Machinability enhancement by DEsigned MicrO-alloying (DEMO)

Important results from the project

The project aimed to develop a concept and methodology for achievement of improved machinability of metallic materials by designed micro-alloying and demonstrate it for one alloy. The micro-alloying should promote a reaction between the metal tool/coating material or the environment, and results in a controlled protective layer on a tool. The goal was completely fulfilled. The concept was demonstrated for 4 commercial alloys of the industrial partners (Outokumpu, Ovako, SMT). One more alloy for SRP Svedala was developed from scratch by using existent Mn-steel as a reference.

Expected long term effects

5 project deliverables covering experimental, modelling and dissemination were planned and achieved to a full extent. On the experimental side, testing procedures were developed for validating TPL formation (D1). Method of diffusion couples (D2) was developed for a control of tool-metal interaction. One manganese steel grade has been produced (D3) as a demonstrator. On the modelling side, an implementation framework has been developed with the use of Thermo-Calc and DICTRA software (D4). The results were made available via a series of publications, conferences, seminars (D5).

Approach and implementation

The project has developed both an understanding and created new methods to enhance machinability by micro-alloying. A combination of different methods and approaches was designed and used to accomplish the project goals. The implementation can be generalized into six methods: (1) Material casting, (2) Machining (including process monitoring and sensing, IR thermography, controlled environment and others), (3) High temperature tribology, (4) Diffusion couples, (5) Microscopy, spectroscopy and diffraction, and (6) Thermodynamic and kinetic modelling.