Effect of Solid-State Phase Transformation on Stress and Distortion for Fe-Co-Ni Ultra-High Strength Steel Components During Welding and Vacuum Gas Quenching Processes

doi:10.11900/0412.1961.2022.00177

Acta Metall Sin

2023, Vol. 59

Issue (12): 1633-1643 DOI: 10.11900/0412.1961.2022.00177

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Effect of Solid-State Phase Transformation on Stress and Distortion for Fe-Co-Ni Ultra-High Strength Steel Components During Welding and Vacuum Gas Quenching Processes

ZHANG Kaiyuan¹^,², DONG Wenchao¹(

), ZHAO Dong³, LI Shijian³, LU Shanping¹(

)

¹Shenyang National Laboratory for Materials Science, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China
²School of Materials Science and Engineering, University of Science and Technology of China, Shenyang 110016, China
³Shenyang Aircraft Corporation, Shenyang 110034, China

Cite this article:

ZHANG Kaiyuan, DONG Wenchao, ZHAO Dong, LI Shijian, LU Shanping. Effect of Solid-State Phase Transformation on Stress and Distortion for Fe-Co-Ni Ultra-High Strength Steel Components During Welding and Vacuum Gas Quenching Processes. Acta Metall Sin, 2023, 59(12): 1633-1643.

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Abstract

Due to its outstanding all-around performance, Fe-Co-Ni ultra-high strength steel (UHSS) is frequently used in crucial load-bearing components. The UHSS components will be significantly deformed during the welding and post-welding heat treatment operations, which makes the subsequent assembly to satisfy usage requirements a challenge. As a result, it is crucial to simulate the entire manufacturing process of UHSS components to investigate and comprehend the laws of stress and distortion in UHSS component weld joints throughout the manufacturing process. In this study, the “thermo-metallurgical-mechanical” coupled finite element model's accuracy is first verified, followed by the development of a heat source model for electron beam welding. The evolution of the microstructure of the weld joint, stress, and distortion in the weld joint of complex components are thus precisely predicted using the linked model throughout the production process of “electron beam welding-vacuum gas quenching”. The primary cause of the severe deformation of complex components is vacuum gas quenching. The solid-state phase transformation cannot be ignored in the simulation process of “electron beam welding-vacuum gas quenching” of the complicated components.

Key words: Fe-Co-Ni ultra-high strength steel numerical simulation solid-state phase transformation residual stress

Received: 17 April 2022

ZTFLH:

TG404

Fund: Natural Science Foundation of Heilongjiang Province(TD2021E006);Major Research and Development Project of Liaoning Province(2020JH1/10100001)

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	ZHANG Kaiyuan
	DONG Wenchao
	ZHAO Dong
	LI Shijian
	LU Shanping

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https://www.ams.org.cn/EN/10.11900/0412.1961.2022.00177 OR https://www.ams.org.cn/EN/Y2023/V59/I12/1633

Fig.1 Schematic of an electron beam welding test plate (a) and the finite element model (b) (BC—boundary condition;YSYMM—symmetric boun-dary condition; U₂—translational degree of freedom along Y axis; UR₁—rotational degree of fre-edom around X axis; UR₃—rotational degree of freedom around Z axis)

Fig.2 Conical heat source model (a) and the comparison between the simulated and experimental morphologies of fusion zone (b) (z_e and z_i are the coordinates of the upper and lower surfaces of the inverted cone along the z direction, respectively; r_e and r_i are the effective heating radii of the upper and lower surfaces of the inverted cone, respectively; r₀(z) is the heating radius attenuated gradually along the z direction; q(r) is the heat source distribution function)

Fig.3 Electron beam welding longitudinal (a) and transverse (b) residual stress contours; and the comparisons between longitudinal (c) and transverse (d) residual stress tested by XRD method and simulation (Data location indicates where is the zone used for the comparisons between the experimental and simulated residual stresses)

Fig.4 Finite element model (a) and corresponding mechanical boundary conditions (b-d) of a Fe-Co-Ni ultra-high strength steel complicated component (A—1st weld pass, B—2nd weld pass; U₁ and U₃—translational degrees of freedom along X and Z axis, respectively)

Fig.5 Vacuum gas quenching process (a) and the simulated and experimental thermal cycle curves for a workpiece (Thermocouples: the spot welded thermocouple positions used for temperature measurement) (b)

Fig.6 Curves of temperature and phase volume fraction with welding time at positions P1 (a) and P2 (b); and the distributions of longitudinal and transverse residual stresses along L1 (c) and L2 (d) as show in Fig.4a for complicated component

Fig.7 Total welding distortion deformation of the component (a) and the deformation of the component along the Z axis (b)

Fig.8 Temperature variations in the component after vacuum gas quenching for 179.5 s (a) and 3000 s (b)

Fig.9 Distortion contours for 0 s (a), 204 s (b), 804 s (c), 2004 s (d), and 4500 s (e) without considering solid-state phase transformation (SSPT)

Fig.10 Phase transformation volume fraction in the component after vacuum gas quenching for 179.6 s (a1), 259.6 s (a2), and 4500 s (a3); and corresponding curves of the phase transformation volume fraction with heating time at positions 1 (b1), 2 (b2), and 3 (b3) on the component

Fig.11 Deformation contour in the component (a) and the comparisons between the experimental and simulated results after vacuum gas quenching at bottom support positions SP1-SP5 (b)

Fig.12 Phase transformation contour (a) and deformation curves of different positions 1 (b) and 3 (c) in Fig.12a during cooling stage of vacuum gas quenching (Insets in Figs.12b and c show the locally enlarged curves)

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