Design of thermal stress control layers in the selective deposition technology of hot axle forging dies
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Abstract
The hardfacing process can effectively overcome surface softening of dies and improve the service life in hot forging operations; however, thermal cracks are frequently generated on deposited areas due to thermal stress from different material properties. A thermal stress control layer (TSCL) is applied to reduce thermal stress and increase fatigue life as a buffer in the vicinity of the joining region between the hardfacing layer and the base metal. The TSCL and hardfacing layer are deposited through layer-by-layer deposition on the surfacing of the substrate using a 3D printing process. The TSCL, which is produced by mixing of Stellite 21 and SKD61, is designed with thicknesses of 0 mm, 1 mm, 1.5 mm, and 2 mm respectively. The study aims to estimate the effect of a TSCL focused on thermal stress in the deposition region via two-dimensional finite element analysis. In addition, the optimal volume of transition regions and composition proportions are also predicted for the hot forging die of an axle shaft.
Keywords
Selective deposition Thermal stress control layer Hot forging die Stellite 21 Finite element analysisAbbreviations
- Φ
Volume ratio of Stellite 21
- E
Young's modulus
- α
Thermal expansion coefficient
- ρ
Density
- CP
Heat capacity
- K
Thermal conductivity
- v
Poison's ratio
- εTSCL
Thermal physical properties of TSCL
- ε1
Thermal physical properties of SKD61
- ε2
Thermal physical properties of Stellite 21
- ρ1
Density of SKD61
- ρ2
Density of Stellite 21
- CPTSCL
Specific heat of TSCL
- CP1
Specific heat of SKD61
- CP2
Specific heat of Stellite 21
- KTSCL
Thermal conductivity of TSCL
- K1
Thermal conductivity of SKD61
- K2
Thermal conductivity of Stellite 21
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