O uso de revestimentos protetores consiste na alternativa mais utilizada para a eliminação ou diminuição dos processos corrosivos nos aços, bem como no alumínio e suas ligas, que apresentam uma ampla gama de aplicações, principalmente na indústria aeronáutica, devido à alta razão resistência/peso e, cujas vidas úteis podem ser comprometidas pela corrosão. Neste trabalho foram produzidos revestimentos a base de sílica e titânia obtidos pelo processo sol-gel em substratos constituídos de aço AISI 1045 e liga de alumínio AA7075, para a proteção à corrosão em ambiente salino. As amostras foram revestidas por imersão (dip-coating) utilizando-se dois tipos de soluções compostas por Tetraetil-Ortosilicato (TEOS) mais 3-Trimetoxisilil-Propil-Metacrilato (TMSPM) (S1) e por Isopropóxido de Titânio (IPT) mais 3-Trimetoxisilil-Propil-Metacrilato (TMSPM) (S2). Tais amostras foram previamente submetidas a pré-tratamentos a 50°C durante 8 horas, para a evaporação dos compostos voláteis e curadas a 60, 100 e a 130°C, por 1, 2 e 3 horas em cada temperatura. As caracterizações foram realizadas por microscopias óptica e eletrônica de varredura, riscamento e ensaios de polarização potenciodinâmicas em NaCl (3,5%). Foram obtidos revestimentos homogêneos em ambos os substratos, que resultaram em todos os casos um grande aumento na resistência à corrosão, em comparação com os respectivos substratos. Os revestimentos curados na temperatura superior (130°C) foram os mais resistentes ao riscamento e proporcionaram as melhores resistências à corrosão em ambos os substratos. / Protective coatings are the most widely used alternative to control the corrosive processes in steel and aluminum alloys. These material exhibit a wide range of applications, especially in the aircraft industry due to the high strength/weight ratio but their performance can be compromised by corrosion. In this work silica and titania based coatings were produced by a sol-gel process and applied on AISI 1045 steel and AA7075 aluminum alloy substrates, seeking for corrosion protection in a saline environment. The samples were coated by dipping using two types of solutions: a) a mix of tetraethyl orthosilicate (TEOS) with 3-trimethoxysilyl-propyl methacrylate (TMSPM) (S1) and b) a mix of titanium isopropoxide (IPT) with 3 -Trimetoxisilil-Propyl methacrylate (TMSPM) (S2). The samples were then subjected to a pre-treatment at 50°C for 8 hours to evaporate the volatile compounds and then cured at 60, 100 and 130°C for 1, 2 and 3 hours at each temperature. The samples were characterized by optical and scanning electron microscopy, scratching tests and potentiodynamic polarization tests in NaCl (3.5%). Both solutions produced homogeneous coatings on both substrates, resulting in a large increase in the corrosion resistances, when compared to the respective substrates. Coatings cured at highest temperature (130°C) were the most scratch resistance and provided the best corrosion resistance in both substrates.

O uso de revestimentos protetores consiste na alternativa mais utilizada para a eliminação ou diminuição dos processos corrosivos nos aços, bem como no alumínio e suas ligas, que apresentam uma ampla gama de aplicações, principalmente na indústria aeronáutica, devido à alta razão resistência/peso e, cujas vidas úteis podem ser comprometidas pela corrosão. Neste trabalho foram produzidos revestimentos a base de sílica e titânia obtidos pelo processo sol-gel em substratos constituídos de aço AISI 1045 e liga de alumínio AA7075, para a proteção à corrosão em ambiente salino. As amostras foram revestidas por imersão (dip-coating) utilizando-se dois tipos de soluções compostas por Tetraetil-Ortosilicato (TEOS) mais 3-Trimetoxisilil-Propil-Metacrilato (TMSPM) (S1) e por Isopropóxido de Titânio (IPT) mais 3-Trimetoxisilil-Propil-Metacrilato (TMSPM) (S2). Tais amostras foram previamente submetidas a pré-tratamentos a 50°C durante 8 horas, para a evaporação dos compostos voláteis e curadas a 60, 100 e a 130°C, por 1, 2 e 3 horas em cada temperatura. As caracterizações foram realizadas por microscopias óptica e eletrônica de varredura, riscamento e ensaios de polarização potenciodinâmicas em NaCl (3,5%). Foram obtidos revestimentos homogêneos em ambos os substratos, que resultaram em todos os casos um grande aumento na resistência à corrosão, em comparação com os respectivos substratos. Os revestimentos curados na temperatura superior (130°C) foram os mais resistentes ao riscamento e proporcionaram as melhores resistências à corrosão em ambos os substratos. / Protective coatings are the most widely used alternative to control the corrosive processes in steel and aluminum alloys. These material exhibit a wide range of applications, especially in the aircraft industry due to the high strength/weight ratio but their performance can be compromised by corrosion. In this work silica and titania based coatings were produced by a sol-gel process and applied on AISI 1045 steel and AA7075 aluminum alloy substrates, seeking for corrosion protection in a saline environment. The samples were coated by dipping using two types of solutions: a) a mix of tetraethyl orthosilicate (TEOS) with 3-trimethoxysilyl-propyl methacrylate (TMSPM) (S1) and b) a mix of titanium isopropoxide (IPT) with 3 -Trimetoxisilil-Propyl methacrylate (TMSPM) (S2). The samples were then subjected to a pre-treatment at 50°C for 8 hours to evaporate the volatile compounds and then cured at 60, 100 and 130°C for 1, 2 and 3 hours at each temperature. The samples were characterized by optical and scanning electron microscopy, scratching tests and potentiodynamic polarization tests in NaCl (3.5%). Both solutions produced homogeneous coatings on both substrates, resulting in a large increase in the corrosion resistances, when compared to the respective substrates. Coatings cured at highest temperature (130°C) were the most scratch resistance and provided the best corrosion resistance in both substrates.

This thesis presents the application of topology to machining at the micro and macro levels through an experimental study, modeling and analysis. Uncoated carbide tools of four different cutting edge radii and four different feed rates are used to perform orthogonal machining on AISI 1045 steel disks. The study analyzes the cutting forces, changing grain boundary parameters, micro-hardness, temperature and correlates them to the residual stresses that hold a key to the product life. This analysis helps to understand and evaluate the aspects of grain boundary engineering that influence the fatigue life of a component. The two components of residual stresses (axial and circumferential) are measured, and are correlated with the different cutting edge radii and feed conditions. A topology-based modeling approach is applied to study and understand various outputs in the machining process. The various micro and macro topological parameters that influence the machining process are studied to develop a model to establish the effects of topological parameters in machining using Maple program.

Forging is a metal forming process which involves non-linear deformations. Finite element and finite volume software programs are commonly used to simulate the process. In these simulations, material properties are required. However, stress-strain relations of the materials at some elevated temperatures are not available in the material libraries of the related software programs. In this study, the stress-strain curves have been obtained by applying the Cook and Larke Simple Compression Test to AISI 1045 steel at several temperatures on a forging press with a capacity of 1000 tons. The stress-strain curves have also been determined by simulating the processes in a commercial finite element software. It is observed that experimental results are consistent with the numerical ones. A modular die set has been designed and manufactured to conduct the Cook and Larke Simple Compression Test. It has been shown that the forging press with data acquisition system can be used as a material testing equipment to obtain stress-strain curves.

<p> Case hardening of steels is extensively used throughout general engineering to produce components with a hardened layer whilst retaining a tough core. This is usually accomplished using different sources of energy, e.g. flame and induction being the most common. In recent years, a new case hardening technology, named 'Grind-Hardening' has surfaced. In this method, the heat dissipated during grinding is utilized to induce martensitic phase transformation in the surface layer of a component. Therefore it is possible to incorporate grinding and surface hardening into a single operation to develop a cost-effective production method. The grinding process then becomes an integrated heat treatment process.</p> <p> In the present study on 'grind hardening', a numerical thermal model has been developed to compute the temperature distribution beneath the ground surface to predict the extent of surface hardening and the case depth. Grinding experiments were conducted in order to examine the influence of various process variables such as wheel depth of cut, feed speed, and wheel preparation. AISI 52100 and 1045 steels were used in this study to evaluate the behavior of plain and alloy steels during grind hardening. Effective case depth was measured using a Vickers hardness tester and was found to be over 0.5 mm for a target hardness of 513 Hv. Microstructure was analyzed using optical and scanning electron microscopes. The microstructure was observed to have fine martensitic laths which give rise to remarkable high hardness.</p> / Thesis / Master of Applied Science (MASc)

Dans ce travail de thèse, une amélioration aussi bien à l’échelle globale qu’à l’échelle locale a été apportée sur la compréhension des mécanismes tribologiques aux interfaces outil-pièce-copeau durant l’usinage à sec de l’acier C45 avec des outils en carbure de tungstène revêtus en TIN. Dans une première partie expérimentale, des essais de frottement ont permis d’étudier la sensibilité des paramètres de frottement sur le comportement tribologique aux interfaces pion-pièce. Ainsi, l’évolution du coefficient de frottement, du flux de chaleur et du coefficient de partage de chaleur aux interfaces outil-pièce-copeau ont été identifiés pour le couple de matériau frottant et frotté. Pour mieux comprendre ces phénomènes, une étude métallographique a été effectuée sur des échantillons. Elle a notamment permis l’obtention des transformations métallurgiques au niveau de la surface superficielle de la pièce : des affinements des grains (déformation plastique) aux basses vitesses de frottement et des couches blanches (durcissement thermique) pour les grandes vitesses. Pour avoir plus de détails, un modèle numérique simulant l’essai de frottement a été développé en se basant sur l’approche Arbitraire Lagrangienne Eulérienne (A.L.E). Ce modèle nous a permis d’avoir plus d’informations sur les grandeurs locales de frottement (pression de contact, température de contact, vitesse locale de glissement, déformation plastique). Un modèle de frottement et un modèle de coefficient de partage de chaleur ont été identifiés à travers cette étude numérique. Dans la deuxième partie expérimentale, deux types d’essais d’usure ont été effectués dans des conditions similaires sur des pions et sur des plaquettes d’outils de coupe de même nuance. Des analyses microscopiques et au MEB couplés à une analyse EDS ont été faites afin de mieux analyser les mécanismes tribologiques durant les essais d’usure. Des similitudes de faciès d’usure ont été observées à différentes échelles d’analyse, sur les pions ainsi que sur les plaquettes d’outils de coupe. Ces similitudes ont permis d’aboutir à une corrélation des phénomènes tribologiques observés sur les pions et ceux observés sur les plaquettes. / In this work, improved both global and local levels has been made on understanding the tribological mechanisms at the chip-tool-workpiece interface in dry machining of a AISI 1045 steel with a TiN coated carbide tool. In the first part, several friction tests have been performed to study the sensitivity of friction parameters on the tribological behavior at pin-workpiece interface. Thus, evolutions of the apparent friction coefficient, of heat flux and of heat flux partition ratio have been identified. To better understand these phenomena, a metallographic study was performed on the samples of the workpiece.It has enabled the achievement of metallurgical transformations in terms of surface area of the room : the refinement of grains (plastic deformation) friction at low speeds and white layers (thermal curing)for high speeds. These results show that the initial state of the steel (ferritic-pearlitic microstructure) has been changed, In fact, two phenomena have been observed. The first phenomenon has been observed for low sliding velocities. In this range of the sliding velocities, the grains have been crushed because of the large plastic deformations. The second phenomenon has been observed by increasing the friction velocity. In fact, the white zones have been identified at the surface layer and which have presented a different structure compared to the initial state of the steel. A 3D A.L.E. numerical model, simulating the friction test, enables to extract local information from the contact area, especially the contact pressure, the contact temperature and the average local sliding velocity. An adhesive friction model and a heat partition coefficient model depending on average local sliding velocity have been identified. These friction models can be utilized in a FEM of the cutting process in order to improve the understanding of the material flow and temperature distribution around cutting tools. In the second part, pin wear in the friction tests and tool wear in machining tests have been performed. To compare the phenomena observed at the tool-chip interfaces during the wear tests in machining with the phenomena observed at the pin-workpiece during the wear tests of friction, similarities of faces have been observed at different scales of analysis on the pins and on the cutting tool inserts.

O presente trabalho tem como objetivo investigar o comportamento elasto-plástico em baixas deformações do fio máquina laminado em aço AISI 1045 destinado a trefilação e processos subsequentes de beneficiamento. Inicialmente, foi obtido material de quatro diferentes lotes de fabricação, sendo todas as amostras retiradas após a etapa de pré-endireitamento do processo de trefilação. O material foi caracterizado através de análise da composição química, metalográfica, determinação de tamanho de grão e segregação. Além disso, o comportamento elasto-plástico do material em ciclos de tração e compressão foi investigado, identificando-se o efeito Bauschinger para três diferentes temperaturas. Os modelos numéricos de Ramberg-Osgood e Ludwig-Hollomon foram utilizados para a definição de uma modelo numérico da curva para utilização em trabalhos futuros de simulação computacional. O modelo de Ludwig-Hollomon foi avaliado como mais satisfatório para baixas deformações e foi então utilizado para o cálculo da curva média de quatro lotes. A partir de curvas de escoamento de aço similar obtidas da literatura, foi possível obter-se uma extrapolação da curva para diferentes taxas de deformação, além da taxa de 0.05s-1, original dos ensaios: 1.6 s-1, 8 s-1, e 40 s-1. / The purpose of this work is to investigate the elastic-plastic behavior at low strains of steel rolled coil AISI 1045 intended for cold-drawing and subsequent processes. First, the material was withdrawn from four different manufacturing batches and all samples were taken from the pre-straightening process step. The material was characterized by means of chemical and metallography analysis, grain size and segregation. Furthermore, the elastic-plastic behavior in tension and compression cycles was investigated and the Bauschinger effect was identified for three different temperatures. The numerical models Ramberg-Osgood and Ludwig-Hollomon were the models used in this work to define the flow curve which can be used in future computer simulation works. The analysis showed that the Ludwig-Hollomon model is more adequate for low strains ranges. Ludwig-Hollomin was used to calculate the average flow curve based on the curves of the four batches. By using literature flow curves of similar steels, it was possible to make an extrapolation and to obtain flow curves at different strain rates beyond the experimental one: 1.6 s-1, 8 s-1, e 40 s-1.

Este trabalho objetiva fazer uma análise do processo de trefilação através do uso de simulação computacional e avaliar a influência de variáveis do processo como lubrificante (coeficiente de atrito) e ângulo de fieira, bem como, verificar a eficácia da simulação na previsão de força, de temperatura e das tensões residuais. Foi realizado um trabalho experimental que envolveu a determinação do coeficiente de atrito através do ensaio do anel e a determinação das curvas de escoamento que foram retiradas de amostras trefiladas de um processo real. Efetuaram-se os cálculos das tensões do processo usando dados de curvas de escoamento e equações da literatura, posteriormente realizaram-se simulações computacionais que foram comparadas aos resultados obtidos através dos cálculos. Também se usou, adicionalmente, a simulação otimizada para avaliar as tensões residuais a fim de averiguar estes resultados de tensões residuais, comparando-os com resultados experimentais obtidos via difração de nêutrons para as mesmas barras que foram extraídas do processo industrial. Observou-se que a curva de escoamento do material é determinante para a obtenção de resultados confiáveis. A simulação foi boa para a estimativa da força, mas ainda apresenta limitações quanto à previsão de tensões residuais. / This paper aims to analyze the drawing process using simulation and evaluate the influence of process variables such as lubricant (friction coefficient) and angle of die as well as verify the effectiveness of simulation to preview the drawing force, temperature and residual stresses. Experimental work was carried out involving the determination of friction coefficient by means of the ring test and determination of flow curves by compression tests. The calculations of the stress of the process using data from the flow curves and equations from the literature have been carried out. Later on the experimental results were compared to the simulated results. It was also used in addition, the optimized simulation to evaluate the residual stresses and the results were then compared with experimental results obtained by neutron diffraction for the same bars that were extracted from the industrial process. The results are very influenced by the flow stress curve chosen. The simulation was satisfactory for the estimation of the drawing force but must be improved for a better estimation of residual stresses.

O presente trabalho tem como objetivo investigar o comportamento elasto-plástico em baixas deformações do fio máquina laminado em aço AISI 1045 destinado a trefilação e processos subsequentes de beneficiamento. Inicialmente, foi obtido material de quatro diferentes lotes de fabricação, sendo todas as amostras retiradas após a etapa de pré-endireitamento do processo de trefilação. O material foi caracterizado através de análise da composição química, metalográfica, determinação de tamanho de grão e segregação. Além disso, o comportamento elasto-plástico do material em ciclos de tração e compressão foi investigado, identificando-se o efeito Bauschinger para três diferentes temperaturas. Os modelos numéricos de Ramberg-Osgood e Ludwig-Hollomon foram utilizados para a definição de uma modelo numérico da curva para utilização em trabalhos futuros de simulação computacional. O modelo de Ludwig-Hollomon foi avaliado como mais satisfatório para baixas deformações e foi então utilizado para o cálculo da curva média de quatro lotes. A partir de curvas de escoamento de aço similar obtidas da literatura, foi possível obter-se uma extrapolação da curva para diferentes taxas de deformação, além da taxa de 0.05s-1, original dos ensaios: 1.6 s-1, 8 s-1, e 40 s-1. / The purpose of this work is to investigate the elastic-plastic behavior at low strains of steel rolled coil AISI 1045 intended for cold-drawing and subsequent processes. First, the material was withdrawn from four different manufacturing batches and all samples were taken from the pre-straightening process step. The material was characterized by means of chemical and metallography analysis, grain size and segregation. Furthermore, the elastic-plastic behavior in tension and compression cycles was investigated and the Bauschinger effect was identified for three different temperatures. The numerical models Ramberg-Osgood and Ludwig-Hollomon were the models used in this work to define the flow curve which can be used in future computer simulation works. The analysis showed that the Ludwig-Hollomon model is more adequate for low strains ranges. Ludwig-Hollomin was used to calculate the average flow curve based on the curves of the four batches. By using literature flow curves of similar steels, it was possible to make an extrapolation and to obtain flow curves at different strain rates beyond the experimental one: 1.6 s-1, 8 s-1, e 40 s-1.

Este trabalho objetiva fazer uma análise do processo de trefilação através do uso de simulação computacional e avaliar a influência de variáveis do processo como lubrificante (coeficiente de atrito) e ângulo de fieira, bem como, verificar a eficácia da simulação na previsão de força, de temperatura e das tensões residuais. Foi realizado um trabalho experimental que envolveu a determinação do coeficiente de atrito através do ensaio do anel e a determinação das curvas de escoamento que foram retiradas de amostras trefiladas de um processo real. Efetuaram-se os cálculos das tensões do processo usando dados de curvas de escoamento e equações da literatura, posteriormente realizaram-se simulações computacionais que foram comparadas aos resultados obtidos através dos cálculos. Também se usou, adicionalmente, a simulação otimizada para avaliar as tensões residuais a fim de averiguar estes resultados de tensões residuais, comparando-os com resultados experimentais obtidos via difração de nêutrons para as mesmas barras que foram extraídas do processo industrial. Observou-se que a curva de escoamento do material é determinante para a obtenção de resultados confiáveis. A simulação foi boa para a estimativa da força, mas ainda apresenta limitações quanto à previsão de tensões residuais. / This paper aims to analyze the drawing process using simulation and evaluate the influence of process variables such as lubricant (friction coefficient) and angle of die as well as verify the effectiveness of simulation to preview the drawing force, temperature and residual stresses. Experimental work was carried out involving the determination of friction coefficient by means of the ring test and determination of flow curves by compression tests. The calculations of the stress of the process using data from the flow curves and equations from the literature have been carried out. Later on the experimental results were compared to the simulated results. It was also used in addition, the optimized simulation to evaluate the residual stresses and the results were then compared with experimental results obtained by neutron diffraction for the same bars that were extracted from the industrial process. The results are very influenced by the flow stress curve chosen. The simulation was satisfactory for the estimation of the drawing force but must be improved for a better estimation of residual stresses.