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A necessidade de redução de custos de produção torna o caster mais vantajoso que o processo de placas, porém a aplicação dos produtos obtidos via vazamento contínuo é limitada pelas condições microestruturais. A alta taxa de resfriamento no processo de vazamento, que pode ultrapassar 300 °C/s, resulta em uma condição de supersaturação dos elementos em solução sólida. Quando as chapas são recozidas, ocorre precipitação na forma de dispersóides que atrasam a recristalização. Quando o material obtido via caster segue o processo convencional de placas laminadas a quente, com recozimento intermediário e têmpera obtida por reduções pré-definidas, o resultado é uma chapa com aspecto superficial e desempenho na estampagem prejudicados pela granulação grosseira. Para otimizar o processo é necessário aprimorar o conhecimento dos fenômenos de encruamento, recuperação, recristalização e crescimento de grãos além de relacioná-los aos processos industriais. A prática usual de processo para o material de caster consiste em um tratamento térmico de homogeneização para precipitar os elementos em solução sólida e melhorar a distribuição dos precipitados para que existam núcleos viáveis para a recristalização. O processo de homogeneização agrega um elevado custo na produção de chapas e pode ser substituído em determinadas aplicações por um tratamento de recristalização parcial que evita o crescimento de grãos. Para o presente trabalho, as amostras foram retiradas de rolos caster brutos de fusão e de placas laminadas a quente, nas ligas AA1200 e AA3003. As bobinas foram laminadas a frio até 0,88 mm e as amostras sofreram tratamentos térmicos em temperaturas entre 150 e 500 °C, com intervalos de 50 °C. O intervalo entre 200 e 450 °C foi melhor detalhado e os tratamentos térmicos foram feitos a cada 10 °C. Todos os tratamentos tiveram duração de 1 hora. Após tratamentos, foram feitas medidas de condutividade elétrica e dureza, ensaios de tração, Erichsen, análises químicas e caracterização microestrutural. O decréscimo das propriedades mecânicas em função do aumento da temperatura do tratamento térmico mostra o efeito da recuperação e recristalização nas amostras de chapas. A evolução das propriedades em função da temperatura é diferente quando se compara caster e placa, devido principalmente à taxa de resfriamento durante o vazamento do caster que mantém os elementos em solução sólida. A diferença é muito mais acentuada na liga AA3003, devido à baixa solubilidade sólida do manganês no alumínio, que precipita durante o tratamento térmico e atrasa a recristalização. Com a evolução das propriedades mecânicas em função da temperatura foi possível determinar a faixa ideal de tratamento térmico para a obtenção das têmperas objetivadas. / The necessity of reducing productions costs makes the continuous casting more advantageous than plates process, however, the application of the products obtained through continuous casting is limited by microstructural conditions. The high rate of cooling in the continuous casting, which can exceed 300 °C/s, results in a condition of supersaturation of the elements in solid solution. When the plates are annealed, precipitation occurs in the form of dispersoids that delays the recrystallization. When the continuous casting material follows the conventional process of hot-rolled plates, with intermediate annealing and hardness achieved by pre-defined reductions, the result is a plate with superficial appearance and performance in drawing hampered by the coarse graining. To optimize the process is necessary to improve the knowledge of the phenomena of cold working, recovery, recrystallization and grain growth in addition to relate them to industrial processes. The practice of process for continuous casting material consists in homogenization heat treatment to precipitate elements in solid solution and improve the distribution of precipitates in order to provide viable nuclei for the recrystallization. The process of homogenization adds a high cost in the production of plates and can be replaced in certain applications for treatment of partial recrystallization that prevents the grain growth. For this paper, the samples were taken from continuous casting rolls as cast and hot-rolled plates, in the alloys AA1200 and AA3003. The coils were cold-rolled up to 0.88 mm and the samples have undergone thermal treatment at temperatures between 150 and 500 °C, with intervals of 50 °C. The interval between 200 and 450 °C was better detailed and heat treatments were performed every 10 °C. All treatments had duration of 1 hour. After treatment, measures of electrical conductivity and hardness were made, besides traction tests, Erichsen, chemical analysis and microstructural characterization. The decrease of mechanical properties as a function of increasing heat treatment temperature shows the effect of recovery and recrystallization in samples of hot-rolled plates. The development of properties depending on the temperature is different when continuous casting and hot-rolled plates are compared, mainly due to the rate of cooling during the casting that keeps the elements in solid solution. The difference is more pronounced in the alloy AA3003, due to the low solid solubility of manganese in aluminum, which precipitates during the heat treatment and delays the recrystallization. With the evolution of mechanical properties according to the temperature, it was possible to determine the optimal range of heat treatment to obtain the desired hardness.

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The objective of this research is to investigate the gasification, in air and carbon dioxide, of anode carbons used in the aluminium industry, to identify any differences in the behaviour of filler coke and the coke from the coal-tar binder pitch, and to study the effect of pitch quality, especially the type and proportion of quinoline insolubles (QI) and the sodium content, on those processes which contribute to excess anode consumption.

This dissertation is concerned with the physical processes which determine friction and lubrication in metal rolling in the mixed lubrication regime, with particular attention paid to the conditions encountered when rolling aluminium foil. Two areas of relevance to the analysis of the rolling process are initially investigated. Firstly, the rheological properties of a typical aluminium foil rolling oil at high pressures and shear rates have been measured using a disc machine. The behaviour of the oil was found to be well described by the Eyring viscous model, at the shear rates and pressure likely to be found in metal rolling. Secondly, the deformation of asperities when the bulk material is deforming has been examined. The theory developed here was found to agree reasonably with experiments. The results of these investigations are used in the analysis of lubrication in metal rolling, considering the hydrodynamic buildup of oil pressure in the entry region and the crushing of the asperities both in the entry region and at the beginning of the work zone. The contact between roll and strip is divided into two regions, that under the asperities and that in the intervening valleys. Calculations for conditions appropriate to strip and foil rolling give the proportion of the two types of contact and the film thicknesses in each region. Measurements of film thicknesses with an experimental mill in a regime where roughness is unimportant were not found to agree well with an existing simple theory of lubrication. This was ascribed to uneven lubrication in the experiments. After taking this into account, the experiments in a regime where roughness was important were found to agree reasonably with the theory developed here. The effect of roughness on traction is measured in a disc machine with elastic contacts. Its behaviour is found to be determined by the bulk properties of the lubricant at the pressures and strain rates under the asperities. Theory and experiments presented in this dissertation lead to a greater understanding of the physical processes determining friction in metal rolling in the mixed lubrication regime. Film thicknesses and friction coefficients in metal rolling may now be estimated with more confidence.

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No description available.