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1

Role of materials design in maintenance engineering in the context of industry 4.0 idea

Dobrzański L. A.

Journal of Achievements in Materials and Manufacturing Engineering

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2019

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Vol. 96, nr 1

12--49

EN

Purpose: The paper presents the issues of designing the maintenance of materials and products in accordance with the idea of Industry 4.0. The author's views on the need for augmentation of the Industry 4.0 model were also presented, as well as the author's original concept that hybrid activities in predictive maintenance and condition-based maintenance should be preceded by designing material, maintenance & manufacturing 3MD at the stage of the product's material designing and technological designing. The 3MD approach significantly reduces the frequency of assumed actions, procedures and resources necessary to remain the condition of this product for the longest possible time, enabling it to perform the designed working functions. Examples of own advanced research on several selected, newly developed materials, used in very different areas of application, confirmed the validity of the scientific hypothesis and the relationship between the studied phenomena and structural effects and the working functions of products and their maintenance and indicated that material design is one of the most important elements guaranteeing progress production at the stage of Industry 4.0 of the industrial revolution. Design/methodology/approach: The author's considerations are based on an extensive literature study and the results of the author's previous study and empirical work. Each of the examples given required the use of a full set of research methods available to modern material engineering, including HRTEM high-resolution transmission electron microscopy. Findings: The most interesting intellectual achievements contained in the paper include presentations of the author's original concepts regarding the augmentation of the Industry 4.0 model, which has been distributed so far, which not only requires augmentation but is actually only one of the 4 elements of the technology platform of the extended holistic model of current industrial development, concerning cyber-IT production aided system. The author also presents his own concept for designing material, maintenance and manufacturing 3MD already at the stage of material and technological design of the product, eliminating many problems related to product maintenance, even before they are manufactured and put into exploitation. Detailed results of detailed structural researches of several selected avant-garde engineering materials and discussion of structural changes that accompanying their manufacturing and/or processing are also included. Originality/value: The originality of the paper is associated with the novelty of the approach to analysing maintenance problems of materials and products, taking into account the requirements of the contemporary stage of Industry 4.0 development. The value of the paper is mainly associated with the presentation of original issues referred to as findings, including the concept of augmentation of the Industry 4.0 model and the introduction and experimental confirmation of the idea by designing material, maintenance and manufacturing 3MD.

2

Effect of plastic deformation rate at room temperature on structure and mechanical properties of high-Mn austenitic Mn-Al-Si 25-3-3 type steel

Borek W., Lis M., Gołombek K., Sakiewicz P., Piotrowski K.

Archives of Materials Science and Engineering

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2019

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Vol. 96, nr 1

22--31

EN

Purpose: The aim of the paper is to determine influence of plastic deformation rate at room temperature on structure and mechanical properties of high-Mn austenitic Mn-Al-Si 25-3-3 type steel tested at room temperature. Design/methodology/approach: Mechanical properties of tested steel was determined using Zwick Z100 static testing machine for testing with the deformation speed equal 0.008 s-1, and RSO rotary hammer for testing with deformation speeds of 250, 500 and 1000s-1. The microstructure evolution samples tested in static and dynamic conditions was determined in metallographic investigations using light microscopy as well as X-ray diffraction. Findings: Based on X-ray phase analysis results, together with observation using metallographic microscope, it was concluded, that the investigated high-Mn X13MnAlSiNbTi25-3-3 steel demonstrates austenitic structure with numerous mechanical twins, what agrees with TWIP effect. It was demonstrated, that raise of plastic deformation rate produces higher tensile strength UTS and higher conventional yield point YS0.2. The UTS strength values for deformation rate 250, 500 and 1000 s-1 grew by: 35, 24 and 31%, appropriately, whereas in case of YS0.2 these were: 7, 74 and 130%, accordingly, in respect to the results for the investigated steel deformed under static conditions, where UTS and YS0.2 values are 1050 MPa and 700 MPa. Opposite tendency was observed for experimentally measured uniform and total relative elongation. Homogeneous austenitic structure was confirmed by X-ray diffractometer tests. Research limitations/implications: To fully describe influence of strain rates on structure and mechanical properties, further investigations specially with using transmission electron microscope are required. Practical implications: Knowledge about obtained microstructures and mechanical properties results of tested X13MnAlSiNbTi25-3-3 steel under static and dynamic conditions can be useful for the appropriate use of this type of engineering material in machines and equipment susceptible to static or dynamic loads. Originality/value: The influence of plastic deformation at room temperature under static and dynamic conditions of new-developed high-manganese austenitic X13MnAlSiNbTi25-3-3 steels were investigated.

3

Microstructure evolution after thermo-mechanical treatment of X11MnSiAl25-1-3 TWIP-type steel

Dobrzańska-Danikiewicz A., Borek W., Mazurkiewicz J., Jagiełło A.

Archives of Materials Science and Engineering

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2013

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Vol. 59, nr 1

14--21

EN

Purpose: The purpose of the article is to present the results of research of the effect of thermal and thermoplastic working on the structure of high-manganese austenitic TWIP steels. Design/methodology/approach: Plastometric tests were performed with DSI (Dynamic System Inc.) Gleeble 3800 instrumentation being the equipment of the Scientific and Didactic Laboratory of Nanotechnology and Materials Technologies of the Institute of Engineering Materials and Biomaterials. Changes in the microstructure after individual stages of hot plastic deformation were determined on the basis of detailed microstructure tests with the light microscope and scanning electron microscope. An X-ray phase qualitative analysis of the examined materials in the condition after casting and after thermoplastic working was carried out with the XPert diffractometer by Philips. Findings: It was concluded based on the tests performed that the structure of the examined austenitic high-manganese steel in the initial condition is represented by austenite with numerous annealing twins. The results obtained for investigations in a continuous compression test will enable to establish power and energy parameters and design a hot compression process, consisting of several phases, of axisymmetric specimens, simulating the final rolling passes. Practical implications: By elaborating the detailed data concerning structural changes and power and energy parameters of the thermoplastic working process of the investigated high-manganese austenitic TWIP steel type, it will be possible to design appropriately the final passes of the hot rolling process to obtain an optimum size of grains, which will in turn influence the improved strength properties of the investigated high-manganese austenitic X11MnSiAl25-1-3 steel. Originality/value: The application of thermoplastic working of high-manganese austenitic TWIP steel.

4

Hot-working of advanced high-manganese austenitic steels

Dobrzański L. A., Borek W.

Journal of Achievements in Materials and Manufacturing Engineering

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2010

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Vol. 43, nr 2

507--526

EN

Purpose: The work consisted in investigation of newly elaborated high-manganese austenitic steels with Nb and Ti microadditions in variable conditions of hot-working. Design/methodology/approach: The force-energetic parameters of hot-working were determined in continuous and multi-stage compression test performed in temperature range of 850 to 1100°C using the Gleeble 3800 thermomechanical simulator. Evaluation of processes controlling work-hardening were identified by microstructure observations of the specimens compresses to the various amount of deformation (4x0.29, 4x0.23 and 4x0.19). The microstructure evolution in successive stages of deformation was determined in metallographic investigations using light, scanning and electron microscopy as well as X-ray diffraction. Findings: The investigated steels are characterized by high values of flow stresses from 230 to 450 MPa. The flow stresses are much higher in comparison with austenitic Cr-Ni and Cr-Mn steels and slightly higher compared to Fe-(15-25)Mn alloys. Increase of flow stress along with decrease of compression temperature is accompanied by translation of εmax strain in the direction of higher deformation. Results of the multi-stage compression proved that applying the true strain 4x0.29 gives the possibility to refine the austenite microstructure as a result of dynamic recrystallization. In case of applying the lower deformations 4x0.23 and 4x0.19, the process controlling work hardening is dynamic recovery and a deciding influence on a gradual microstructure refinement has statical recrystallization. The steel 27Mn-4Si-2Al-Nb-Ti has austenite microstructure with annealing twins and some fraction of ε martensite plates in the initial state. After the grain refinement due to recrystallization, the steel is characterized by uniform structure of γ phase without ε martensite plates. Research limitations/implications: To determine in detail the microstructure evolution during industrial rolling, the hot-working schedule should take into account real number of passes and higher strain rates. Practical implications: The obtained microstructure - hot-working relationships can be useful in the determination of power-force parameters of hot-rolling and to design a rolling schedule for high-manganese steel sheets with fine-grained austenitic structures. Originality/value: The hot-deformation resistance and microstructure evolution in various conditions of hot-working for the new-developed high-manganese austenitic steels were investigated.

5

Wpływ procesu ciągnienia na własności mechaniczne stali TWIP

Muskalski Z., Stradomski Z., Pilarczyk J., Suliga M., Herian J.

Hutnik, Wiadomości Hutnicze

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2005

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Vol. 72, nr 2

107-109

PL

W pracy przedstawiono wyniki badań procesu ciągnienia drutu ze stali TWIP. Określono podatność tej stali na odkształcenie plastyczne w procesie ciągnienia oraz określono jego własności mechaniczne, sposób umacniania się oraz strukturę. Stwierdzono, że struktura wysokomanganowego austenitu mimo szybkiego umacniania się stali umożliwia odkształcanie go w procesie ciągnienia do około 76 %, a otrzymany w tym procesie drut odznacza się wysokimi własnościami mechanicznymi i dużą twardością.

EN

The investigation of drawing process of TWIP steel wires was shown in this paper. It was defined the susceptibility TWIP steel on plastic strain and described its mechanical properties, work hardening and structure. It was found that in spite fast hardening TWIP steel because of high contain of manganese, it is possible to drawing this steel with total draft 76 % and received in this process wire shows high mechanical properties and high hardness.