Vol. 26 No. 4 2024 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. 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 Journal “Obrabotka Metallov – Metal Working and Material Science” is indexed in the world's largest abstracting bibliographic and scientometric databases Web of Science and Scopus. 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.
OBRABOTKAMETALLOV Vol. 26 No. 4 2024 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 Aff airs, 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. Korotkov, D.Sc. (Engineering), Professor, Kuzbass State Technical University, Kemerovo; 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, V.P. Larionov Institute of the Physical-Technical Problems of the North of the Siberian Branch of the RAS, Yakutsk; Alexander S. Yanyushkin, D.Sc. (Engineering), Professor, I.N. Ulianov Chuvash State University, Cheboksary
Vol. 26 No. 4 2024 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Manikanta J.E., Ambhore N., Shamkuwar S., Gurajala N.K., Dakarapu S.R. Investigation of vegetable-based hybrid nanofl uids on machining performance in MQL turning........................................................................................... 6 Dama Y.B., Jogi B.F., Pawade R., Kulkarni A.P. Impact of print orientation on wear behavior in FDM printed PLA Biomaterial: Study for hip-joint implant...................................................................................................................... 19 GrinenkoA.V., ChumaevskyA.V., Sidorov E.A., Utyaganova V.R.,AmirovA.I., Kolubaev E.A. Geometry distortion, edge oxidation, structural changes and cut surface morphology of 100mm thick sheet product made of aluminum, copper and titanium alloys during reverse polarity plasma cutting...................................................................................... 41 Somatkar A., Dwivedi R., Chinchanikar S. Comparative evaluation of roller burnishing of Al6061-T6 alloy under dry and nanofl uid minimum quantity lubrication conditions............................................................................................... 57 Karlina Yu.I., Konyukhov V.Yu., Oparina T.A. Assessment of the quality and mechanical properties of metal layers from low-carbon steel obtained by the WAAM method with the use of additional using additional mechanical and ultrasonic processing..................................................................................................................................................... 75 EQUIPMENT. INSTRUMENTS Yusubov N.D., Abbasova H.M. Systematics of multi-tool setup on lathe group machines............................................... 92 Toshov J.B., Fozilov D.M., Yelemessov K.K., Ruziev U.N., Abdullayev D.N., Baskanbayeva D.D., Bekirova L.R. Increasing the durability of drill bit teeth by changing its manufacturing technology......................................................... 112 Pospelov I.D. Investigation of the distribution of normal contact stresses in deformation zone during hot rolling of strips made of structural low-alloy steels to increase the resistance of working rolls..................................................... 125 Ablyaz T.R., Blokhin V.B., Shlykov E.S., Muratov K.R., Osinnikov I.V. Manufacturing of tool electrodes with optimized confi guration for copy-piercing electrical discharge machining by rapid prototyping method.......................... 138 MATERIAL SCIENCE Shubert A.V., Konovalov S.V., Panchenko I.A. A review of research on high-entropy alloys, its properties, methods of creation and application.................................................................................................................................................. 153 Syusyuka E.N., Amineva E.H., Kabirov Yu.V., Prutsakova N.V. Analysis of changes in the microstructure of compression rings of an auxiliary marine engine.......................................................................................................... 180 Dudareva A.A., Bushueva E.G., Tyurin A.G., Domarov E.V., Nasennik I.E., Shikalov V.S., Skorokhod K.A., Legkodymov A.A. The eff ect of hot plastic deformation on the structure and properties of surface-modifi ed layers after non-vacuum electron beam surfacing of a powder mixture of composition 10Cr-30B on steel 0.12 C-18 Cr-9 Ni-Ti............................................................................................................................................................................. 192 Boltrushevich A.E., Martyushev N.V., Kozlov V.N., Kuznetsova Yu.S. Structure of Inconel 625 alloy blanks obtained by electric arc surfacing and electron beam surfacing........................................................................................... 206 Sablina T.Y., Panchenko M.Yu., Zyatikov I.A., Puchikin A.V., Konovalov I.N., Panchenko Yu.N. Study of surface hydrophilicity of metallic materials modifi ed by ultraviolet laser radiation........................................................................ 218 EDITORIALMATERIALS 234 FOUNDERS MATERIALS 243 CONTENTS
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 4 2024 Analysis of changes in the microstructure of compression rings of an auxiliary marine engine Elena Syusyuka 1, a, *, Elena Amineva 1, b, Yuri Kabirov 2, c, Natalia Prutsakova 3, d 1 Admiral Ushakov State Maritime University, 93, Lenin Ave., Novorossiysk, 353924, Russian Federation 2 South Federal University, 105/42, Bolshaya Sadovaya str., Rostov-on-Don, 344006, Russian Federation 3 Don State Technical University, 1, Gagarin Square, Rostov-on-Don, 344003, Russian Federation a https://orcid.org/0000-0002-4237-0697, sollain66@rambler.ru; b https://orcid.org/0000-0001-8965-9730, elika-11@mail.ru; c https://orcid.org/0000-0002-9975-3410, salv62@mail.ru; c https://orcid.org/0000-0003-2761-286X, shpilevay@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. 2024 vol. 26 no. 4 pp. 180–191 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2024-26.4-180-191 ART I CLE I NFO Article history: Received: 24 June 2024 Revised: 12 August 2024 Accepted: 24 September 2024 Available online: 15 December 2024 Keywords: Marine engine Reliability Compression rings Wear Deformations Microstructure Metallographic studies Textural inhomogeneities Embrittlement of crystallites X-ray diff raction Macro- and microstructure of the material Dislocation density Phase analysis Microstresses Coherent scattering regions ABSTRACT Introduction. The cylinder-piston group (CPG) of a marine-type internal combustion engine is subjected to high operational loads. The reliability, durability and effi ciency of the engine depend on the proper operation of the CPG. The change in the direction of piston movement and the lack of lubrication caused by the spraying of lubricant during operation, lead to increased wear of the moving package of piston rings. Having determined the factors infl uencing the changes in the structure of the metal during operation, it can be taken into account in the manufacturing technology and hardening of these parts. The subject of the study: the object of research is the used-out upper and lower compression rings of the cylinder-piston group of the HIMSEN 4H21/32 auxiliary marine engine. Purpose of the work is to consider the change in the structure and microstructure of the material of the compression piston rings of the HIMSEN 4H21/32 auxiliary marine engine arising as a result of operation; to compare the results of evaluating microstresses and deformations of the surface layer of parts by metallographic methods and X-ray diff raction analysis for various operating conditions of the upper and lower compression rings. Methods. Metallographic and X-ray methods were used in the study. The conditions of X-ray photography are described; X-ray diff raction analysis was carried out on a Dron-3M diff ractometer. Residual microdeformations were determined, as well as the sizes of coherent scattering regions (D) and the density of dislocations on the surfaces of the samples. Results of the work. The results of metallographic and X-ray diff raction analysis (XRD) are presented. The residual macro- and microstresses and the sizes of the coherent scattering regions (D) of the surface layer of compression rings are determined. The results of X-ray diff raction analysis are comparable with the results of metallographic studies, and the convergence of the results is observed. Scope of the results application: the results of the study can be used in the selection of manufacturing technology for compression rings of marine internal combustion engines (MICE). Conclusions. It is advisable to evaluate changes in the manifestations of the stress state of cast iron under the infl uence of various factors. This will allow selecting the optimal technology for manufacturing compression rings to ensure the reliability of its operation. Ring quality control by various methods of structure assessment also makes it possible to predict the conditions of destruction of compression rings during operation. An increase in the degree of defectiveness of the upper ring occurs due to various kinds of deformations of the crystallites. As a result of inelastic deformations during ring operation, the resulting dislocations cause strong mechanical stresses. For citation: Syusyuka E.N., Amineva E.H., Kabirov Yu.V., Prutsakova N.V. Analysis of changes in the microstructure of compression rings of an auxiliary marine engine. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2024, vol. 26, no. 4, pp. 180–191. DOI: 10.17212/1994-6309-2024-26.4-180-191. (In Russian). ______ * Corresponding author Syusyuka Elena N., Ph.D. (Engineering), Associate Professor Admiral Ushakov State Maritime University, 93, Lenin Ave., 353924, Novorossiysk, Russian Federation Tel.: +7 918 4478192, e-mail: sollain66@rambler.ru Introduction The cylinder-piston group (CPG) of a marine-type internal combustion engine is subjected to high operational loads. The reliability, durability and economic effi ciency of the engine depend on the proper operation of the CPG. The change in the direction of piston movement and the lack of lubrication caused
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 4 2024 by the splashing of lubricant during operation, lead to increased wear of the moving package of piston rings located in the upper part of the cylinder [1]. Compression rings and oil rings are part of the CPG. Oil rings are used in four-stroke engines with a lubricant spray system to remove excess oil from the bottom of the cylinder and regulate its fl ow to the top of the cylinder. Compression rings have two functions: sealing and heat dissipation, as well as helping to distribute oil over the cylinder walls during operation. During operation, the compression rings make several types of movement. Forward-backward (radial) movement of the rings within the piston groove (ring grooves on the cylindrical surface of the piston) creates deformations perpendicular to the formations and contribute to wear of both the rings and the bottom surface of the piston groove. This leads to deterioration of the sealing eff ect of compression rings, and afterwards to radial vibration and ring breakage, most often in the middle part, opposite the lock. Axial movement is due to the diff erence in gas pressure above and below the ring, the gravity of the ring itself and the friction force between the ring and the piston groove surface. Rotational movement of the rings is caused by the engine shaft revolutions. The operating conditions of the upper and lower compression rings are diff erent. The pressure behind the upper compression ring is 0.75Pr, behind the lower compression ring is 0.20Pr (Pr is the operating pressure) and is one of the components of the force pressing the rings to the cylinder, and also creates radial deformations of the ring material. This causes increased wear of the upper compression ring and the lower surface of the piston groove on which it is seated. The service life of the CPG depends is highly dependent on the wear rate of the compression rings. In order to increase the service life of piston rings, various methods of hardening of mating surfaces have been developed: plastic deformation, hardening by high frequency currents, creation of adhesive surfaces, placement of wear-resistant inserts in the friction zone of the ring at the top dead center, porous chromium plating, grinding of grooves for fi lling with tin, application of hardening coatings of molybdenum and other materials that increase tribotechnical properties [2, 3]. High strength and elasticity, wear resistance, low coeffi cient of friction are the main design requirements for rings. The uniform distribution of radial pressure around the circumference of the ring is of great importance [4]. Piston rings are made of grey alloyed cast iron with lamellar graphite or high-strength cast iron with spheroidal graphite. Along with high casting properties grey cast iron has good damping ability, high antifriction properties, lower tendency to thermal deformations compared to steel. Diff erences of phase states of grey cast irons, diff usion of elements, inhomogeneity of linear and volume expansion coeffi cients of ferrite, cementite and graphite lead to anisotropy of stress state. This is a source of nucleation and development of defects called dislocations. It seems expedient to evaluate the change of cast iron stress state manifestations under the infl uence of various factors in order to predict the conditions of compression rings fracture in the process of operation. The technology of compression rings manufacturing is determined by reliability requirements and is described in the relevant standards for each type of rings. Quality control of rings is carried out by various methods of assessing the structure of castings, taking into account the technology of hardening, normalisation, heat treatment and machining [1–5]. The use of grey cast iron for the manufacture of compression rings is due to its good fl uidity and low shrinkage. Mechanical properties of cast iron are determined by the quantitative ratio of structural components, mainly ferrite, pearlite and graphite. Cast iron with perlite base is the strongest and most wearresistant. Ferrite reduces mechanical properties of cast iron. Large graphite inclusions reduce strength, but provide high cyclic toughness and low sensitivity to external notches. The material structures of the upper and lower rings undergo signifi cant changes during operation. Rings made of grey alloyed cast iron with lamellar graphite should have a certain microstructure: the metallic base consists of medium and fi ne lamellar or sorbitic pearlite. Perlite corresponds to high hardness, wear resistance and good machinability by cutting. The presence of ferrite in the form of individual small inclusions should not exceed 5 % of the section area. Ferrite indicates a decrease in mechanical properties and wear resistance of cast iron.
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 4 2024 Non-structural cementite is not allowed. Phosphide eutectic may be present in the form of small uniform inclusions or broken meshes, and triple phosphide eutectic with plates is not allowed [6]. The appearance of cementite in the structure leads to brittleness [7, 8]. According to GOST 7133-80, rings made of cast iron with spheroidal graphite as a metallic base should contain fi ne, sorbitic and medium plate pearlite. The percentage of cementite in the form of small inclusions should not exceed 10 % of the section area, and the percentage of ferrite should not exceed 10 % of the section area. There are techniques of the optical-mathematical method of describing metallographic images that allow estimating the percentage of inclusions of various phases of high chromium cast iron [9]. The problem of improving the reliability of CPG can be solved by comprehensive studies of possible operational changes in materials, using modern testing, research techniques and analytical programs. With any dynamic and thermal impact on the rings during operation the internal structure of the material changes, the plastic deformation zone acquires characteristic features. This is confi rmed by layer-by-layer texture analysis of metal in the brittle fracture region for an undeformed new specimen and a specimen with defects after operation [10]. An increase in dislocation density, changes in the microstructure, and possible appearance of textural inhomogeneities can be studied using metallographic methods and diff raction of X-ray and electron diff raction [11–14]. The analysis of literature sources on this subject allows us to draw conclusions about the relationship between changes in the structure and operational properties of the material. In the work [15] the researchers found out that when the material of the working parts of submersible pumps made of cast iron is changed, when the lamellar form of graphite inclusions is changed to spherical, such operational characteristics of cast iron as strength and ductility are signifi cantly improved, but there is an increased volumetric shrinkage and worse fl owability in liquid state. These factors should be taken into account when selecting the technology of compression rings manufacturing. A similar nature of the infl uence of microstructure changes on the material properties is observed for cast irons and steels. Analysis of changes in the microstructure and crystallographic texture of ferritic steel during stress corrosion failure (SCF) using scanning electron microscopy made it possible to determine the size and type of nonmetallic inclusions, the elemental composition of corrosion products, and the nature of fracture in the zone of SCF [16]. Within the framework of X-ray diff raction analysis (XRD), which took into account the shape and size of grains-crystallites, crystallographic texture, atomic occupancy of the crystal lattice, atomic displacements, Debye-Waller factor and instrumental line broadening, the parameters of the fi ne structure of ferritic steel in the fracture zone and in the zone free from the CRN were estimated. It is shown that the fracture region is characterised by a high density of introduced edge-type dislocations, strong elastic distortions of the crystal lattice and a relatively small size of coherent scattering regions (CSR). Many studies on various steels show that increasing the strain rate at high temperatures increases the threshold strain, which occurs before the onset of dynamic recrystallization of austenite. When boron microalloying is used, the opposite eff ect is observed, i.e. the threshold strain decreases. The presence of boron in the solution promotes the formation of grains at the boundaries, which prevents the rearrangement of atoms and facilitates the migration of these grains. Rapid dynamic recrystallization improves the ductility of steel and also promotes grain refi nement, which reduces its brittleness [17–18]. It is also interesting to study the eff ect of the stress-strain state on the propagation of cracks in quasicleavages of steel subject to embrittlement due to the presence of hydrogen. The role of hydrogen in the crack propagation mechanism was investigated, and it was found that the crack path in quasi-scales in hydrogen embrittled ferritic and ferritic-perlitic low-carbon steels is determined more by the nature of the stress-strain state than by the microstructure or the crystallographic orientation of individual grains [19]. There are new technologies for the production of steel piston rings, which provide for surface grinding [20], surfacing wear-resistant coatings, including the development of a method of three-layer hardening of its surface. This method includes carbonitriding, ion implantation of titanium nitride and then sulfi ding, which leads to improved processing and increased wear resistance of piston rings [21]. Electroacoustic sputtering method can be very eff ective in hardening of piston rings [22]. The resulting nanocrystalline
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 4 2024 coating on the metal surface is less susceptible to relaxation, which allows increasing the service life of the part by 6–8 times. Objectives of the study: to examine the changes in the structure and microstructure of the material of the upper and lower compression piston rings of the HIMSEN 4H21/32 auxiliary marine engine, arising as a result of the operation of these rings under diff erent conditions and diff erent loads; to compare the microstresses arising due to deformations of the surface layer of the upper and lower compression rings, using metallographic methods and the method of X-ray structural analysis. Materials and methods The subject of the study is the end-of-life piston compression rings (upper and lower) of the HIMSEN 4H21/32 auxiliary marine engine. Existing methods of metallographic research and X-ray diff ractometry [14–24] allow studying the stress state and atomic structure, microstrain and particle size variation of the material. In this study, metallographic and X-ray methods were used to investigate the microstructure of compression rings. Changes in the structure of the material of the upper ring during wear caused by the diff erent operating conditions of the upper and lower compression rings results in a loss of mobility of the lower ring. This means that the entire thermal and mechanical load is borne by the hot reserve of the upper ring. The analysis of changes in the material structure of the upper and lower rings will allow confi rming the diff erences in dynamic and thermal eff ects on the material during operation, which will allow determining the technological parameters for the manufacture of rings and its special hardening. Specimens for preparing sections to determine the microstructure and phase composition of the material were made by cutting perpendicular to the ring generatrix (Fig. 1). Since dynamic and thermal loads are equally probable in all radial directions in the ring plane, the location of the cut is of no particular importance. If a possible fracture or crack is present, the location of the cut should be adjacent to the defect. In order to reveal the entire microstructure, etching was carried out with nital solution (4 % alcoholic solution of HNO3) for 1 minute. The quality of etching was controlled using a metallographic microscope MMN-2. The same microscope was used to obtain photographs of the microstructure of the cross-sections of the rings (Figs. 2, 3). X-ray diff raction studies at room temperature were carried out on a Dron-3M diff ractometer. The diffraction profi les were imaged using Bragg-Brentano geometry on CuKα-radiation with a wavelength of 1.5406 Å (the average value of the K-α1,2 Cu wavelength, usually used for processing X-ray radiographs) in the interval of angles 20°< 2θ < 90°, with a scanning step of 0.02° and pulse set time at each point t = 2 s. The diff raction profi les of the compression rings were processed using PowderCell the computer program, version 2.3, and the ICSD database was used to analyze and clarify the structural characteristics. Note that a signifi cant background in the X-ray images is associated with the fl uorescence of iron when its atoms are excited by K-α copper radiation. The lattice parameters, the sizes of coherent scattering regions on the surfaces of the specimens, as well as lattice microdistortions (microstrains) and dislocation density were determined. The Selyakov-Sherrer formula [23] was used to estimate the eff ective sizes D of the coherent scattering regions (mosaic blocks). , cos k D λ = β θ (1) Fig. 1. Ring cutting pattern
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 4 2024 where k is a coeffi cient depending on the particle shape and is close to 1; λ is the radiation wavelength; β is the half-width of diff raction refl ection; θ is the diff raction angle. Dislocation density ρD [24] was calculated from eff ective crystallite sizes according to the formula 2 3 . D D − ρ = (2) The size of the coherent scattering regions D was estimated from the most intense diff raction refl ection 110 lying in the region of small angles 2θ. The broadening of refl ections caused by the Kα1 – Kα2 doublet, which is signifi cant at large diff raction angles, can be neglected for it. The contribution to the broadening of diff raction lines due to microstrain is also present; the relative lattice strain d d Δ [25] was determined by the formula 4tg d d Δ β = θ. (3) The separation of the contributions of microstresses and crystallite refi nement to the broadening of diff raction refl ections showed that microstrains have the main infl uence on the broadening of refl ections. Results and discussion The microstructure of undeformed rings (Fig. 2 a) consists of graphite inclusions and pearlitic matrix. In addition, the microstructure shows a small amount of ferrite grains, but its amount is not high, about 5 %. Photographs of the microstructure (Figs. 2 b, 3) of the cross-sections of the compression rings, which have served its service life, indicate that the cast iron has a fi ne plate-like pearlitic base with insignifi cant (not more than 5 %) inclusion of ferrite grains [6, 9, 11]. This corresponds to international standards for compression rings. Schemes of structures permissible for the material of compression rings were selected according to GOST 3443-87 “Castings from cast iron with diff erent graphite shape. Methods of structure determination” [6]. a b Fig. 2. Photo of the microstructure of the upper compression ring: a – before deformation during operation; b – after deformation during operation The fi rst photo represents the microstructure of the upper compression ring and shows the presence of lamellar cementite: the base is fi ne-plate pearlite with insignifi cant inclusion of ferrite grains; the presence of some cementite elements indicates increased brittleness of this material. The measured Brinell hardness of the ring material is HB135 (regulated hardness for compression rings of marine engines of this size is 92–102). The increase of hardness is accompanied by higher brittleness of the material. The second photo shows the microstructure of the lower compression ring: the primary base is pearlite with inclusions of
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 4 2024 fi ne-grained ferrite. The material hardness of the lower compression ring is less than HB85. The lower ring is subjected to lower temperatures, so the structural changes here are signifi cantly lower. However, cyclic loads and deformation eff ects lead to the formation of fatigue cracks and a decrease in mechanical properties. The cementite inclusions in the upper compression ring occupy a larger area than the cementite inclusions in the lower compression ring. This indicates more signifi cant mechanical and thermal stresses on the upper ring. Also, according to the microphotographic images, microcrystallites are observed to be crushed in the most stressed material, which correlates with the X-ray diff raction data (Table 1). Fig. 3. Photo of the microstructure of the lower compression ring Ta b l e 1 Results of X-ray diff raction data processing Phase a, Å V, Å3 hkl 2θ β, grad D, Å Dislocation density ρD, см -2 Lattice micro-distortions Δd/d Fe, lower ring 2.8785 23.9 110 44.20 0.5 180 9.3·1011 0.00758 Fe, upper ring 2.8870 24.1 110 44.07 0.63 142 14.8·1011 0.00998 Fig. 4, a and b show fragments of X-ray diff raction patterns of the surfaces of the lower (a) and upper (b) compression rings. The results of X-ray diff raction data processing are summarized in Table 1. As shown by the X-ray diff raction studies (Table 1), the upper compression ring shows an increase in dislocation density (approximately 60 %) as well as larger values of lattice microstrains (approximately 30 %) compared to the lower ring. In addition, in the upper compression ring there is a greater refi nement of the coherent scattering Fig. 4. X-ray patterns of the surfaces of the lower (a) and upper (b) compression rings a b
OBRABOTKAMETALLOV MATERIAL SCIENCE Vol. 26 No. 4 2024 regions (average size of the perfection regions D), approximately by 20 %, which in the experiment corresponds to larger values of the half-widths of the X-ray refl ections (Fig. 4) and slight increase in the cell parameters Conclusion The changes in the structure, microstructure and hardness of the material of the compression piston rings of the HIMSEN 4H21/32 auxiliary marine engine, which occur as a result of operation, are experimentally established in this work, using X-ray diff raction and metallographic analysis methods. Adiff erence of half-widths of X-ray diff raction refl ections of iron in the material of the upper compression ring in comparison with the lower one is established, which testifi es to the reduction of the average size of coherent scattering regions due to diff erent conditions of operation of the rings. At the same time, a diff erence in the dislocation density of 1.6 times is observed, it is 9.3 1011 cm−2 for the lower compression ring and 14.8 1011 cm−2 for the upper compression ring. A diff erence in the values of microstrains for the two rings is also established (for the lower compression ring, microdeformations are approximately 1.3 times higher). It should also be noted that the crystal lattice parameters of iron for the upper ring are increased compared to the lower ring. Thus, the results of metallographic and X-ray analyses indicate a higher degree of defectiveness of the upper compression ring as compared to the lower ring due to a greater refi nement of microcrystallites and the appearance of stronger stresses due to dislocations and inelastic deformations during ring operation. The results obtained show that to increase the durability and stability of the rings, it is necessary to harden the rings material itself, as well as the surfaces of these rings. It is expedient to evaluate changes in the manifestations of the stress state of cast iron under the infl uence of various factors. This will allow selecting the optimal technology of compression rings manufacturing to ensure the reliability of its operation. Quality control of rings using various methods also makes it possible to predict the conditions under which compression rings may be damaged during operation. References 1. Putintsev S.V. Mekhanicheskie poteri v porshnevykh dvigatelyakh: spetsial’nye glavy konstruirovaniya, rascheta, ispytanii [Mechanical losses in piston engines: special chapters of design, calculation, testing]. Moscow, Bauman MSTU Publ., 2011. 288 p. 2. Guzhvenko I.N., Chanchikov V.A., Pryamukhina N.V., Strinzha E.A. Issledovanie eff ektivnosti ispol’zovaniya sloistogo modifi katora treniya v tsilindroporshnevoi gruppe sudovogo dizel’nogo dvigatelya [Researching of the effi ciency of the use of a layer frequency modifi cator in the cylinder-piston group of the ship diesel engine]. Morskie intellektual’nye tekhnologii = Marine Intellectual Technologies, 2018, vol. 3-1 (41), pp. 135–142. 3. Taylor D.A. Introduction to marine engineering. London, Boston, Butterworths, 1990 (Russ. ed.: Teilor D.A. Osnovy sudovoi tekhniki. Moscow, Transport Publ., 1987. 320 p.). 4. Voznitskii I.V., PundaA.S. Sudovye dvigateli vnutrennego sgoraniya. T. 1 [Marine internal combustion engines. Vol. 1]. Moscow, Morkniga Publ., 2010. 260 p. 5. Skoblo T.S., Sidashenko A.I., Klochko O.Yu., Saychuk A.V., Rybalko I.N. Otsenka lokal’noi strukturnoi neodnorodnosti v otlivkakh iz serogo chuguna [Evaluation of local structural inhomogeneity in castings from the grey cast-iron]. Agrotekhnika i energoobespechenie, 2017, vol. 4 (17), pp. 141–150. (In Russian). 6. Martyushev N.V., Pashkov E.N. Bronze sealing rings defects and ways of its elimination. Applied Mechanics and Materials, 2013, vol. 379, pp. 82–86. DOI: 10.4028/www.scientifi c.net/AMM.379.82. 7. Anisovich A.G., Andrushevich A.A. Mikrostruktury chernykh i tsvetnykh metallov [Microstructures of ferrous and non-ferrous metals]. Minsk, Belaruskaya navuka Publ., 2015. 131 p. ISBN 978-985-08-1883-6. 8. Skoblo T.S., Klochko O.Yu., Belkin E.L., SidashenkoA.I.,Avetisyan V.K. Strukturoobrazovanie vysokokhromistykh chugunov v intervale temperatur magnitnogo prevrashcheniya karbidnykh faz [Structure formation of highchromium cast irons in the temperature range of magnetic transformation of carbide phases]. Pis’ma o materialakh = Letters on materials, 2020, vol. 10 (2), pp. 129–134. DOI: 10.22226/2410-3535-2020-2-129-134.
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