Effects of Billet Preheating Temperature on the Microstructure and Operational Reliability of Hot-Forged C45 Steel Horns

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Abstract
This study examined the effect of billet preheating temperature ranging from 1220 to 1275 oC on the microstructure and performance of C45 steel ultrasonic horns. Six samples were fabricated and evaluated for microstructure and ultrasonic performance at 28 kHz through DEFORM-3D simulations and experimental forging trials. The unforged sample (Horn 1) exhibited the highest Qm (3,434), reflecting minimal energy loss under free resonance conditions. However, it failed during ultrasonic operation due to severe local heating and burning at the horn belly, indicating poor thermal reliability. The sample forged at 1,266 oC (Horn 5) showed refined, Dynamically Recrystallized (DRX) microstructures with reduced anisotropy and stable resonance frequencies close to 28 kHz. These results confirm that billet heating temperature strongly governs both microstructural evolution and acoustic behavior. The optimal preheating temperature of 1266 °C ensures a refined, homogeneous microstructure that provides the necessary mechanical integrity and thermal stability for reliable ultrasonic horn operation.

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