep S., Gurbhinder B. Modification of EN9 steel surface by salt bath nitrocarburising process. Journal of Materials Science and Surface Engineering, 2017, vol. 5, no. 4, pp. 577–580. 3. Zuno-Silva J., Ortiz-Domínguez M., KeddamM., Elias-Espinosa M., Damián-Mejía O., Cardoso-Legorreta E., Abreu-Quijano M. Boriding kinetics of Fe2B layers formed on AISI 1045 steel. Journal of Mining and Metallurgy. Section B: Metallurgy, 2014, vol. 50 (2), pp. 101–107. 4. Balanovskii A., Huy V.V. (2017). Plazmennaya poverkhnostnaya tsementatsiya s ispol’zovaniem grafitovogo pokrytiya [Plasma surface carburizing with graphite paste]. Pis’ma o materialakh = Letters on Materials, 2017, vol. 7, no. 2, pp. 175–179. DOI: 10.22226/2410-3535-2017-2-175-179. 5. KolosovA.D., Gozbenko V.E., Shtayger M.G., Kargapoltsev S.K., BalanovskiyA.E., KarlinaA.I., SivtsovA.V., Nebogin S.A. Comparative evaluation of austenite grain in high-strength rail steel during welding, thermal processing
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