Investigating AlSi coating fracture at high temperatures using acoustic emission sensors

Zaman, Shakil Bin; Hazrati, Javad; Rooij, M.B. de; Matthews, D.T.A.; Boogaard, A.H. van den

doi:10.1016/j.surfcoat.2021.127587

Cited by 15 publications

(16 citation statements)

References 37 publications

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“…To investigate the effect of temperature on the fracture of AlSi coating, normal load tests, friction tests, tensile tests and hot stamping of a B-pillar are performed. More information can be found in [10,14,18,21]. Information on the test process parameters can be found in Table 1.…”

Section: Experimental Methodsmentioning

confidence: 99%

“…During tensile deformation at high temperatures, several authors reported fracture of the AlSi coating [7][8][9][10]. For instance, Gui et al [7] performed uniaxial tensile deformation in the temperature range 700-800 °C (after heat treatment 920 °C 5 min) and observed mode I coating fracture, and a rise in coating crack density with a decrease in deformation temperature The authors also observed three stages of cracking, starting with a crack initiation, then multiple crack initiations and finally crack saturation, after which the cracks only widen with continued straining.…”

Section: Introductionmentioning

confidence: 99%

“…Furthermore, recent publications on lab-scale experiments neglect the effect of strain state in the sheet metal on AlSi coating fracture. Studies on lab scale experiments (normal load, hot friction tests and uniaxial tensile tests) were already published [10,14,18,21] by the authors. To enable translation of lab-scale experiments to real hot stamping applications, a summary of the lab scale tests results is made.…”

Section: Introductionmentioning

confidence: 99%

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Temperature and strain dependent fracture of AlSi coating in hot stamping of press hardening steel

et al. 2022

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In hot stamping severe tool wear occurs. The main tool wear mechanism is the so-called compaction galling, in which fractured particles from the coating of the part (blank) being build-up and become compacted upon the tools. Since fractured particles play an important role in the wear mechanism, fracture of the AlSi coating is investigated. For this purpose, simplified B-pillar parts are pressed at several temperatures to investigate the effect of temperature, strain and tool contact on the fracture behavior of the AlSi coating. Three positions which exhibit different strain modes are analysed by means of optical topography and optical microscopy measurements. The results indicate a strong correlation between the AlSi coating fracture, strain and temperature. For instance, at relatively low forming temperatures (i.e. 650 ºC), mode I fracture as well as spallation of the coating and at higher temperatures (750 and 800 ºC) mainly mode I coating fractures are observed. Interestingly, this type of mode I coating fractures are found to widen, eventually giving rise to mode II coating fractures along the coating-substrate interface. The onset strain of coating fracture is low and approximately at strains of 0.017, coating cracks are observed at all start temperatures. At contact-dominated regions, additional coating cracks are observed mainly due to a drop in blank temperature and added shear stresses due to the relative sliding between the blank and tools.

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Section: Experimental Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Temperature and strain dependent fracture of AlSi coating in hot stamping of press hardening steel

et al. 2022

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“…High-energy AE signals were related to the opening fracture mode (Mode I), while low-energy signals were linked to interfacial cracking (the formation of ridges, Mode II) as shown in Figure 11 [6]. The cracking that occurred in the AlSi coating was primally attributed to the formation of intermetallic compounds (i.e., FeAl and Fe 2 Al 5 ) through Fe-diffusion, which also resulted in void formation in the coatings [6,73].…”

Section: High-temperature Experimentationmentioning

confidence: 99%

“…In contrast, the Cr coating, which has a much higher fracture toughness than the TiCrAlN coating, resisted the crack initiation leading to longer fatigue life. Isothermal tensile tests conducted at different temperatures were combined with the AE method to study the fracture behavior of AlSi-coated Press-Hardened Steel (PHS) [6,73]. The cracking mode of the AlSi coating was identified by means of AE sensors during the deformation process.…”

Section: High-temperature Experimentationmentioning

confidence: 99%

A Review on In Situ Mechanical Testing of Coatings

et al. 2022

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Real-time evaluation of materials’ mechanical response is crucial to further improve the performance of surfaces and coatings because the widely used post-processing evaluation techniques (e.g., fractography analysis) cannot provide deep insight into the deformation and damage mechanisms that occur and changes in coatings’ material corresponding to the dynamic thermomechanical loading conditions. The advanced in situ examination methods offer deep insight into mechanical behavior and material failure with remarkable range and resolution of length scales, microstructure, and loading conditions. This article presents a review on the in situ mechanical testing of coatings under tensile and bending examinations, highlighting the commonly used in situ monitoring techniques in coating testing and challenges related to such techniques.

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Influence of high temperature during tensile test for stainless steel using acoustic emission

Mohammad,

Othman,

Ismail

2023

Process Safety Progress

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This paper explores the application of acoustic emission (AE) monitoring in mechanical and materials studies, specifically focusing on the detection of plastic deformation, fracture, and crack growth. However, the influence of high temperature on AE signals and its effects on mechanical properties are not fully understood due to the limitations of sensors in high‐temperature environments. To address this gap, the study investigates the impact of high temperatures on the mechanical properties of stainless steel SS304 using AE techniques during tensile testing. Two temperature conditions were tested: 600 and 700°C. AE sensors connected to specimens captured AE activity using a designated waveguide, and a Continuous Creep Monitoring Instrument (CCMi) recorded the responses. Sensitivity testing using the pencil‐lead break (PLB) technique ensured the sensor's capability. The proposed frequency‐based analysis method, fast Fourier transform amplitude (FFTA) analysis, was employed to effectively analyze the AE signals. The results revealed significant AE features and frequency distributions associated with elastic deformation, plastic deformation, and fracture regions. These findings establish a foundation for utilizing AE techniques in crack detection and monitoring under high‐temperature loading, contributing to equipment reliability and structural integrity.

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Investigating AlSi coating fracture at high temperatures using acoustic emission sensors

Cited by 15 publications

References 37 publications

Temperature and strain dependent fracture of AlSi coating in hot stamping of press hardening steel

Temperature and strain dependent fracture of AlSi coating in hot stamping of press hardening steel

A Review on In Situ Mechanical Testing of Coatings

Influence of high temperature during tensile test for stainless steel using acoustic emission

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