Earticle

In this study, residual stress and surface roughness were investigated experimentally to evaluate surface integrity on surface layer machined by CBN, ceramics and WC cutting tools. When machining difficult-to-cut material (hardened STD11 steel $H_{R}$C 60), residual stresses remaining in machined surface layer were mainly compressive. The increase of flank wear caused a shift of the compressive residual stress maximum to greater workpiece depths, but the changes did not penetrate the workpiece beneath a depth of 300 .mu. m. Surface roughness was influenced considerably by variations of the cutting speed and feed. In machining hard material, CBN and A1$_{2}$ $O_{3}$ ceramics cutting tool materials proved significantly superior to mixed ceramics A1$_{2}$ $O_{3}$-TiC and WC in evaluation of surface integrity.y.

본 논문은 철강 제품의 제조 공정 중에 철강 표면에 불규칙하고 불균일하게 형성되는 스케일의 특성 분석에 관한 것이다. 고온에서 제작되는 철강 제품은 공기 중의 산소와 접촉하여 단 시간에 철산화물을 형성하게 된다. 이러한 철산화물을 스케일이라고 한다. 스케일은 철강 제품의 산화막 역할을 하여 제품 표면을 보호하는 역할도 하지만 불균일하게 형성된 스케일은 오히려 철강 제품의 외관을 해치게 되며 추가 공정 시에 적잖은 문제 거리가 된다. 산세공정을 통해 산(acid)으로 스케일을 제거하는 공정이 있지만 이 공정 또한 스케일의 특성 파악이 전제가 되지 않은 상태로 시행되고 있는 실정이다. 따라서 본 논문에서는 보다 효과적이고 효율적인 공정을 위하여 스케일의 특성 파악에 대한 내용을 소개하며, 이에 전파가 이용된다.. 전파를 이용하여 스케일의 분포, 접합 특성, 철강 코일의 스케일 분포 등을 연구할 수 있는 실험 장비를 소개한다. 또한 이론적 분석과 간단한 시뮬레이션으로 통하여 이의 타당성을 입증한다.

This paper deals with the analysis of characteristics of the scale non-uniformly formed on the surface of the steel during the steel production processes. The steel made at the high temperature contacts with the oxygen in the air, so forms the scale immediately. The scale has a role to protect the surface of the steel product as a oxide-layer, but the scale formed non-uniformly spoils the exterior of the steel product and occurs the problems about the next processes. There is a pickling process to remove the scale of the steel products, but the real situation is that the pickling process is not also based on the analysis of the characteristics of the scale. Therefore, this paper describe the procedures of the analysis of the scale more effectively using the radio-frequency wave. Using the radio-frequency wave, this paper introduce the experimentations to analyze the distributions of scale, the junction characteristics between the surface of steel and scale and the distributions of scale on the produced steel coil. Also, according to the simple simulations, this paper proves the proprieties about the above contents.

To find proper lathe machining parameters for SA182 Grade 304 stainless steel (SS), six kinds of samples with different machining surface states were prepared using a lathe. Surface morphologies and microstructures of near surface deformed layers on different samples were analysed. Surface morphologies and chemical composition of oxide films formed on different samples in simulated primary water with $100{\mu}g/L\;O_2$ at $310^{\circ}C$ were characterized. Results showed that surface roughness was mainly affected by lathe feed. Surface machining caused grain refinement at the top layer. A severely deformed layer with different thicknesses formed on all samples. In addition to high defect density caused by surface deformation, phase transformation, residual stress, and strain also affected the oxidation behaviour of SA182 Grade 304 SS in the test solution. Machining parameters used for # 4 (feed, 0.15 mm/r; back engagement, 2 mm; cutting speed, 114.86 m/min) and # 6 (feed,0.20 mm/r; back engagement, 1 mm; cutting speed, 73.01 m/min) samples were found to be proper for lathe machining of SA182 Grade 304 SS.

Duplex Stainless Steel의 Plasma Nitriding 처리 시 가스량과 처리온도가 표면 특성에 미치는 영향을 조사하였다. $N_2$함량 및 처리 온도가 각각 10%에서 25%로 $400^{\circ}C$에서 $430^{\circ}C$로 증가함에 따라서 질소가 과고용된 S-phase의 두께 및 표면 경도가 증가하였으나, 내부 식성은 $Cr_2N$ 및 $(Fe,Cr)_4N$이 석출하여 감소하였다. 질소를 10%로 고정하고 $CH_4$함량을 증가시키면 1%일 때 S-phase의 두께가 최대가 되며 그이후로 감소하였다. 처리온도 $400^{\circ}C$일 때 질소함량이 10%, $CH_4$ 함량이 5%일 경우 내식성이 모재보다 증가하였다.

Various heat-treated and surface coating methods are used to mitigate abrasion in sliding machine parts. The most cost effective of these methods involves hard coatings such as diamond-like carbon (DLC). DLC has various advantages, including a high level of hardness, low coefficient of friction, and low wear rate. In practice, a supporting layer is generally inserted between the DLC layer and the steel substrate to improve the load carrying capacity. In this study, an indentation and sliding contact problem involving a small, hard, spherical particle and a DLC-coated steel surface is modeled and analyzed using a nonlinear finite element code, MARC, to investigate the influence of the supporting layer thickness on the coating characteristics and the related coating failure mechanisms. The results show that the amount of plastic deformation and the maximum principal stress decrease with an increase in the supporting layer thickness. However, the probability of the high tensile stress within the coating layer causing a crack is greatly increased. Therefore, in the case of DLC coating with a supporting layer, fatigue wear can be another important cause of coating layer failure, together with the generally well-known abrasive wear.

Various heat-treated and surface coating methods are used to mitigate abrasion in sliding machineparts. The most cost effective of these methods involves hard coatings such as diamond-like carbon (DLC). DLChas various advantages, including a high level of hardness, low coefficient of friction, and low wear rate. In practice,a supporting layer is generally inserted between the DLC layer and the steel substrate to improve the loadcarrying capacity. In this study, an indentation and sliding contact problem involving a small, hard, spherical particleand a DLC-coated steel surface is modeled and analyzed using a nonlinear finite element code, MARC, toinvestigate the influence of the supporting layer thickness on the coating characteristics and the related coatingfailure mechanisms. The results show that the amount of plastic deformation and the maximum principal stressdecrease with an increase in the supporting layer thickness. However, the probability of the high tensile stresswithin the coating layer causing a crack is greatly increased. Therefore, in the case of DLC coating with a supportinglayer, fatigue wear can be another important cause of coating layer failure, together with the generallywell-known abrasive wear.

Austenitic stainless steel castings using expandable polystylene(referred to hereafter as EPS) patterns are often affected by distinctive defects associated with incomplete decomposition of the EPS as the molds are filled with metal. The quality of the castings, with particular reference to carbon pick-up in austenitic stainless steel is further influenced to a significant extent by such factors as reduced pressure, the additive by adding $Na_2CO_3$ in coating. The steel composition and microstructure were examined at the surface layer of castings, at depths of 1mm, by taking successive layers of swarf and analysis. In experiments, the carburizing atmosphere was neutralized, showing that the coating performed efficiently by decomposing almost instantly on heating and liberating $CO_2$. The upper parts of castings obtained using EPS patterns were slightly higher in carbon pick-up than other parts. Comparing the 316L and 304 stainless steel castings, qualitative and quantative differences could be found between the carbon pick-up behaviours as influence of the carbon content and alloying elements. Carbide former such as Cr makes carbon more soluble in the steel. This must make carbon pick-up in the surface layer but at the same time richer in carbon especially in the 304 stainless steel castings.

Since the early 1980's the use of zinc-aluminum alloy-coated steel sheet(Galvalume) for vehicular corrosion protection has increased drastically. It is consisting of 55%Al-43.4% Zn-1.6%Si. Galvalume has a good corrosion resistance, heat reflectivity and shiny appearance, which has a dendritic structure of alloy layer. It has a good corrosion resistance due to dendritic structure. But, this also has a weak point against moisture during long period of transportation as sheeted and or coiled without any relation of chromating on the surface of steel sheet or not because of high humidity and temperature. Here, We studied the corrosion mechanism by the moisture.

A systematic investigation was made on the influence of processing parameters such as gas composition and treatment temperature on the surface characteristics of hardened layers of low temperature plasma nitrided 316L Austenitic Stainless Steel. Various nitriding processes were conducted by changing temperature ($370^{\circ}C$ to $430^{\circ}C$) and changing $N_2$ percentage (10% to 25%) for 15 hours in the glow discharge environment of a gas mixture of $N_2$ and $H_2$ in a plasma nitriding system. In this process a constant pressure of 4 Torr was maintained. Increasing nitriding temperature from $370^{\circ}C$ to $430^{\circ}C$, increases the thickness of S phase layer and the surface hardness, and also makes an improvement in corrosion resistance, irrespective of nitrogen percent. On the other hand, increasing nitrogen percent from 10% to 25% at $430^{\circ}C$ decreases corrosion resistance although it increases the surface hardness and the thickness of S phase layer. Therefore, optimized condition was selected as nitriding temperature of $430^{\circ}C$ with 10% nitrogen, as at this condition, the treated sample showed better corrosion resistance. Moreover to further increase the thickness of S phase layer and surface hardness without compromising the corrosion behavior, further research was conducted by fixing the $N_2$ content at 10% with introducing various amount of $CH_4$ content from 0% to 5% in the nitriding atmosphere. The best treatment condition was determined as 10% $N_2$ and 5% $CH_4$ content at $430^{\circ}C$, where the thickness of S phase layer of about $17{\mu}m$ and a surface hardness of $980HV_{0.1}$ were obtained (before treatment $250HV_{0.1}$ hardness). This specimen also showed much higher pitting potential, i.e. better corrosion resistance, than specimens treated at different process conditions and the untreated one.

여기서는 오스테나이트 스테인리스강에 내구성능을 부여하기 위하여 여러 가지 공정온도 조건 중에서 플라즈마 이온질화 처리하여 질화층을 제작하였다. 이와같은 이온질화 층들에 대해서 형성기구를 해석함을 물론 경도, 마모 및 충격 시험들의 기계적 특성과 염수분무시험(Salt Spray Test), 침지 자연전위($E_{coor}$), 전기화학적 양분극 부식 특성을 평가하였다. 이들 층은 표면, 경화 깊이, 미세조직 및 결정구조를 분석하였고, 질화층 표면의 기계적 특성 및 부식 특성과의 상관관계를 해명-정리하였다.