Acoustic Emission Monitoring of Ultra-Fast Low Energy Ceramization and Thermite Reaction for Ultra High Strength Steel Processing

Document Type : Original Article

Authors

1 Ph.D. Postgraduate, Benha College of Engineering, Benha University, Egypt.

2 Professor of Engineering, German University in Cairo (GUC).

3 Staff members, Benha College of Engineering, Benha University, Egypt.

10.1088/1742-6596/3058/1/012011

Abstract

This study explores the application of an ultra-fast ceramization process to enhance the performance of ultra-high-strength steels (UHSS), specifically Mn-Al steel (S-52), crucial for aerospace and automotive applications. The aim is to achieve an optimal balance between strength and ductility through in-situ synthesis of a borate glass ceramic cladding. A thermite-driven fusion reaction, conducted in an induction furnace at 220°C for 30 minutes utilizing a waveguide and
powder pack, facilitated the ceramization. The kinetics of this thermochemical process, including alloy segregation and phase transformations, were monitored through acoustic emission and thermal imaging. Microstructural characterization using scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDX) elucidated the reaction mechanism, revealing five sequential stages. The process involved localized melting and alloy segregation, followed by stress-induced two-phase transformation; a thermite reaction resulted in material defragmentation, while twinning
and recrystallization contributed to the formation of specific microstructural features, culminating in the development of a robust ceramic/metal interface achieved through both chemical and mechanical bonding. The correlation between these stages and acoustic and thermal data provides a comprehensive understanding of the ceramization kinetics and interface formation. Acoustic emission events characteristics: count, count rate, amplitude, duration, energy, rise time and
frequency are captured and correlated with SEM and thermal imaging. Acoustic characterizations are also captured for ultra-high strength steel with total 1,048,576 signal by 2324 microseconds in 30 mins.

Keywords

The International Conference on Applied Mechanics and Mechanical Engineering
Volume 22, Issue 22
22nd International Conference on Applied Mechanics & Mechanical Engineering, AMME-22
2025
Pages 1-11

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