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Machinability improvement by in-operando Tool Protection Layers through designed steel alloying : The case of manganese steel

Bjerke, Axel LU orcid ; Norgren, Susanne LU ; Larsson, Henrik ; Markström, Andreas ; Lenrick, Filip LU orcid ; M'Saoubi, Rachid LU ; Petersson, Jörgen ; Melk, Latifa LU and Bushlya, Volodymyr LU (2024) In Journal of Materials Processing Technology 330.
Abstract

Improvements in machinability by alloying of the workpiece often adversely impact the end user properties of a material. For example, the common use of non-metallic inclusions can lead to improved tool life during turning or milling, but often adversely affects weldability, corrosion, and wear resistance. A cutting tool material meets kilometers of workpiece material during a machining operation. Hence elements in small quantities in the workpiece may insignificantly affect the end user properties but may have large effects on tool wear. One such effect is the formation of refractory and wear resistant reaction products between the workpiece and tool. Such reaction products forming on tool surfaces may lead to improved machinability.... (More)

Improvements in machinability by alloying of the workpiece often adversely impact the end user properties of a material. For example, the common use of non-metallic inclusions can lead to improved tool life during turning or milling, but often adversely affects weldability, corrosion, and wear resistance. A cutting tool material meets kilometers of workpiece material during a machining operation. Hence elements in small quantities in the workpiece may insignificantly affect the end user properties but may have large effects on tool wear. One such effect is the formation of refractory and wear resistant reaction products between the workpiece and tool. Such reaction products forming on tool surfaces may lead to improved machinability. This paper proposes the use of small amounts of alloying to induce such a Tool Protection Layer. Additionally, the paper develops a computational framework for designed alloying which balances formation of Tool Protection Layers, its in-process retention, and the functional properties of the alloy. The method has been validated for a case of manganese steel. The calculations were validated first by a wide range of diffusion experiments. Then by industrial turning of cast alloys, by comparing one reference and two newly designed alloys based on the alloying concept. The alloy with 0.003 mol fractions of Al resulted in more than 3 times increase in tool life, due to in-operando formation of Al2O3 Tool Protection Layer. The designed manganese steel maintained its functional properties with respect to abrasive wear resistance and retained its ability to work harden.

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author
; ; ; ; ; ; ; and
organization
publishing date
type
Contribution to journal
publication status
in press
subject
keywords
Electron microscopy, Machinability, Thermodynamic modeling, Tool wear
in
Journal of Materials Processing Technology
volume
330
article number
118496
publisher
Elsevier
external identifiers
  • scopus:85197741632
ISSN
0924-0136
DOI
10.1016/j.jmatprotec.2024.118496
language
English
LU publication?
yes
additional info
Publisher Copyright: © 2024 The Authors
id
e21f3ac7-2941-47c9-be53-844261365232
date added to LUP
2024-07-15 10:10:01
date last changed
2024-07-16 14:01:57
@article{e21f3ac7-2941-47c9-be53-844261365232,
  abstract     = {{<p>Improvements in machinability by alloying of the workpiece often adversely impact the end user properties of a material. For example, the common use of non-metallic inclusions can lead to improved tool life during turning or milling, but often adversely affects weldability, corrosion, and wear resistance. A cutting tool material meets kilometers of workpiece material during a machining operation. Hence elements in small quantities in the workpiece may insignificantly affect the end user properties but may have large effects on tool wear. One such effect is the formation of refractory and wear resistant reaction products between the workpiece and tool. Such reaction products forming on tool surfaces may lead to improved machinability. This paper proposes the use of small amounts of alloying to induce such a Tool Protection Layer. Additionally, the paper develops a computational framework for designed alloying which balances formation of Tool Protection Layers, its in-process retention, and the functional properties of the alloy. The method has been validated for a case of manganese steel. The calculations were validated first by a wide range of diffusion experiments. Then by industrial turning of cast alloys, by comparing one reference and two newly designed alloys based on the alloying concept. The alloy with 0.003 mol fractions of Al resulted in more than 3 times increase in tool life, due to in-operando formation of Al<sub>2</sub>O<sub>3</sub> Tool Protection Layer. The designed manganese steel maintained its functional properties with respect to abrasive wear resistance and retained its ability to work harden.</p>}},
  author       = {{Bjerke, Axel and Norgren, Susanne and Larsson, Henrik and Markström, Andreas and Lenrick, Filip and M'Saoubi, Rachid and Petersson, Jörgen and Melk, Latifa and Bushlya, Volodymyr}},
  issn         = {{0924-0136}},
  keywords     = {{Electron microscopy; Machinability; Thermodynamic modeling; Tool wear}},
  language     = {{eng}},
  publisher    = {{Elsevier}},
  series       = {{Journal of Materials Processing Technology}},
  title        = {{Machinability improvement by in-operando Tool Protection Layers through designed steel alloying : The case of manganese steel}},
  url          = {{http://dx.doi.org/10.1016/j.jmatprotec.2024.118496}},
  doi          = {{10.1016/j.jmatprotec.2024.118496}},
  volume       = {{330}},
  year         = {{2024}},
}