High Magnetic Field Processing - A Heat-Free Heat Treating Method (2012)

The High and Thermal Magnetic Processing/Electro-magnetic Acoustic Transducer (HTMP/EMAT) technology has been shown to be an enabling disruptive materials processing technology, that can achieve significant improvements in microstructure and consequently material performance beyond that achievable through conventional processing, and will lead to the next generation of advanced performance structural and functional materials. HTMP exposure increased the reaction kinetics enabling refinement of microstructural features such as finer martensite lath size, and finer, more copious, homogeneous dispersions of strengthening carbides leading to combined strength and toughness improvements in bainitic steels. When induction heating is applied in a high magnetic field environment, the induction heating coil is configured so that high intensity acoustic/ultrasonic treatment occurs naturally. The configuration results in a highly effective electromagnetic acoustical transducer (EMAT). HTMP combined with applying high-field EMAT, produce a non-contact ultrasonic treatment that can be used to process metal alloys in either the liquid state resulting in significant microstructural changes over conventional processing. Proof-of-principle experiments on cast irons resulted in homogeneous microstructures in small castings along with improved casting surface appearance. The experiment showed that by exposing liquid metal to the non-contact acoustic/ultrasonic processing technology developed using HMFP/EMAT wrought-like microstructures were developed in cast components. This Energy Intensive Processes (EIP) project sponsored by the DOE EERE Advanced Manufacturing Office (AMO) demonstrated the following: (1) The reduction of retained austenite in high carbon/high alloy steels with an ambient temperature HTMP process, replacing either a cryogenic or double tempering thermal process normally employed to accomplish retained austenite transformation. HTMP can be described as a 'heat-free', heat treating technology. Lower residual stresses in HTMP treated materials are anticipated since no thermal strains are involved in inducing the transformation of retained austenite to martensite in high alloy steel. (2) The simultaneous increase of 12% in yield strength and 22% in impact energy in a bainitic alloy using HTMP processing. This is a major breakthrough in materials processing for the next generation of structural materials since conventionally processed materials show a reduction in impact toughness with an increase in yield strength. HTMP is a new paradigm to beneficially increase both yield strength and impact energy absorption simultaneously. (3) HTMP processing refined both the martensite lath population and the carbide dispersion in a bainitic steel alloy during Gausstempering. The refinement was believed to be responsible for the simultaneous increase in strength and toughness. Hence, HTMP significantly impacts nucleation and growth phenomenon. (4) HTMP processing developed comparable ultimate tensile strength and twice the impact energy in a lower cost, lower alloy content ({approx}8% alloy content) steel, compared to highly alloyed, (31% alloy elements involving Ni, Co, and Mo) 250-grade margining steel. Future low-cost HTMP alloys appear viable that will exceed the structural performance of highly alloyed materials that are conventionally processed. This economic benefit will enable U.S. industry to reduce cost (better more competitive worldwide) while maintaining or exceeding current performance. (5) EMAT processed cast iron exhibits significantly higher hardness (by 51% for a 9T condition) than a no-field processed sample. (6) EMAT produced microstructures in cast iron resulted in an unique graphite nodule morphology, a modified pearlite content, and unique carbide types, that formed during solidification and cooling. (7) EMAT processed nanoparticle dispersions in Mg resulted in a very fine, unagglomerated distribution of the nanoparticles in the magnesium matrix. This provides a breakthrough technology to make the next generation of nanocomposite reinforced metal matrix composites which can be tailored to exhibit higher strength and ductility combinations not only at ambient temperature but at elevated temperatures where enhanced creep resistance is observed. This technology can be extended to non-metallic systems as long as a conductive containment vessel is utilized that will convey the EMAT signal into the material of interest during processing. (8) Facilitation of HTMP/EMAT technology commercialization, throughout the course of the project. Two technology limitations were overcome that led to the first generation commercial prototype HTMP/EMAT system which was initially installed at ORNL. (9) During this project, a production-scale equipment design to enable commercialization of HMFP technology was conceptualized, designed, fabricated, and installed at ORNL as a commercial-scale prototype system.