Les alliages à base de Nickel constituent les meilleurs matériaux actuellement développés pour répondre aux sollicitations sous hautes températures dans les domaines de l’aéronautique du nucléaire etc… L’objectif de ce travail de thèse est d’étudier leur comportement en température sous sollicitations de fretting usure. Dans cette étude, on s’intéresse à un contact René125/Waspaloy représentatif d’une application aéronautique. Dans un premier temps nous avons étudié l’effet de la température. On montre qu’à partir de 400°C, l’interface génère la formation d’une glaze layer lubrifiante qui réduit considérablement la cinétique de l’usure. En fixant la température à 700°C (température de l’application industrielle), nous avons étudié la stabilité de ces couches protectrices vis-à-vis de la pression de contact, de l’amplitude de glissement, de la fréquence et du nombre de cycle appliqués. Cette analyse montre une évolution bilinéaire de l’usure avec une usure initiale rapide liée à la formation de la « glaze layer » puis une usure additionnelle quasiment nulle dès que la « glaze layer » est formée. Ces travaux montrent que le volume d’usure associée à la formation de la « glaze layer » est fonction de la vitesse de glissement. Au dessus d’une vitesse seuil de glissement, la formation de la « glaze layer » protectrice devient plus difficile. Une courbe maîtresse est ainsi établie. Des analyses chimiques des interfaces associées à des essais interrompus ont permis d’établir le scénario de formation de ces glaze layers. Pour finir, une étude comparative des revêtements développés dans le cadre du projet INNOLUB a été menée de façon à sélectionner le revêtement offrant les meilleures propriétés tribologiques pour l’application étudiée. / Nickel based alloys are the most developed materials nowadays for applications at high temperature, as in aeronautics, nuclear…The aim of this study is to understand their behavior at high temperature under fretting wear solicitations. Thereby, we had focused on a tribosystem formed of Waspaloy/René 125, which represent the crankcase/blade contact of the low pressure Turbine. We started studying the temperature effect, it is been noticed that above T = 400°C, a lubricant tribofilm, called the Glaze Layer is generated at the interface of the contact, which enable an abrupt reduction in friction and wear rate. The temperature was than fixed at 700°C (service temperature), so the glaze layer stability was analyzed as a function of contact pressure, sliding amplitude, frequency and number of cycles imposed. This analysis shows a bilinear wear evolution, characterized by a fast initial wear related to the formation of the glaze layer, followed by almost no wear once the glaze layer is formed. This study showed that the wear rate related to the glaze layer formation is dependent of the sliding velocity. Above a sliding velocity threshold, the formation of a stabilized glaze layer is quite difficult. A Master curve is here established. Microscopic and spectroscopic investigations are conducted to analyze the interface based on interrupted tests of a very short duration. Leading to a precise description of the glaze layer formation mechanisms. At the end of this study, a comparative analysis of different coatings developed to improve these components behavior, in the framework of INNOLUB project was established, allowing choosing the coating offering the best tribological properties and lifetime.

Les superalliages monocristallins à base de nickel sont utilisés en aéronautique pour les aubes de turbines. Cette étude est consacrée à la modélisation du comportement en fluage du superalliage monocristallin AM1 après mise en radeaux, au cours d’essais isothermes à contrainte variable. Des diffractogrammes (200) ont été obtenus in situ par diffractométrie trois axes en rayonnement synchrotron, à haute température (950-1150°C) pour des paliers de contrainte entre 0 et 300MPa. Pour chaque phase, les déformations élastiques se déduisent de la position des pics et les contraintes, déformations plastiques et vitesses de déformation sont obtenues par la mesure du désaccord paramétrique, en utilisant un modèle composite en série. Ces résultats sont combinés à une caractérisation post mortem en microscopie électronique : morphologie des phases, densité et nature des dislocations. La mesure in situ du désaccord paramétrique donne accès à la densité instantanée de dislocations aux interfaces y/y’. Dans la phase ylors d’incréments de la contrainte appliquée, la contrainte de Von Mises augmente, puis se relaxe jusqu’à une contrainte seuil. Cette contrainte est en accord avec la contrainte d’Orowan et les largeurs des couloirs mesurées post mortem. La déformation plastique de la phase y’ est produite par montée de dislocations de vecteur de Burgers perpendiculaire à l’axe de traction sous l’action de la seule contrainte transverse et contrôlée par l’entrée de dislocations depuis les interfaces. Une simulation des pics de diffraction permet de reproduire l’évolution de leur largeur en fonction de la nature et de la répartition des dislocations aux interfaces et dans la phase y' / Nickel-based superalloys are used in aeronautics for turbine blades. This study aims at modelling the creep behaviour of single-crystalline AM1 superalloy with a rafted γ/γ’ microstructure during isothermal tests under variable applied stresses. (200) diffraction profiles are obtained with a triple crystal diffractometer and high energy synchrotron radiation at high temperature (950-1150°C) with an applied stress varying between 0 and 300 MPa. For each phase, the elastic strain is deduced from the peaks’ positions and the stress, plastic strain rate from the lattice mismatch, assuming a model lamellar composite material. Post mortem characterizations by electronic microscopy completes the results: morphology of each phase, dislocations densities and nature. The measurement of lattice mismatch leads to an in situ estimation of the dislocations’ density at the γ/γ’ interfaces. For the γ phase, during successive jumps of the applied stress, the Von Mises stress increases and then relaxes down to a threshold stress. This stress is in agreement with Orowan stress deduced from the post mortem measurements of the γ channels’ width. Plastic strain of the γ' phase is produced by climb of dislocations with Burgers’ vectors perpendicular to the tensile axis under the mere transversal stress and is controlled by the entrance of dislocations into the rafts from the interfaces. The distribution of elastic strains was simulated by assuming two main contributions: dislocations at the γ/γ’ interfaces and within the γ’ rafts. The simulation reproduces the absolute magnitude of the peaks’ width, as well as their increase with dislocation densities

<p>Modern structural materials utilize tailored microstructures to retain peak performance within the most volatile operating conditions. Features such as grain size, grain boundary (GB) character and morphology and secondary phases are just a few of the tunable parameters. By tailoring these types of microstructural features, the deformation behavior of the material is also altered. The localization of plastic strain directly correlated to material failure. Thus, a systematic approach was utilized to understand the effect of microstructural features on the localization of plastic deformation utilizing digital image correlation (DIC). First, at the macroscopic scale, strain accumulation is known to form parallel to the plane of maximum shear stress. The local deviations in the deformation pathways at the meso-scale are investigated relative to the plane of maximum shear stress. The deviations in the deformation pathways are observed to be a function of the accumulated local plastic strain magnitude and the grain size. Next, strains characterized via DIC were used to calculate a value of incremental slip on the active slip systems and identify cases of slip transmission. The incremental slip was calculated based on a Taylor-Bishop-Hill algorithm, which determined a qualitative assessment of deformation on a given slip system, by satisfying compatibility and identifying the stress state by the principle of virtual work. Inter-connected slip bands, between neighboring grains, were shown to accumulate more incremental slip (and associated strain) relative to slip bands confined to a single grain, where slip transmission did not occur. These results rationalize the role of grain clusters which lead to intense strain accumulation and thus serve as potential sites for fatigue crack initiation. Lastly, at GB interfaces, the effect of GB morphology (planar or serrated) on the cavitation behavior was studied during elevated temperature dwell-fatigue at 700 °C. The resulting γ′ precipitate structures were characterized near GBs and within grains. Along serrated GBs coarsened and elongated <a>γ′ </a>precipitates formed and consequently created adjacent regions that were denuded of γ′ precipitates. Dwell-fatigue experiments were performed at low and high stress amplitudes which varied the amount of imparted strain on the specimens.<a> Additionally, the regions denuded of the γ′ precipitates were observed to localize strain and to be initial sites of cavitation.</a> <a>These results present a quantitative strain analysis between two GB morphologies, which provided the micromechanical rationale for the increased proclivity for serrated GBs to form cavities.</a></p>

The thesis is focused on clarifying fatigue damage mechanisms and fatigue-creep damage mechanisms of MAR-M 247 and IN 713LC polycrystalline Ni-based superalloys. This thesis begins with basic information about nickel-based superalloys and their microstructure, followed by a description of fatigue and creep mechanisms and their mutual interaction. The next part contains experimentally obtained results describing the behavior of MAR-M 247 and IN 713LC superalloys under various sets of conditions. Three testing temperatures - 800, 900 and 950 °C were used for the measurement of fatigue properties under symmetrical loading cycle, because in the temperature range 800 – 950 °C, the mechanism of fatigue crack propagation of both superalloys should change from the originally crystallographic at "lower" temperatures (800 °C) to non-crystallographic at "higher" temperatures (950 °C). In addition the effect of processing technology on fatigue properties was studied on the superalloy IN 713LC. High-frequency cyclic loading (about 120 Hz) with high mean stress at elevated temperatures was applied to induce fatigue-creep interaction. The combined fatigue-creep loading was performed on the IN 713LC superalloy at 800 °C and on the MAR-M 247 superalloy at 900 °C.

In der vorliegenden Arbeit werden neuartige Co-Basislote entwickelt, welche zum Hochtemperaturlöten von Co-Basis-Superlegierungen eingesetzt werden können. Diese werden hinsichtlich ihres Schmelzverhaltens, ihrer Mikrostruktur und ihrer mechanischen Eigenschaften charakterisiert. Die wesentliche Herausforderung besteht in der Vermeidung von Sprödphasenbändern im Lötgut, welche die Eigenschaften der Verbindungen verschlechtern, auch bei großen Spaltbreiten. Hierzu wird ausgehend vom Stand der Wissenschaft und Technik wird ein Legierungskonzept erarbeitet und umgesetzt. Es werden Schmelztemperaturen im Bereich kommerzieller Co-Basislote erreicht ohne dass nachteilige Sprödphasenbänder gebildet werden. Bei den mit kommerziellen Loten besonders kritischen zu lötenden großen Spaltbreiten zeichnen sich die entwickelten Legierungen durch erhöhte Zugfestigkeit und Duktilität aus. Das Potenzial der Lote wird anhand von Zugversuchen bei geringen und großen Spaltbreiten aufgezeigt, deren Ergebnisse mit der Mikrostruktur und in-situ Analysen zum Rissfortschritt korreliert werden. / This thesis deals with the development of novel Co-based brazing fillers, which can be employed for brazing of Co-based superalloys. The developed filler alloys are characterized with regard to their microstructure and their mechanical properties. The main challenge is the prevention of brittle intermetallic phase seams inside the braze metal, especially at high gap width. These phase seams deteriorate the mechanical properties of the joints significantly. For this purpose a new alloying concept is investigated. The melting temperatures of the developed filler alloys are similar to commercially available Co based fillers. Detrimental intermetallic phase seams do not occur. At high gap width, the developed filler alloys exhibit superior mechanical properties in comparison to commercially available fillers. The capability of the developed filler alloys is demonstrated using monotonic tensile tests at low and high gap width at different test temperatures. The results are correlated with the microstructure and in-situ analyses of the mechanisms of crack growth.

<p>Ni-based superalloys continue to exert themselves as the industry standards in high stress and highly corrosive/oxidizing environments, such as are present in a gas turbine engine, due to their excellent high temperature strengths, thermal and microstructural stabilities, and oxidation and creep resistances. Gas turbine engines are essential components for energy generation and propulsion in the modern age. However, Ni-based superalloys are reaching their limits in the operating conditions of these engines due to their melting onset temperatures, which is approximately 1300 °C. Therefore, a new class of materials must be formulated to surpass the capabilities Ni-based superalloys, as increasing the operating temperature leads to increased efficiency and reductions in fuel consumption and greenhouse gas emissions. One of the proposed classes of materials is termed refractory complex concentrated alloys, or RCCAs, which consist of 4 or more refractory elements (in this study, selected from: Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, and W) in equimolar or near-equimolar proportions. So far, there have been highly promising results with these alloys, including far higher melting points than Ni-based superalloys and outstanding high-temperature strengths in non-oxidizing environments. However, improvements in room temperature ductility and high-temperature oxidation resistance are still needed for RCCAs. Also, given the millions of possible alloy compositions spanning various combinations and concentrations of refractory elements, more efficient methods than just serial experimental trials are needed for identifying RCCAs with desired properties. A coupled computational and experimental approach for exploring a wide range of alloy systems and compositions is crucial for accelerating the discovery of RCCAs that may be capable of replacing Ni-based superalloys. </p> <p>In this thesis, the CALPHAD method was utilized to generate basic thermodynamic properties of approximately 67,000 Al-bearing RCCAs. The alloys were then down-selected on the basis of certain criteria, including solidus temperature, volume percent BCC phase, and aluminum activity. Machine learning models with physics-based descriptors were used to select several BCC-based alloys for fabrication and characterization, and an active learning loop was employed to aid in rapid alloy discovery for high hardness and strength. This method resulted in rapid identification of 15 BCC-based, four component, Al-bearing RCCAs exhibiting room-temperature Vickers hardness from 1% to 35% above previously reported alloys. This work exemplifies the advantages of utilizing Integrated Computational Materials Engineering- and Materials Genome Initiative-driven approaches for the discovery and design of new materials with attractive properties.</p> <p> </p> <p><br></p>

Sanicro 28 and Alloy 625 are corrosion-resistant nickel alloys with a fully austenitic structure and a very low carbon content, which means they are both well suited for cold working. Since the millennium shift deformation twinning has been a live research issue as it enhances strength and ductility simultaneously. As nickel has been pointed out as a high stacking fault energy element and deformation twinning should be promoted by a low stacking fault energy level they have been considered as opposite poles. Nonetheless, it is known since long that deformation twins can emerge in high stacking fault face centred cubic elements at low temperatures. In this thesis, we have investigated deformation twinning behaviour in corrosion-resistant nickel alloys. The objective is trying to distinguish between deformation twinning in TWIP steel and corrosion resistant nickel alloys regarding for instance size and bundles. Interrupted uniaxial tensile tests have been performed at several cold working temperatures for the alloys: Sanicro 28 (31% nickel) and Alloy 625 (61% nickel). The microstructure has been characterized in homogeneous deformation volume, by scanning electron microscopy electron backscattering diffraction and electron channelling contrast imaging, transmission electron microscopy and X-ray diffraction. In one investigation fracture behaviour has also been studied with secondary electrons. Ab initio calculations, crystal plasticity modelling and DAMASK simulations have been performed to support emphasizing active deformation mechanisms. It has been revealed that deformation twinning can occur in high Ni alloys. With increasing deformation twinning levels, the diffuse necking decreases. Ab initio calculations indicates that the initiation of deformation twins cannot be determined solely by the stacking fault energy. Distinct features were discovered at low strains that could be rejected from being neither deformation twins nor stacking faults. Level of texture increases with increasing strain and decreasing temperature and the texture modes are changed with decreasing temperature. / Sanicro 28 och Alloy 625 är två legeringar med ett imponerande korrosionsmotstånd, ett lågt kolinnehåll och en helaustenitisk struktur. Det gör dem väl lämpade för kallbearbetning. Sedan millenieskiftet har aktivten varit mycket hög inom forskningsområdet: deformationstvillingar. TWIP (twinning induced plasticity)-effekten har den så eftertraktade egenskapen att både styrkan och duktiliteten förbättras på samma gång. Eftersom nickel har en hög staplingsfelsenergi och TWIP-effekten har uppmätts/beräknats till att aktiveras vid ett snävt och lågt värde, för densamma, har ett ökande nickelinnehåll och TWIP-effekten setts som direkta motpoler. Trots det, har man länge vetat om att deformationstvillingar också framträder, om än, vid låga temperaturer, i legeringar med kubiskt ytcentrerat gitter och hög staplingsfelsenergi. I den här avhandlingen har vi undersökt hur deformationstvillingar utvecklas, om de ens kan bildas i korrosionsbeständiga legeringar med ett högt nickelinnehåll. Målet är att se om det finns några större skillnader i tvillingbeteendet i TWIP-stål i jämförelse med korrosionsbeständiga legeringar med ett högt nickelinnehåll. Några egenskaper vi har tänkt att undersöka är: tjocklek på tvillingarna och om tvillingarna bildas i grupper. Vi hoppas på så sätt kunna svara på den övergripande forskningsfrågan: är det möjligt att designa ett rostfritt TWIP-stål, baserat på det vanligaste legeringssystemet för rostfria austenitiska stål, nämligen: järn-krom-nickel? Enaxliga dragprov har genomförts vid flera kallbearbetningstemperatuer; de har utförts både till brott och till förutbestämda töjningsnivåer. Legeringarna som har testats är: Sanicro 28 (31% nickel) och Alloy 625 (61% nickel). Mikrostrukturen har framför allt karakteriserats i material uttaget från volym där deformationen har varit homogen. De analysmetoder som har använts är: svepelektronmikroskopi, mer specifikt: ”electron backscatter diffraction” och ”electron channelling contrast imaging”. Transmissionselektronmikroskop och röntgendiffraktion har också använts. I en undersökning har också brottbeteende studerats med hjälp av "secondary electrons". Ab initioberäkningar, modellering av kristallplasticitet och materialbeteende med hjälp av DAMASK har också utförts för att kunna se vilka deformationsmekanismer som är aktiva. Vi upptäckte att deformationstvillingar faktiskt kan bildas i korrosionsbeständiga legeringar med ett högt nickelinnehåll. Den diffusa midjebildningen minskar på samma gång som andelelen deformationstvillingar ökar. Ab initioberäkningarnas resultat indikerar också på att deformationstvillingarnas inträde inte enbart kan bestämmas med staplingsfelsenergin. Tydliga mikrostrukturmönster upptäcktes med hjälp av transmissionsmiroskop och vid låga töjningsnivåer. De mikrostrukturmönstren kunde avfärdas från att vara både deformationstvillingar och staplingsfel. Texturnivån ökar med ökande töjningsnivå och sjunkande temperatur. Typen av textur förändras också med sjunkande temperatur. / <p>Funding agency: Tube division, Alleima AB</p>

Pesquisadores e indústrias de todo o mundo estão firmemente comprometidos com o propósito de fazer o processo de usinagem ser precisamente veloz e produtivo. A forte concorrência mundial gerou a procura por processos de usinagem econômicos, com grande capacidade de produção de cavacos e que produzam peças com elevada qualidade. Dentre as novas tecnologias que começaram a ser empregadas, e deve tornar-se o caminho certo a ser trilhado na busca da competitividade em curto espaço de tempo, está a tecnologia de usinagem com altas velocidades (HSM de High Speed Machining). A tecnologia HSM surge como componente essencial na otimização dos esforços para manutenção e aumento da competitividade global das empresas. Durante os últimos anos a usinagem com alta velocidade tem ganhado grande importância, sendo dada uma maior atenção ao desenvolvimento e à disponibilização no mercado de máquinas-ferramentas com rotações muito elevadas (20.000 - 100.000 rpm). O processo de usinagem com alta velocidade está sendo usado não apenas para ligas de alumínio e cobre, mas também para materiais de difícil usinabilidade, como os aços temperados e superligas à base de níquel. Porém, quando se trata de materiais de difícil corte, têm-se observado poucas publicações, principalmente no processo de torneamento. Mas, antes que a tecnologia HSM possa ser empregada de uma forma econômica, todos os componentes envolvidos no processo de usinagem, incluindo a máquina, o eixo-árvore, a ferramenta e o pessoal, precisam estar afinados com as peculiaridades deste novo processo. No que diz respeito às máquinas-ferramenta, isto significa que elas têm que satisfazer requisitos particulares de segurança. As ferramentas, devido à otimização de suas geometrias, substratos e revestimentos, contribuem para o sucesso deste processo. O presente trabalho objetiva estudar o comportamento de diversas geometrias ) de insertos de cerâmica (Al2O3 + SiCw e Al2O3 + TIC) e PCBN com duas concentrações de CBN na forma padrão, assim como modificações na geometria das arestas de corte empregadas em torneamento com alta velocidade em superligas à base de níquel (Inconel 718 e Waspaloy). Os materiais foram tratados termicamente para dureza de 44 e 40 HRC respectivamente, e usinados sob condição de corte a seco e com utilização da técnica de mínima quantidade de lubrificante (minimal quantity lubricant - MQL) visando atender requisitos ambientais. As superligas à base de níquel são conhecidas como materiais de difícil usinabilidade devido à alta dureza, alta resistência mecânica em alta temperatura, afinidade para reagir com materiais da ferramenta e baixa condutividade térmica. A usinagem de superligas afeta negativamente a integridade da peça. Por essa razão, cuidados especiais devem ser tomados para assegurar a vida da ferramenta e a integridade superficial de componentes usinados por intermédio de controle dos principais parâmetros de usinagem. Experimentos foram realizados sob diversas condições de corte e geometrias de ferramentas para avaliação dos parâmetros: força de corte, temperatura, emissão acústica e integridade superficial (rugosidade superficial, tensão residual, microdureza e microestrutura) e mecanismos de desgaste. Mediante os resultados apresentados, recomenda-se à geometria de melhor desempenho nos parâmetros citados e confirma-se a eficiência da técnica MQL. Dentre as ferramentas e geometrias testadas, a que apresentou melhor desempenho foi a ferramenta cerâmica CC650 seguida da ferramenta cerâmica CC670 ambas com formato redondo e geometria 2 (chanfro em T de 0,15 x 15º com raio de aresta de 0,03 mm). / Researchers and industry personnel around the world are firmly committed to the purpose of doing the machining process dramatically faster and more precise. The tough global competition has generated a search for more economical machining processes, with high ability for chip removal and, in this way, producing high quality workpieces. Among the new technologies available nowadays, the high speed machining (HSM) is pointed out as the main solution to obtain competitiveness in a short period of time. The HSM technology appears as an essential component to optimize the efforts for maintaining, and increasing, the global competitiveness. During the last years, high speed machining technology has received great attention, specially the development and availability in the market of machine tools with high rotational speeds (20.000 - 100.000 rpm). The HSM has been used not only to machine aluminum and copper alloys, but also to difficult to machine rnaterials, such as hardened steels and nickel based superalIoys. However, for difficult to machine materiais, the literature is very incipient, specially concerning the turning process. However, before the HSM technology be used in an economic way, alI the components involved in the machining process, including the machine, the spindle, the tool and the operators, need to be tuned with the peculiarities of this new process. Concerning the tooling, they have to satisfy peculiar requirements of safety. Due to the optimization of their geometries, substrates and coatings, the cutting tools are contributing to the success of the process. The present work aims at the study of several insert geometries of ceramic tools (Al2O3 + SiCw and Al2O3 + TiC) and PCBN, with two concentrations of CBN, in the standard format and with modifications on the cutting edge geometry, working in the high speed turning of nickel based superaIloys (lnconel 718 and Waspaloy]. MateriaIs were heat treated to hardness of 44 and 40 HRC, respectively, and machined under dry cutting condition and also with minimal quantity of lubricant (MQL) to attend environmental requirements. The nickel based superalloys are known as difficult to cut materials due to their high hardness, high mechanical strength at high temperature, chemical affinity to tool materiaIs and lower thermal conductivity. The machining of superalloys affects negatively the integrity of the workpiece. For this reason, tool life and surface integrity of the machined component must be carefully analyzed throughout the control of the main machining parameters. Practical experiments were implemented using several cutting conditions and tool geometries to evaluate the following parameters: cutting force, temperature, acoustic emission and surface integrity (surface finishing, residual stress, microhardeness and microstructure) and wear mechanisms. Analyzing the results, the most suitable geometry for the mentioned parameters is recommended and the efficiency of the MQL technical is confirmed. Among all inserts and geometries tested, the CC650 ceramic tool presented better results, followed by the CC670 ceramic tool, both with round format and edge geometry number 2 (chamfer in T 0,15 x 15° with hone of 0,03 mm).

Pesquisadores e indústrias de todo o mundo estão firmemente comprometidos com o propósito de fazer o processo de usinagem ser precisamente veloz e produtivo. A forte concorrência mundial gerou a procura por processos de usinagem econômicos, com grande capacidade de produção de cavacos e que produzam peças com elevada qualidade. Dentre as novas tecnologias que começaram a ser empregadas, e deve tornar-se o caminho certo a ser trilhado na busca da competitividade em curto espaço de tempo, está a tecnologia de usinagem com altas velocidades (HSM de High Speed Machining). A tecnologia HSM surge como componente essencial na otimização dos esforços para manutenção e aumento da competitividade global das empresas. Durante os últimos anos a usinagem com alta velocidade tem ganhado grande importância, sendo dada uma maior atenção ao desenvolvimento e à disponibilização no mercado de máquinas-ferramentas com rotações muito elevadas (20.000 - 100.000 rpm). O processo de usinagem com alta velocidade está sendo usado não apenas para ligas de alumínio e cobre, mas também para materiais de difícil usinabilidade, como os aços temperados e superligas à base de níquel. Porém, quando se trata de materiais de difícil corte, têm-se observado poucas publicações, principalmente no processo de torneamento. Mas, antes que a tecnologia HSM possa ser empregada de uma forma econômica, todos os componentes envolvidos no processo de usinagem, incluindo a máquina, o eixo-árvore, a ferramenta e o pessoal, precisam estar afinados com as peculiaridades deste novo processo. No que diz respeito às máquinas-ferramenta, isto significa que elas têm que satisfazer requisitos particulares de segurança. As ferramentas, devido à otimização de suas geometrias, substratos e revestimentos, contribuem para o sucesso deste processo. O presente trabalho objetiva estudar o comportamento de diversas geometrias ) de insertos de cerâmica (Al2O3 + SiCw e Al2O3 + TIC) e PCBN com duas concentrações de CBN na forma padrão, assim como modificações na geometria das arestas de corte empregadas em torneamento com alta velocidade em superligas à base de níquel (Inconel 718 e Waspaloy). Os materiais foram tratados termicamente para dureza de 44 e 40 HRC respectivamente, e usinados sob condição de corte a seco e com utilização da técnica de mínima quantidade de lubrificante (minimal quantity lubricant - MQL) visando atender requisitos ambientais. As superligas à base de níquel são conhecidas como materiais de difícil usinabilidade devido à alta dureza, alta resistência mecânica em alta temperatura, afinidade para reagir com materiais da ferramenta e baixa condutividade térmica. A usinagem de superligas afeta negativamente a integridade da peça. Por essa razão, cuidados especiais devem ser tomados para assegurar a vida da ferramenta e a integridade superficial de componentes usinados por intermédio de controle dos principais parâmetros de usinagem. Experimentos foram realizados sob diversas condições de corte e geometrias de ferramentas para avaliação dos parâmetros: força de corte, temperatura, emissão acústica e integridade superficial (rugosidade superficial, tensão residual, microdureza e microestrutura) e mecanismos de desgaste. Mediante os resultados apresentados, recomenda-se à geometria de melhor desempenho nos parâmetros citados e confirma-se a eficiência da técnica MQL. Dentre as ferramentas e geometrias testadas, a que apresentou melhor desempenho foi a ferramenta cerâmica CC650 seguida da ferramenta cerâmica CC670 ambas com formato redondo e geometria 2 (chanfro em T de 0,15 x 15º com raio de aresta de 0,03 mm). / Researchers and industry personnel around the world are firmly committed to the purpose of doing the machining process dramatically faster and more precise. The tough global competition has generated a search for more economical machining processes, with high ability for chip removal and, in this way, producing high quality workpieces. Among the new technologies available nowadays, the high speed machining (HSM) is pointed out as the main solution to obtain competitiveness in a short period of time. The HSM technology appears as an essential component to optimize the efforts for maintaining, and increasing, the global competitiveness. During the last years, high speed machining technology has received great attention, specially the development and availability in the market of machine tools with high rotational speeds (20.000 - 100.000 rpm). The HSM has been used not only to machine aluminum and copper alloys, but also to difficult to machine rnaterials, such as hardened steels and nickel based superalIoys. However, for difficult to machine materiais, the literature is very incipient, specially concerning the turning process. However, before the HSM technology be used in an economic way, alI the components involved in the machining process, including the machine, the spindle, the tool and the operators, need to be tuned with the peculiarities of this new process. Concerning the tooling, they have to satisfy peculiar requirements of safety. Due to the optimization of their geometries, substrates and coatings, the cutting tools are contributing to the success of the process. The present work aims at the study of several insert geometries of ceramic tools (Al2O3 + SiCw and Al2O3 + TiC) and PCBN, with two concentrations of CBN, in the standard format and with modifications on the cutting edge geometry, working in the high speed turning of nickel based superaIloys (lnconel 718 and Waspaloy]. MateriaIs were heat treated to hardness of 44 and 40 HRC, respectively, and machined under dry cutting condition and also with minimal quantity of lubricant (MQL) to attend environmental requirements. The nickel based superalloys are known as difficult to cut materials due to their high hardness, high mechanical strength at high temperature, chemical affinity to tool materiaIs and lower thermal conductivity. The machining of superalloys affects negatively the integrity of the workpiece. For this reason, tool life and surface integrity of the machined component must be carefully analyzed throughout the control of the main machining parameters. Practical experiments were implemented using several cutting conditions and tool geometries to evaluate the following parameters: cutting force, temperature, acoustic emission and surface integrity (surface finishing, residual stress, microhardeness and microstructure) and wear mechanisms. Analyzing the results, the most suitable geometry for the mentioned parameters is recommended and the efficiency of the MQL technical is confirmed. Among all inserts and geometries tested, the CC650 ceramic tool presented better results, followed by the CC670 ceramic tool, both with round format and edge geometry number 2 (chamfer in T 0,15 x 15° with hone of 0,03 mm).

<p>  </p> <p>There has been a growing interest within the aerospace industry for shifting towards a digital twin approach, for reliable assessment of individual components during the product lifecycle - across design, manufacturing, and in-service maintenance, repair & overhaul (MRO) stages. The transition towards digital twins relies on continuous updating of the product lifecycle datasets and interoperable exchange of data applicable to components, thereby permitting engineers to utilize current state information to make more-informed downstream decisions. In this thesis, we primarily develop a framework to store, track, update, and retrieve product lifecycle data applicable to a serialized component, its features, and individual locations. </p> <p>From a structural integrity standpoint, the fatigue performance of a component is inherently tied to the component geometry, its material state, and applied loading conditions. The manufacturing process controls the underlying material microstructure, which in turn governs the mechanical properties and ultimately the performance. The processing also controls the residual stress distributions within the component volume, which influences the durability and damage tolerance of the component. Hence, we have demonstrated multiple use cases for fatigue life assessment of critical aerospace components, by using the developed framework for efficiently tracking and retrieving (i) the current geometric state, (ii) the material microstructure state, and (iii) residual stress distributions.</p> <p>Model-based definitions (MBDs) present opportunities to capture both geometric and non-geometric data using 3D computer-aided design (CAD) models, with the overarching aim to disseminate product information across different stages of the lifecycle. MBDs can potentially eliminate error-prone information exchange associated with traditional paper-based drawings and improve the fidelity of component details, captured using 3D CAD models. However, current CAD capabilities limit associating the material information with the component’s shape definition. Furthermore, the material attributes of interest, viz., material microstructures and residual stress distributions, can vary across the component volume. To this end, in the first part of the thesis, we implement a CAD-based tool to store and retrieve metadata using point objects within a CAD model, thereby creating associations to spatial locations within the component. The tool is illustrated for storage and retrieval of bulk residual stresses developed during the manufacturing of a turbine disk component, acquired from process modeling and characterization. Further, variations in residual stress distribution owing to process model uncertainties have been captured as separate instances of the disk’s CAD models to represent part-to-part variability as an analogy to track individual serialized components for digital twins. The propagation of varying residual stresses from these CAD models within the damage tolerance analysis performed at critical locations in the disk has been demonstrated. The combination of geometric and non-geometric data inside the MBD, via storage of spatial and feature varying information, presents opportunities to create digital replica or digital twin(s) of actual component(s) with location-specific material state information.</p> <p>To fully realize a digital twin description of components, it is crucial to dynamically update information tied to a component as it evolves across the lifecycle, and subsequently track and retrieve current state information. Hence, in the second part of the thesis, we propose a dynamic data linking approach to include material information within the MBDs. As opposed to storing material datasets directly within the CAD model in the previous approach, we externally store and update the material datasets and create data linkages between material datasets and features within the CAD models. To this end, we develop a model-based feature information network (MFIN), a software agnostic framework for linking, updating, searching, and retrieving of relevant information across a product’s lifecycle. The use case of a damage tolerance analysis for a compressor bladed-disk (blisk) is demonstrated, wherein Ti-6Al-4V blade(s) are linear friction welded to the Ti-6Al-4V disk, comprising well-defined regions exhibiting grain refinement and high residuals stresses. By capturing the location-specific microstructural information and residual stress fields at the weld regions, this information was accessed within the MFIN and used for downstream damage tolerant analysis. The introduction of the MFIN framework facilitates access to dynamically evolving as well as location-specific data for use within physics-based models.</p> <p>In the third part of thesis, we extend the MFIN framework to enable a physics-based, microstructure sensitive and location-specific fatigue life analysis of a component. Traditionally, aerospace components are treated as monolithic structures during lifing, wherein microstructural information at individual locations are not necessarily considered. The resulting fatigue life estimates are conservative and associated with large uncertainty bounds, especially in components with gradient microstructures or distinct location-specific microstructures, thereby leading to under usage of the component’s capabilities. To improve precision in the fatigue estimates, a location-specific lifing framework is enabled via MFIN, for tracking and retrieval of microstructural information at distinct locations for subsequent use within a crystal plasticity-based fatigue life prediction model. A use case for lifing dual-microstructure heat treated LSHR turbine disk component is demonstrated at two locations, near the bore (fine grains) and near the rim (coarse grains) regions. We employ the framework to access (a) the grain size statistics and (b) the macroscopic strain fields to inform precise boundary conditions for the crystal plasticity finite-element analysis. The illustrated approach to conduct a location-specific predictive analysis of components presents opportunities for tailoring the manufacturing process and resulting microstructures to meet the component’s targeted requirements.</p> <p>For reliably conducting structural integrity analysis of a component, it is crucial to utilize their precise geometric description. The component geometries encounter variations from nominal design geometries, post manufacturing or after service. However, traditionally, stress analyses are based on nominal part geometries during assessment of these components. In the last part of the thesis, we expand the MFIN framework to dynamically capture deviations in the part geometry via physical measurements, to create a new instance of the CAD model and the associated structural analysis. This automated workflow enables engineers for improved decision-making by assessing (i) as-manufactured part geometries that fall outside of specification requirements during the materials review board or (ii) in-service damages in parts during the MRO stages of the lifecycle. We demonstrate a use case to assess the structural integrity of a turbofan blade that had experienced foreign object damage (FOD) during service. The as-designed geometry was updated based on coordinate measurements of the damaged blade surfaces, by applying a NURBS surface fit, and subsequently utilized for downstream finite-element stress analysis. The ramifications of the FOD on the local stresses within the part are illustrated, providing critical information to the engineers for their MRO decisions. The automated flow of information from geometric inspection within structural analysis, enabled by MFIN, presents opportunities for effectively assessing products by utilizing their current geometries and improving decision-making during the product lifecycle.</p>