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Article Citation - WoS: 123Citation - Scopus: 135Wire arc additive manufacturing of high-strength low alloy steels: study of process parameters and their influence on the bead geometry and mechanical characteristics(Springer London Ltd, 2020) Yildiz, Ahmet Suat; Davut, Kemal; Koc, Baris; Yilmaz, OguzhanAdditive manufacturing (AM) is becoming increasingly popular since it offers flexibility to produce complex designs with less tooling and minimum material at shorter lead times. Wire arc additive manufacturing (WAAM) is a variant of additive manufacturing which allows economical production of large-scale and high-density parts. The WAAM process has been studied extensively on different steels; however, the influence of process parameters, specifically wire feed speed (WFS), travel speed (TS), and their ratio on bead geometry, microstructure, and mechanical properties, are yet to be studied. The present work aims at closing this gap by using the WAAM process with robotic cold metal transfer (CMT) technology to manufacture high-strength structural steel parts. For that purpose, single-bead welds were produced from HSLA steel by varying WFS between 5 and 10 m/min and the WFS to TS ratio between 10 and 20. Those variations produce heat inputs in the range of 266-619 J/mm. The results have shown that the wire feed speed to travel speed ratio is the major parameter to control the heat input. Increasing heat input increases characteristic bead dimension, whereas it reduces the hardness. In the second part of experiments, two single-bead walls were deposited via the parallel deposition strategy and one multiple-bead wall was produced using the oscillation strategy. The tensile properties were tested along two directions: parallel and perpendicular to deposition directions. For the yield strength and tensile strength, the difference between horizontally and vertically tested specimens was smaller than the standard deviations. On the other hand, the total and uniform elongation values exhibit up to 10% difference in the test direction, indicating anisotropy in ductility. Those tensile properties were attributed to repeated thermal cycles during the WAMM process, which can cause heat transfer in multiple directions. The yield strength of the multiple-bead wall produced via oscillation was lower, whereas its ductility was higher. The tensile properties and hardness differences were found to correlate well with the microstructure.Article Microstructure-Based Prediction of Mechanical Properties of Austempered Ductile Iron Using Multiple Linear Regression Analysis(Springer Int Publ AG, 2025) Yalcin, M. Alp; Davut, KemalMultiple linear regression analysis (MLRA) was used to predict the mechanical properties of austempered ductile iron (ADI) including yield and tensile strength, uniform elongation, hardening exponent, as well as fracture energy by building a model that uses characteristic features of microstructural constituents as input parameters. The complex multi-scale microstructure of ADI, which is composed of spherical graphite particles over 10 mu m diameter; and an ausferritic matrix with sub-micron sized features, makes it ideal for prediction of mechanical properties. For that purpose, low alloyed ductile iron samples austempered between 300 and 400 degrees C for 45-180 min were tensile tested, and also multi-scale microstructural characterization were carried out using optical microscope, SEM, and EBSD technique. Moreover, a sensitivity analysis was performed to determine which microstructural parameter(s) each mechanical property is most sensitive to. The results show that tensile and yield strength are most sensitive to size and morphology of matrix phases. Moreover, the size and aspect ratio of acicular ferrite correlate well with those of high-carbon austenite; since both form during transformation of parent austenite into ausferrite during austempering treatment. Equiaxed parent austenite grains transform into ausferrite with acicular morphology during the austempering treatment; and presence of equiaxed austenite grains in the austempered samples indicates untransformed regions during austempering treatment. Ductility was found to be more sensitive to nodularity of graphite particles, and this sensitivity was attributed to the size difference between graphite particles and grain size of matrix phases.Article Citation - WoS: 1Citation - Scopus: 1Chemical Composition Optimization and Isothermal Transformation of Δ-Transformation Plasticity Steel for the Third-Generation Advanced High-Strength Steel Grade(Wiley-v C H verlag Gmbh, 2024) Okur, Onur; Davut, Kemal; Palumbo, Gianfranco; Nalcaci, Burak; Guglielmi, Pasquale; Yalcin, Mustafa Alp; Erdogan, MehmetA new low-manganese transformation-induced plasticity steel is designed with optimized nickel content to achieve superior strength and ductility while minimizing the use of expensive nickel. The steel is optimized using JMatPro software, then cast, and hot rolled. To assess the effect of intercritical annealing on austenite (martensite at room temperature) volume fraction and carbon content, hot-rolled steel samples quenched from different annealing temperatures (680-1100 degrees C) are used. Additionally, hot-rolled steel coupons are intercritically annealed at about 50% austenite formation temperature (740 degrees C) and then subjected to isothermal treatments at 300-425 degrees C for varying times (10-90 min). After optimizing these treatments to maximize retained austenite (RA), tensile specimens are heat-treated first at 740 degrees C and then isothermally at 325 degrees C. Thermodynamic calculations suggest that aluminum combined with silicon may lead to the delta ferrite formation, and even minimal nickel content can stabilize a considerable amount of austenite. In the experimental studies, it is shown that lower-temperature bainitic holding enhances austenite stability by enriching the carbon content. Optimized two-stage heat treatments yield up to 25.8% RA, with a tensile strength of 867.2 MPa and elongation of 40.6%, achieving a strength-elongation product of 35.2 GPax%, surpassing the third-generation advanced high-strength steel grades minimum requirement of 30 GPax%.
