Charles Witness Siyasiya

There is a lack of knowledge regarding the effects of different film-pressure distribution modes associated with the abnormal appearance of the viscosity wedge effect (VWE) and squeeze effect in hard elastohydrodynamic lubrication (EHL) contacts. This study investigates and demonstrates three characteristic film-pressure distribution modes which are caused by the appearance of a collaboration between the VWE and squeeze effect, as well as the corresponding friction, wear and temperature characteristics, in hard EHL contacts. Pure sliding EHL experiments are conducted using a wear test machine with an oscillatory sliding ball-on-flat configuration. The sliding conditions selected ensured that each film-pressure generating mechanism appearing in the EHL contact area generates enough film-pressure to induce sliding contact fatigue (SCF), which appears in a form of plastic deformation, on the sliding surfaces. Analysis of SCF behaviour reveals the appearance of a collaboration between the VWE and squeeze effect, as well as three distinct film-pressure distribution modes associated with this collaboration. The film-pressure distribution modes are categorized as i.e., type A, type B and type C, based on the position and magnitude of the inlet dimple (a characteristic trait of the VWE) in the EHL contact area. Each pressure distribution mode demonstrates distinct friction, wear rate and temperature characteristics, which indicates a strong dependence of friction, wear and temperature behaviour on the position and magnitude of the inlet dimple. It is not clear whether the position and magnitude of the inlet dimple is influenced by the composition of the lubricant or surface roughness effects.

1. AbstractBuilding on the background of micro-alloyed weathering steel applications, this paper utilised cyclic corrosion testing to simulate industrial atmospheric conditions and investigated two types of weathering steel with different phosphorus contents subjected to various heat treatment processes i.e., thermomechanical processing (TMCP), annealing, and normalising. The results indicate that the rust layer of weathering steel is primarily composed of α-FeOOH, γ-FeOOH, and Fe3O4/γ-Fe2O3, with small amounts of sulphates. Comparing TMCP and annealed steels to TMCP, annealed, and normalized steels, the latter is the optimal process for enhancing the corrosion resistance of both weathering steels investigated in this work. Furthermore, as the phosphorus content increases, the influence of the processing condition on the corrosion rate is significantly reduced.

The South African aluminium industry faces technical challenges related to cladded ingots used in automotive heat exchangers, creating a need for offline processing methods that can replicate rolling processes like roll bonding, as large-scale industrial trials are costly and difficult to control. To address this, Mintek established a comprehensive offline manufacturing facility for process and product development of rolled metal products, focusing on the thermomechanical processing of aluminium alloys. In this study, stacked AA4045/AA3003mod coupons were processed under controlled conditions by varying thickness reduction, temperature, and reheating, aiming to investigate the effect of isothermal soaking time on microstructure and mechanical properties. Tensile tests were performed on clad sheets before and after brazing heat treatment, and fracture surfaces were examined via scanning electron microscopy. Samples heated at 505 °C for ≥38 h, followed by cold rolling and annealing, fell at the lower end of the 9031-H24 specification for yield strength, which is important for this application (i.e., the minimum tensile yield strength of 145 MPa and the ultimate tensile strength (UTS) range of 190 to 230 MPa). Fracture surface analysis revealed a dimple-dominated structure in cold-rolled and annealed samples, indicating ductile fracture. The study concludes that the offline roll-bonding method successfully replicates industrial cladding processes, and that isothermal soaking duration significantly influences mechanical performance, though careful control of thermal exposure is necessary to meet the specified mechanical properties.

The fabrication of NiTiZr alloys by solid-state routes remains challenging due to limited atomic diffusion and the high reactivity of Ti and Zr. Mechanical alloying offers a potential pathway for synthesising such systems; however, complete alloy formation is not always achieved under practical milling conditions. Researchers have infrequently explored the mechanical alloying of NiTiZr, and this study systematically investigates the effect of milling time on microstructural evolution rather than claiming complete alloy synthesis. A high-energy planetary ball mill was used to mechanically process elemental powders of Ni, Ti, and Zr for 5–28 h. The examination revealed that longer milling times resulted in progressive crystallite refinement and increased lattice strain, while particle morphology evolved from irregular to more globular shapes due to repeated fracture and cold welding. After 28 h of milling, limited reacted regions containing Ni, Ti, and Zr were observed (~4.6% area fraction), while most of the powder remained heterogeneous and polyphasic, with no evidence of complete Ni₅₀Ti₃₀Zr₂₀ alloy formation. X-ray diffraction showed significant peak broadening without systematic 2θ peak shifts, indicating severe plastic deformation and crystallite refinement rather than definitive solid-solution formation of the allot. Differential scanning calorimetry revealed exothermic thermal events between 300 °C and 470 °C, which are attributed to defect recovery and thermally activated structural rearrangements rather than confirmed martensitic or crystallisation transformations. These results demonstrate that high-energy ball milling alone is effective for particle size reduction and defect generation but insufficient for producing a fully homogeneous Ni₅₀Ti₃₀Zr₂₀ alloy within 28 h. Additional activation energy, such as post-milling heat treatment or extended processing, is required to promote complete alloying in this system.

Ferritic stainless steels (FSSs) are viable alternatives to nickel containing austenitic stainless steels. The AISI 436 FSS grade is fully ferritic at all temperature ranges, and therefore, grain refinement can only be achieved through controlling inclusions during solidification and/or recrystallization. In this work, the effects of strain and inter-pass time on the restoration behavior of 436 were systematically investigated using the Gleeble 1500 thermomechanical processing simulator. The aim of the study was to promote the accumulation of strain by delaying recrystallization during roughing rolling simulation to improve the driving force for recrystallization during finishing rolling simulation at lower temperature. Three roughing rolling schedules were designed, i.e., the first simulated the existing industry practice (Control), the second with increased inter-pass time (INT) and the last with both increased inter-pass time and strain per pass (INT + S). Roughing and finishing were each simulated in three-passes, amounting to a total of six-passes. The SEM-EBSD results revealed that the Control and INT schedules resulted in higher strain localization, particularly around particles. On the contrary, the increased inter-pass times and strains (INT + S) led to less strain accumulation. Annealing after roughing rolling simulation led to the nucleation of fine grains in the Control, which suggests that delaying finishing rolling would promote recrystallization and the breakdown of the cast structure.

AISI 301LN metastable austenitic stainless steels (MASSs) are known to exhibit high work‐hardening rates attributed to martensite evolution during straining which results in the second‐phase strengthening mechanism. This enhances surface hardness and potentially reduces wear and rolling contact fatigue (RCF). The aim of this study is therefore to evaluate the work hardening, wear, and RCF performance of AISI 301LN metastable austenitic stainless steel as a possible alternative material for rolling and sliding applications by varying the contact conditions such as slip ratio against the standard R350HT rail steel using a twin‐disc simulator. The results show that 301LN MASS has high surface work hardening and increased hardness because of martensitic transformation, while R350HT rail steel has only slightly changed. The formation of a hard martensitic phase is also confirmed by X‐ray diffraction analysis as well as by two other techniques, indicating a secondary hardening effect. Although it shows potential for work hardening, its susceptibility to wear‐related problems may make it less suitable for rolling and sliding applications due to a cracking and spalling mechanism induced by martensite formation. The surface strains required for the observed martensite formation are calculated and found to be very high, approaching 0.4.

Nb-Ti high-strength low-alloy pipeline steel was subjected to a six-pass rolling process followed by the coiling process at different temperatures between 600 and 650 °C using the thermo-mechanical testing system Gleeble 3500 (Gleeble, New York, NY, USA). This experimental steel was subjected to 72% heavy reduction through a thermos-mechanical controlled process. Thereafter, the microstructures were observed using optical microscopy, scanning electron microscopy, electron backscatter scanning diffraction, and transmission electron microscopy coupled with energy dispersive spectrometry and selected area electron diffraction. For the selected three coiling temperatures of 600, 625, and 650 °C, acicular ferrite, polygonal ferrite, and pearlite were observed, and morphology and statistical analysis were adopted for the study of precipitates. Based on the estimation by the Ashby–Orowan formula, the incremental strength through precipitation strengthening decreases with coiling temperatures and reaches 26.67 Mpa at a coiling temperature of 600 °C. Precipitation-time-temperature curves were obtained to explain the transformation of precipitates. The (Nb, Ti)(C, N) particles tended to precipitate in the acicular ferrite with [011]_{(Nb, Ti)(C, N)}//[011]_α-Fe orientation. The lower coiling temperature provided enough driving force for the nucleation of precipitates while inhibiting their growth.

Due to the rising need for energy saving, high-performing automotive heat exchangers, demand has significantly grown in recent years. As a result, effective fin-tube heat exchangers are becoming more popular. These tubes are typically made by rolling flat strips of AA3003 aluminum alloys that have either one or both sides coated with AA4xxx alloys. The AA3003 type of alloy is typically used as the core, which is then covered in either AA4045 or AA4343, which melts during the brazing process to adhere the fins to the tubes. To maintain the optimal size and distribution of manganese (Mn)-containing precipitates, preheating parameters are carefully controlled. Then, longer soaking times or higher soaking temperatures result in larger precipitates, which cause the final product to exhibit poor mechanical properties. Therefore, it is crucial to optimize the different manufacturing steps, such as homogenization, soaking time, and brazing in order to achieve a high quality product. Studies on the impact of homogenization temperature and time on the microstructure of AA3xxx aluminum alloys have been conducted. However, there has been little research on the impact of soaking (reheating) time on AA3003 cladded alloys. Hence, the effects of isothermal soaking time on the microstructure and mechanical properties of AA3003 cladded with AA4045 alloy were investigated in this work. Optical microscopy (OM) and scanning electron microscopy (SEM) were used to characterize the microstructure and identify intermetallic phases. The final microstructure in terms of grain structure at various homogenization times was characterized by electron backscattered diffraction (EBSD). After the hot-rolling and cold-rolling of the as-received material, large particles of intermetallic (mainly in the form of Chinese script morphology consisting of Fe-Mn-Si) were broken into smaller particles with an increased Fe, Mn, and Si content, indicating the formation of an α-Al(Fe,Mn)Si phase. The α-Al(Mn,Fe)Si was found to be a dominant dispersoid precipitate in the modified AA3003 core. Coarsening of the Al(Mn,Fe)Si dispersoids at 505 °C was only observed at a 45 h homogenization time. The hardness trend with homogenization time was found to be similar to that after homogenization, cold working, and annealing, with exception of an increase in hardness in the latter possibly due to strain hardening (from cold-rolling).