Numerical calculation and experimental research on crack arrest by detour effect and Joule heating of high pulsed current in remanufacturing

Jing Yu, Hongchao Zhang, Dewei Deng, Shengzhi Hao, Asif Iqbal

Research output: Contribution to journalArticle

13 Scopus citations

Abstract

The remanufacturing blanks with cracks were considered as irreparable. With utilization of detour effect and Joule heating of pulsed current, a technique to arrest the crack in martensitic stainless steel FV520B is developed. According to finite element theory, the finite element (FE) model of the cracked rectangular specimen is established firstly. Then, based on electro-thermo-structure coupled theory, the distributions of current density, temperature field, and stress field are calculated for the instant of energizing. Furthermore, the simulation results are verified by some corresponding experiments performed on high pulsed current discharge device of type HCPD-I. Morphology and microstructure around the crack tip before and after electro pulsing treatment are observed by optical microscope (OM) and scanning electron microscope (SEM), and then the diameters of fusion zone and heat affected zone (HAZ) are measured in order to contrast with numerical calculation results. Element distribution, nano-indentation hardness and residual stress in the vicinity of the crack tip are surveyed by energy dispersive spectrometer (EDS), scanning probe microscopy (SPM) and X-ray stress gauge, respectively. The results show that the obvious partition and refined grain around the crack tip can be observed due to the violent temperature change. The contents of carbon and oxygen in fusion zone and HAZ are higher than those in matrix, and however the hardness around the crack tip decreases. Large residual compressive stress is induced in the vicinity of the crack tip and it has the same order of magnitude for measured results and numerical calculation results that is 100 MPa. The relational curves between discharge energies and diameters of the fusion zone and HAZ are obtained by experiments. The difference of diameter of fusion zone between measured and calculated results is less than 18.3%. Numerical calculation is very useful to define the experimental parameters. An effective method to prevent further extension of the crack is presented and can provide a reference for the compressor rotor blade remanufacturing. The remanufacturing blanks with cracks were considered as irreparable. With utilization of detour effect and Joule heating of pulsed current, a technique to arrest the crack in martensitic stainless steel FV520B is developed. According to finite element theory, the finite element (FE) model of the cracked rectangular specimen is established firstly. Then, based on electro-thermo-structure coupled theory, the distributions of current density, temperature field, and stress field are calculated for the instant of energizing. Furthermore, the simulation results are verified by some corresponding experiments performed on high pulsed current discharge device of type HCPD-I. Morphology and microstructure around the crack tip before and after electro pulsing treatment are observed by optical microscope (OM) and scanning electron microscope (SEM), and then the diameters of fusion zone and heat affected zone (HAZ) are measured in order to contrast with numerical calculation results. Element distribution, nano-indentation hardness and residual stress in the vicinity of the crack tip are surveyed by energy dispersive spectrometer (EDS), scanning probe microscopy (SPM) and X-ray stress gauge, respectively. The results show that the obvious partition and refined grain around the crack tip can be observed due to the violent temperature change. The contents of carbon and oxygen in fusion zone and HAZ are higher than those in matrix, and however the hardness around the crack tip decreases. Large residual compressive stress is induced in the vicinity of the crack tip and it has the same order of magnitude for measured results and numerical calculation results that is 100 MPa. The relational curves between discharge energies and diameters of the fusion zone and HAZ are obtained by experiments. The difference of diameter of fusion zone between measured and calculated results is less than 18.3%. Numerical calculation is very useful to define the experimental parameters. An effective method to prevent further extension of the crack is presented and can provide a reference for the compressor rotor blade remanufacturing.

Original languageEnglish
Pages (from-to)745-753
Number of pages9
JournalChinese Journal of Mechanical Engineering (English Edition)
Volume27
Issue number4
DOIs
StatePublished - Jul 2014

Keywords

  • Crack arrest
  • High pulse current
  • Microstructure
  • Numerical simulation
  • Remanufacturing

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