The research work in this thesis involves an experimental and theoretical investigation for high speed machining of AISI 4140 medium carbon steels and AISI D2 tool steels which are classified as being difficult to machine materials. An experimental program was carried out to determine the cutting forces, chip formation, the secondary deformation zone thickness and surface roughness at different cutting speeds using a 0.4mm and 0.8mm nose radii ceramic tools and -7?? rake angle for annealed (virgin) AISI 4140 and heat treated AISI 4140 steel. Another series of experiments was carried out on the annealed (virgin) and heat treated AISI D2 with 0.4mm, 0.8mm and 1.2mm nose radii CBN (Cubic Boron Nitride) tools under various cutting conditions. A theoretical model is developed by taking into account the flow stress properties of the AISI 4140 (0.44% carbon content) to use with the Oxley Machining approach. To find the flow stress data for AISI D2 tool steel, the Johnson and Cook empirical constitutive equation is used as the constitutive model. In addition, the magnitude of tool radius should be also considered to determine the prediction of cutting performances. To account for the effect of nose radius edge in hard machining, a simplified geometrical method is used to model the parameters for application in the Oxley Model and works for the cutting conditions considered here. These extensions to the Oxley machining theory were verified by experimental results. These results show a good agreement between the Oxley machining theory and hard machining experiment at data. The research work described in this thesis provides useful data for hard machining conditions.

The research work in this thesis involves an experimental and theoretical investigation for high speed machining of AISI 4140 medium carbon steels and AISI D2 tool steels which are classified as being difficult to machine materials. An experimental program was carried out to determine the cutting forces, chip formation, the secondary deformation zone thickness and surface roughness at different cutting speeds using a 0.4mm and 0.8mm nose radii ceramic tools and -7?? rake angle for annealed (virgin) AISI 4140 and heat treated AISI 4140 steel. Another series of experiments was carried out on the annealed (virgin) and heat treated AISI D2 with 0.4mm, 0.8mm and 1.2mm nose radii CBN (Cubic Boron Nitride) tools under various cutting conditions. A theoretical model is developed by taking into account the flow stress properties of the AISI 4140 (0.44% carbon content) to use with the Oxley Machining approach. To find the flow stress data for AISI D2 tool steel, the Johnson and Cook empirical constitutive equation is used as the constitutive model. In addition, the magnitude of tool radius should be also considered to determine the prediction of cutting performances. To account for the effect of nose radius edge in hard machining, a simplified geometrical method is used to model the parameters for application in the Oxley Model and works for the cutting conditions considered here. These extensions to the Oxley machining theory were verified by experimental results. These results show a good agreement between the Oxley machining theory and hard machining experiment at data. The research work described in this thesis provides useful data for hard machining conditions.

The research work in this thesis involves an experimental and theoretical investigation for high speed machining of AISI 4140 medium carbon steels and AISI D2 tool steels which are classified as being difficult to machine materials. An experimental program was carried out to determine the cutting forces, chip formation, the secondary deformation zone thickness and surface roughness at different cutting speeds using a 0.4mm and 0.8mm nose radii ceramic tools and -7?? rake angle for annealed (virgin) AISI 4140 and heat treated AISI 4140 steel. Another series of experiments was carried out on the annealed (virgin) and heat treated AISI D2 with 0.4mm, 0.8mm and 1.2mm nose radii CBN (Cubic Boron Nitride) tools under various cutting conditions. A theoretical model is developed by taking into account the flow stress properties of the AISI 4140 (0.44% carbon content) to use with the Oxley Machining approach. To find the flow stress data for AISI D2 tool steel, the Johnson and Cook empirical constitutive equation is used as the constitutive model. In addition, the magnitude of tool radius should be also considered to determine the prediction of cutting performances. To account for the effect of nose radius edge in hard machining, a simplified geometrical method is used to model the parameters for application in the Oxley Model and works for the cutting conditions considered here. These extensions to the Oxley machining theory were verified by experimental results. These results show a good agreement between the Oxley machining theory and hard machining experiment at data. The research work described in this thesis provides useful data for hard machining conditions.

Bibliography: pages 68-70. / An investigation involving the vibratory cavitation erosion of WC-Co alloys was undertaken in order to determine the mechanisms of material removal. Nineteen grades of WC-Co alloys were studied. These alloys had been previously characterised according to microstructural and mechanical properties. Further characterisation by way of Young's modulus and density of the materials was undertaken. An investigation of the i nfluence of various parameters on cavitation erosion established a binder content dependence on erosion. For two grain sizes, erosion was found to increase to a maximum at 12 vo1-% binder content (1.8 μm grain size) and 23 vol-% binder (2.8 μm grain size). The main mode of material removal was found to be cobalt removal followed by WC grain pull-out. In high binder content alloys, cobalt removal was predominant with little loss of WC grains. X-ray diffraction showed that the allotropic phase transformation of the binder under cavitational attack was beneficial to the erosion resistance of these alloys. The erosion of low binder content alloys was controlled by the contiguity of the WC skeleton. Maximum erosion occurred at binder contents which corresponded to the combination of a fragile WC skeleton and a small volume of available cobalt for strain induced transformation.

The metallurgy and superconductivity of the Nb-Ti-Ta ternary alloy system were studied. The Nb-Ti, and Ta-Ti binary samples, and Nb-Ti-Ta ternary samples were precipitation heat treated under different schedules. After the precipitating heat treatment, the samples were characterized by X-Ray Diffraction (XRD) techniques. Equilibrium binary and ternary phase diagrams based on the different alloy compositions and heat treatment temperatures were developed. The Ta-Ti binary phase diagram is very close to the ASM standard phase diagram. The ��-phase boundary of Nb-Ti binary phase diagram developed here is at a higher temperature relative to the ASM standard one. A working ternary equilibrium phase diagram for the Nb-Ti-Ta system has been developed that is based on the experimental measurements and quantitative thermodynamic calculations. Measurements of superconducting critical temperature, Tc, show a good agreement with previous measurements of Tc in the ternary alloys. / Graduation date: 2002

Due to the aluminum industry demands, a large effort has recently been devoted to the development of special alloys to be used as inert anodes for a newly designed aluminum reduction cell. The implementation of this new technology aims at the replacement of the graphite anodes that have been used for over 100 years in aluminum smelting, which would reduce fossil carbon consumption, and eliminate the emission of carbon dioxide and of perfluorocarbons. Ternary alloys containing copper, nickel, and iron have been the subject of the research activities. The present research focused on the stability of the Cu-Ni-Fe alloys at high temperatures in oxidizing and fluoridating environments. The experimental methods included thermodynamic calculations of the phase diagram ('Thermocalc'), optical microscopy and microprobe microstructural and chemical investigations (EMIPA-WDS), small-angle neutron scattering (SANS), differential thermal analysis (DTA), and air-oxidation studies. The results have led to the optimization of the Cu-Ni-Fe ternary phase diagram and to an extensive study of the thermodynamics and kinetics of the spinodal decomposition and discontinuous reactions occurring during ageing as a function of alloy composition. The oxidizing reactions occurring in air at high temperatures at the surface of the alloys have been also discussed in terms of thermodynamic and kinetic laws. The phase formation in a fluorine containing environment as encountered in an aluminum electrolytic cell is predicted using principles of physical chemistry. / Graduation date: 2004 / Best scan available. Figures in original document are very dark and have a moray pattern.

Aluminum 5XXX alloys are of industrial importance and interest as they combine a wide range of desirable strength, forming and welding characteristics with a high resistance to corrosion. The presence of Mg in these alloys ensures favorable mechanical properties. However, the room temperature stretching performance of these alloys is limited. Moreover, Al-Mg alloys are known for being susceptible to the Portevin-LeChatelier effect when deformed at room temperature. Nevertheless, improvements in ductility can be achieved through warm forming, especially when the ductility approaches superplastic levels. / The aim of this study was to test for enhanced ductility in three coarse-grained Al-Mg alloys namely, super-pure Al-3%Mg and Al-5%Mg, and commercial AA 5056 alloy. The temperature-dependent flow stress and rate sensitivity behavior of these alloys was investigated by means of tensile testing using ASTM E8M-04 standard samples. Samples were deformed to 10% strain to allow enough deformation to occur such that serrations in the dynamic strain aging (DSA) temperature/strain rate range would be rendered visible on a stress-strain curve. Using this information, the regions of negative and higher-than-normal strain rate sensitivity ('m') were plotted and tensile tests to failure were performed in the vicinity of maximum 'm'. ASTM E2448-06 standard samples for superplasticity tensile testing were used in this case. / A maximum ductility of 170% was recorded with these samples and this was found to increase to nearly 300% when the gage length was shortened. It was observed that the DSA serrations were more prominent at lower strain rates, higher temperatures and higher Mg contents. The results of this study show clearly that if the rate sensitivity is high enough, then enhanced ductility in coarse-grained materials is possible at temperatures well below the maximum test temperature.

Thesis submitted in fulfilment of the requirements for the degree Master of Technology: Mechanical Engineering in the Faculty of Engineering at the Cape Peninsula University of Technology 2013 / High temperatures encountered in combustion chambers of jet engines has demanded the creation of new technologies and new materials for the construction of one of the most critical elements of these systems - the stator and rotor turbine blades. They have to withstand extreme temperatures for extended periods without the loss of mechanical strength, conditions under which many steels and alloys fail. Such failure is ascribed to the combination of high temperatures and high centrifugal forces, resulting in creep. The high temperature creep mechanism of grain boundary sliding has limited the operation capability of fine-grained equiaxed castings. Higher operating temperatures were achieved with higher alloy contents and coarse-grained equiaxed castings. This is especially prevalent in multi-crystalline structures in which grain boundaries present weaknesses in the structure. However, notwithstanding these improvements, high temperature resistant alloys formed as single crystal structures offer the necessary material properties for safe performance under these extreme conditions. Damage to turbine blade surfaces is often caused by oxidation and hot corrosion. For this reason, turbine blades are coated with a thermal barrier coating (TBC), which consists of ceramic materials that reduce the heat flux through the airfoil. In this research work, modelling and simulation techniques were initially used to study the directional solidification (DS) of crystal structures during vacuum investment casting. The modelling of the solidification process was implemented using a Finite Element casting simulation software, ProCAST, to predict thermal and flow profiles. These models allowed the study of the dendritic growth rate, the formation of new grains ahead of the solid/liquid interface and the morphology of the dendritic microstructure. These studies indicated the opportunity to optimise the velocity of the solidification front (solidification rate) for single crystal structures. The aim of this research was therefore to investigate the effect of the solidification rate (or withdrawal velocity) on the quality of SC castings. The investigations were carried out for nickel-based superalloy CMSX-4 turbine blade casts and rods using the Bridgman process for vacuum investment casting. The SC castings were heat treated to improve the grain structure for enhanced creep resistance. The heat treated SC castings were inspected by X-ray diffraction to analyse crystallographic orientation and chemical composition; and by SEM, OP (optical microscopy) and microprobe analysis to analyse the microstructure; in addition to macrostructural investigations. In the experimental analysis, the formation of new grains ahead of the solidi/liquid interface and the effect of dendrite packing patterns on the primary dendrite spacing were investigated. Creep tests were conducted to compare the creep properties of the SC castings for different withdrawal rates, and to draw conclusions regarding the effect of withdrawal rate on the microstructure (and hence the creep properties) of SC castings.

Orientadores: Amauri Garcia, José Eduardo Spinelli / Tese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-23T18:46:28Z (GMT). No. of bitstreams: 1 FreitasFeitosa_EmmanuelleSa_D.pdf: 38383286 bytes, checksum: d05ac1e591269c92fc7418ac0e23fbd1 (MD5) Previous issue date: 2013 / Resumo: As ligas monotéticas à base de alumínio destacam-se por suas características tribológicas, principalmente as que se caracterizam pela fase minoritária (p. ex. bismuto, chumbo e índio) dispersa na matriz de alumínio, pois essas dispersões de elementos de baixas temperaturas de fusão e dureza, em função de suas propriedades autolubrificantes escoam facilmente em condições de deslizamento, resultando em um comportamento tribológico favorável. Já ligas hipoeutéticas Pb-Sb, mesmo as bem diluídas, possuem aplicações práticas bastante interessantes. Suas características estruturais e mecânicas, fazem com que o uso dessas ligas seja apropriado para a fabricação de conectores e grades positivas de baterias chumbo-ácido. Existe uma falta de estudos consistentes da evolução microestrutural de ligas monotéticas durante condições de solidificação transitória devidamente associada a propriedades de aplicação. Esse tipo de solidificação é de importância primordial, uma vez que engloba a maioria dos processos industriais envolvendo a transformação líquido/sólido. O presente estudo objetiva contribuir para o desenvolvimento de correlações entre microestruturas de solidificação e as resistências ao desgaste e à corrosão. Para o desenvolvimento do presente estudo, foram escolhidas composições representativas de ligas monotéticas Al-Pb; Al-Bi e Al-In, para análise da influência de parâmetros microestruturais sobre as resistências ao desgaste e à corrosão e uma liga hipoeutética Pb-Sb para avaliar as condições térmicas de surgimento de espaçamentos dendríticos terciários e seu efeito sobre a resistência à corrosão. Para tanto foram realizados experimentos de solidificação unidirecional em regime transitório para a caracterização da evolução das condições térmicas e da microestrutura resultante. As variáveis térmicas como velocidades de crescimento e taxas de resfriamento foram determinadas experimentalmente por curvas de resfriamento adquiridas ao longo do comprimento dos lingotes unidirecionais. Amostras das ligas monotéticas com diferentes espaçamentos interfásicos e diâmetros da fase minoritária, foram submetidas a ensaios de resistência ao desgaste em esfera rotativa, e são propostas leis experimentais correlacionando o volume de desgaste com o espaçamento interfásico da microestrutura. Essas mesmas amostras foram também submetidas a ensaios de corrosão em solução de NaCl sendo também estabelecidas correlações entre resistência à corrosão e características paramétricas da microestrutura. Para uma liga hipoeutética Pb-Sb é desenvolvido um estudo que visa complementar trabalhos anteriores, no sentido de identificar o papel de espaçamentos dendríticos terciários na resistência à corrosão de ligas Pb-Sb. Após a caracterização microestrutural são determinadas sob que condições de solidificação surgem as ramificações terciárias e realizados ensaios de corrosão em amostras representativas em uma solução de H2SO4. Mostra-se também como a evolução, o grau e a escala das ramificações dendríticas afeta a resistência à corrosão. Busca-se com esses estudos experimentais estabelecer uma pré-programação das condições de solidificação visando o desenvolvimento de microestruturas mais resistentes ao desgaste e à corrosão / Abstract: Al-based monotectic alloys are particularly important by their tribological characteristics, mainly those having the minority phase (e.g. bismuth, lead and indium) disseminated in particles along the aluminum matrix. These particles have lower melting temperatures and hardness and flow easily due to their inherent self-lubricant properties, leading to good tribological behavior. On the other hand Pb-Sb alloys, even those having low Pb contents, have interesting practical applications. Their intrinsic mechanical and structural characteristics make them appropriate for the manufacture of connectors and positive grids of lead-acid batteries. There is a lack of systematic studies on the microstructural evolution of monotectic alloys under transient solidification conditions associated with application properties. This class of solidification is of prime importance since it encompasses the majority of industrial processes involving the liquid/solid transformation. The present study aims to contribute to the development of correlations between solidification microstructures and wear and corrosion resistances. For this, representative compositions of Al-Pb; Al-Bi e Al-In monotectic alloys have been chosen to permit the effect of microstructural parameters on the wear and corrosion resistances to be analyzed, as well as a hypoeutectic Pb-Sb alloy with a view to evaluating the thermal conditions that are conducive to the development of dendritic tertiary branches and their effect on the corrosion resistance. Directional solidification experiments were carried out under transient conditions to permit the characterization of the thermal evolution and the corresponding as-cast microstructure. The thermal variables, such as the solidification rate and cooling rate have been experimentally determined from the cooling curves acquired along the castings length. Samples of monotectic alloys, having different interphase spacings and diameters of the minority phase, have been subjected to ball crater wear tests, and experimental laws correlating the wear volume with the microstructural interphase spacing are proposed. These samples have also been subjected to corrosion tests in a NaCl solution and correlations between the corrosion resistances and parametric features of the microstructure have also been established. A complementary study on a hypoeutectic Pb-Sb alloy has been developed with a view to identifying the role of tertiary dendritic branches on the corrosion resistances of Pb-Sb alloys. After the microstructural characterization, conditions determining the onset of tertiary dendritic branches have been determined and corrosion tests were carried out on representative samples in a H2SO4 solution. It is also shown how the evolution, the grade and scale of dendritic branches affect the corrosion resistance. The aim of these experimental studies was to establish the pre-programming of solidification conditions in the search of microstructures having higher wear and corrosion resistances / Doutorado / Materiais e Processos de Fabricação / Doutor em Engenharia Mecânica

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