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The aim of this thesis work is to design and manufacture a Dissimilar Channel Angular Pressing (DCAP) system for severe plastic deformation of aluminum alloy sheets in order to obtain ultra-fine grained structure. First, a DCAP system was designed by Finite Element Analysis and constructed after various optimization trials. Next, 6061-T0 aluminum alloy plates were severely deformed by various DCAP passes through the system. The samples were characterized by metallography, X-ray diffraction, tension and hardness tests. It has been observed that the yield strength was improved about 100 % after 2 DCAP passes, and 45 nm sub-grain size was obtained.

In recent times, application of aluminum alloys is favored in the transportation sectors such as the aerospace and automobile industries where reduced fuel consumption and greenhouse gas emission are major priorities. In these applications, these alloys can be exposed to dynamic shock loading conditions as in the case of car crash and birds’ collision during aircraft’s take-off or landing. This study therefore focused on the deformation and damage mechanisms in AA 2017, AA 2024 and AA 2624 aluminum alloys under both quasi-static and dynamic impact loading conditions. Cylindrical specimens of the selected aluminum alloys were investigated under both quasi-static loading at 3.2 x10-3 s-1 using an Instron R5500 mechanical testing machine and dynamic impact loading using the split Hopkinson pressure bar at strain rates ranging between 2000 and 8000 s-1. The effects of strain rate and temper condition on the microstructural evolution in the alloys during mechanical loading were studied. The electron backscatter diffraction (EBSD) technique was used to investigate the texture of the naturally-aged AA 2017 and AA 2624 alloys before and after dynamic shock loading. The contributions of the major alloying elements such as copper, magnesium and silicon to the microstructural evolution and deformation behavior of the alloys under the dynamic shock loading condition were also studied using the energy dispersive spectroscopy (EDS) technique. Results showed that the morphology and atomic distribution of particles in the investigated alloys are functions of the temper condition. The hardness of all the three alloys was higher in the age-hardened conditions than the annealed ones. Although deformation of the alloy under quasi-static compressive loading was dominated by strain hardening, flow softening leading to strain localization and formation of shear bands occurred once certain critical strain values were reached. Under both quasi-static and dynamic loading, the alloys with low Cu:Mg ratio (AA 2024 and AA 2624) showed higher mechanical strength in age-hardened condition than that with high Cu:Mg ratio (AA 2017). All the alloys in the annealed condition exhibited an enhanced plasticity and formability. Intense strain localization leading to formation of adiabatic shear bands (ASBs) was the principal contributor to failure in the alloys under dynamic impact loading. Both deformed and transformed bands were observed, with cracking occurring mainly along the transformed shear bands. The tendency for formation of adiabatic shear bands is observed to be a function of the alloy composition, temper condition, strain, strain rate and strain hardening rate. In the natural aging condition, AA 2024 showed the highest susceptibility to formation of ASBs followed by AA 2624 and AA 2017 in that order. On the other hand, AA 2024 has the least susceptibility in the artificially-aged condition. Occurrence of bifurcation of transformed bands in dynamic impacted specimens is dependent on temper condition, strain and strain rate. The mechanism of fracture of the precipitation hardened samples is typical of ductile fracture occurring sequentially by nucleation, growth, and coalescence of micro-voids processes within transformed band. Elongated grains were observed to arrest propagating shear band depending on the angle the band makes with elongated grains. The higher the angle of inclination of a shear band to the grain on its path, the higher the tendency of the grain to stop its propagation. Texture analysis of the impacted specimens of AA 2017-T451 and AA 2624-T351 shows that the former has a higher tendency for the evolution of ultra-fine DRX grains within the transformed shear band. High strain rate led to the development of CD//<111> orientations at the expense of CD//<110> orientations. Schmid factor calculations performed on few different orientations in the starting microstructure shows that CD//<110> is less susceptible to slip deformation and consequently underwent rotation to CD//<111>.

Η παρουσία της βλάβης διάβρωσης στις αεροπορικές δομές, έχει αποδειχθεί ότι συμβάλλει σημαντικά στην υποβάθμιση της δομικής τους ακεραιότητας. Ταυτόχρονα, οι χρονοβόρες και αυξημένου κόστους διεργασίες και έλεγχοι που πραγματοποιούνται για την αποφυγή ή την επιδιόρθωση της διάβρωσης δεν είναι πάντα αποδοτικές. Στην τρέχουσα βιομηχανική πρακτική, σε περιπτώσεις στατικής φόρτισης, η βλάβη διάβρωσης αντιμετωπίζεται θεωρώντας ότι έχει επέλθει μείωση της φέρουσας διατομής ίση με το βάθος της διαβρωτικής προσβολής και ακολουθεί εκ νέου υπολογισμός των τάσεων. Στις δυναμικές φορτίσεις, τα τρήμματα θεωρούνται ως πιθανά σημεία έναρξης των ρωγμών κόπωσης. Όμως, παρά την αναγνώριση της διάβρωσης ως έναν από τους μηχανισμούς που επιδρούν αρνητικά στη δομική ακεραιότητα μιας αεροπορικής δομής, ούτε και στον σχεδιασμό των αεροπορικών κατασκευών με ανοχή στη βλάβη, ο οποίος είναι ο σύγχρονος τρόπος σχεδιασμού και βασίζεται στις αρχές της θραυστομηχανικής, η βλάβη διάβρωσης λαμβάνεται υπόψη. Ως αποτέλεσμα, η επίδραση της διάβρωσης στη δομική ακεραιότητα των υλικών κάποιες φορές υποεκτιμάται. Σκοπός της παρούσας διδακτορικής διατριβής είναι να συμβάλλει στην ανάπτυξη ικανοτήτων για την εκτίμηση της υποβάθμισης των μηχανικών ιδιοτήτων του διαβρωμένου υλικού με δεδομένα τα μεταλλογραφικά χαρακτηριστικά της βλάβης διάβρωσης. Στο πλαίσιο αυτό, αναπτύσσεται μια μεθοδολογία η οποία επιτρέπει την υπολογιστική προσομοίωση της συμπεριφοράς εφελκυσμού του διαβρωμένου υλικού με δεδομένα τα μεταλλογραφικά χαρακτηριστικά της βλάβης διάβρωσης. Η εργασία περιλαμβάνει ένα πειραματικό και ένα υπολογιστικό σκέλος. Το πειραματικό σκέλος περιλαμβάνει την εκτενή μεταλλογραφική μελέτη της βλάβης διάβρωσης, τη διεξαγωγή μηχανικών δοκιμών εφελκυσμού και τη μελέτη των επιφανειών θραύσης για την αναγνώριση των φυσικών μηχανισμών της βλάβης σε δοκίμια προ-διαβρωμένα για διαφορετικούς χρόνους έκθεσης στο διαβρωτικό περιβάλλον. Τα κύρια αποτελέσματα της πειραματικής διαδικασίας συνοψίζονται ως εξής: Η βλάβη διάβρωσης συσσωρεύεται βαθμιαία και εξελίσσεται, σε συνάρτηση με τον χρόνο έκθεσης, από τρημματική σε διάβρωση αποφλοίωσης. Οι μηχανικές δοκιμές εφελκυσμού στο διαβρωμένο υλικό έδειξαν μια μέτρια υποβάθμιση των ιδιοτήτων αντοχής, αλλά ταυτόχρονα μια σημαντική πτώση των ιδιοτήτων ολκιμότητας. Η μελέτη των επιφανειών θραύσης ανέδειξε την ύπαρξη ψαθυροποιημένων περιοχών κάτω από το στρώμα διάβρωσης. Η ύπαρξη τέτοιων ψαθυροποιημένων ζωνών έχει αποδοθεί από προηγούμενες εργασίες στην προσρόφηση υδρογόνου που παράγεται κατά την διαδικασία της διάβρωσης. Το υπολογιστικό σκέλος περιλαμβάνει την ανάπτυξη μοντέλου πεπερασμένων στοιχείων σε μίκρο και μάκρο-κλίμακα. Για την προσομοίωση της συμπεριφοράς εφελκυσμού του διαβρωμένου υλικού σε μίκρο-κλίμακα αναπτύχθηκε μια Αντιπροσωπευτική Μοναδιαία Κυψελίδα (Representative Unit Cell) που περιλαμβάνει τρήμματα αντιπροσωπευτικά του χρόνου έκθεσης σε διαβρωτικό περιβάλλον. Η τοπικά υποβαθμισμένη συμπεριφορά εφελκυσμού του υλικού, λόγω της ύπαρξης των τρημμάτων, προσδιορίζεται από τις αντιπροσωπευτικές μοναδιαίες κυψελίδες και εισάγεται τοπικά σε ένα μοντέλο μάκρο-κλίμακας. Το μοντέλο λαμβάνει υπόψη την διαφορετική ένταση της βλάβης διάβρωσης στις διάφορες περιοχές του δοκιμίου. Τα αποτελέσματα του μοντέλου έδειξαν ικανοποιητική σύγκλιση με τις μηχανικές δοκιμές σε ότι αφορά στις ιδιότητες αντοχής. Αντίθετα, έδειξαν υποτίμηση της πειραματικά παρατηρούμενης μείωσης των ιδιοτήτων ολκιμότητας. Η υποτίμηση αυτή οφείλεται στο γεγονός ότι το μοντέλο, κα' αρχήν, δεν λαμβάνει υπόψη τους φυσικούς μηχανισμούς της ψαθυροποίησης του υλικού λόγω διάβρωσης. Η μεθοδολογία που αναπτύχθηκε αποτελεί βήμα για τη σύνδεση της βλάβης διάβρωσης με τις απομένουσες μηχανικές ιδιότητες του υλικού και, επομένως, την ασφαλέστερη εκτίμηση της απομένουσας αντοχής διαβρωμένων αεροπορικών δομών. / Corrosion damage accumulation represents a major threat for the structural integrity of metallic aircraft structures and moreover has a strong effect on the load bearing capacity of aging aircraft structures. Corrosion damage is evaluated by means of metallographic features such as pitting density, depth and shape of pits, onset of exfoliation, etc. For the case of static loading, corrosion damage is usually accounted through reducing the metal thickness by the depth of corrosion attack and then calculating the corresponding stress increase. For the case of fatigue, corrosion pits are considered as possible onsets for fatigue cracks. The aim of the present PhD thesis is to contribute to establish a link between the metallographic features of corrosion damage and the degradation of the mechanical properties of a corroded material. Towards this objective, a methodology is developed which allows the numerical simulation of the tensile behavior of the corroded material based on the metallographic features of the corrosion damage. The present work is divided in two parts: a) the experimental investigation and b) the numerical analysis. The experimental part includes an extensive metallographic investigation of the occurring corrosion damage. Moreover, tensile tests were performed on the pre-corroded material which was exposed to the corrosive solution for several exposure periods. Finally, an examination of the fracture surfaces for the identification of the physical mechanisms of the damage has also been conducted. The main conclusion extracted from the metallographic procedure is that corrosion damage evolves from pitting to exfoliation progressively. The tensile tests performed on the pre corroded material revealed a moderate reduction concerning the tensile strength but a significant degradation of the tensile ductility even after short exposure periods. The examination of the fracture surfaces revealed the presence of quasi-cleavage zones beneath the depth of corrosion attack. The formation of these zones has been attributed by previous investigations to hydrogen diffusion and trapping into the corroded material during the corrosion process. The simulation procedure involves the development of a multi scale finite element model. The corrosion damage has been accounted for by introducing 3D Representative Unit Cells (RUCs) developed in the micro scale, with geometrical characteristics obtained by the metallographic analysis data of the corroded material. The degradation of the Representative Unit Cell’s mechanical properties due to the presence of the damage has been recorded. A 3D Finite Element model of a tensile specimen has been developed. This model has been used to simulate the tensile behavior of the corroded material, by including elements with degraded properties extracted from the RUC analysis. For the different exposure times RUCs with different geometrical characteristics were used so as to account for the evolving corrosion damage. The simulation results correlate well with the respective tensile behavior of the alloy obtained by the mechanical tests. As far as tensile ductility is concerned a significant deviation was observed, due to the fact that the finite element model does not account for the embrittlement of the material due to hydrogen absorption. The developed methodology represents a step towards the establishment of a link between the metallographic features of the corrosion damage and the residual mechanical properties of the material, and thus the more reliable estimation of the residual strength of the corroded aircraft structures.

Submitted by Ronildo Prado (ronisp@ufscar.br) on 2017-07-03T18:18:01Z No. of bitstreams: 1 DissLBO.pdf: 5087062 bytes, checksum: ed0430974a336dc3223e730ae90cc724 (MD5) / Approved for entry into archive by Ronildo Prado (ronisp@ufscar.br) on 2017-07-03T18:18:29Z (GMT) No. of bitstreams: 1 DissLBO.pdf: 5087062 bytes, checksum: ed0430974a336dc3223e730ae90cc724 (MD5) / Approved for entry into archive by Ronildo Prado (ronisp@ufscar.br) on 2017-07-03T18:18:35Z (GMT) No. of bitstreams: 1 DissLBO.pdf: 5087062 bytes, checksum: ed0430974a336dc3223e730ae90cc724 (MD5) / Made available in DSpace on 2017-07-03T18:18:45Z (GMT). No. of bitstreams: 1 DissLBO.pdf: 5087062 bytes, checksum: ed0430974a336dc3223e730ae90cc724 (MD5) Previous issue date: 2017-03-03 / Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq) / The main application of 319 aluminum alloy is for manufacturing components for automobile industry. One of the main concerns related to the recycling of this metal is regarding the incorporation of impurities as iron, for instance. Due to its low solubility in solid aluminum, the presence of this element leads to the formation of intermetallic compounds such as α-Al8Fe2Si and β-Al9Fe2Si2, the most common iron phases in Si-containing Al-alloys. The β phase is harmful to mechanical properties because of its platelet like morphology. Spray forming is an advanced processing technique which can mitigate the deleterious effect of these intermetallic phases. However, the solidification process of spray formed metals is still an open discussion. In these sense, the aim of this work is to contribute to a better understanding of the solidification process of spray formed 319 aluminum alloy. The work was divided in three stages: the first evaluated the presence and morphology of intermetallic phases by varying the pouring temperature and Fe content (0.6 and 1.2 in mass percent); the second evaluated the eutectic Al-Si morphology through varying the processing conditions; and finally, the third evaluated the solute distribution in the final microstructure, in this case other aluminum alloys were studied together with the 319 (2024 and 7050). The basis for discussion the phenomena was a solidification model for spray formed metals recently proposed in the literature, which defines the process in two stages, being the final solidification occurring at low cooling rate. The results showed that by controlling the processing parameters it is possible to mitigate the β-Al9Fe2Si2 formation, as well as to alter the eutectic Al-Si morphology. The third stage indicated the possibility of maintenance of certain solute in solid solution on the periphery of aluminum grains. It could be concluded that the solidification model was adequate to explain the phenomena presented in this work. / A liga de alumínio 319 possui como aplicação a fabricação de componentes da indústria automobilística. Um dos principais problemas relacionados à reciclagem destas ligas é a incorporação de impurezas como o ferro. Devido à baixa solubilidade deste elemento, sua presença leva a formação de compostos intermetálicos, sendo o α-Al8Fe2Si e o β-Al9Fe2Si2 os mais comuns em sistemas com silício. A fase β é a mais danosa às propriedades mecânicas devido à sua morfologia de placas, sendo que uma rota de processamento que se mostra viável no sentido de mitigação do efeito deletério deste intermetálico é a conformação por spray. Apesar disso, o processo de solidificação desta técnica ainda é um assunto debatido na comunidade científica. Neste contexto, este trabalho possui o objetivo de contribuir para um melhor entendimento sobre o processo de solidificação da liga de alumínio 319 conformada por spray. O trabalho foi dividido em três etapas: a primeira avaliou a presença dos intermetálicos de ferro variando-se a temperatura de vazamento e o teor de ferro (0,6% e 1,2% em peso); a segunda avaliou a morfologia do eutético Al-Si através das alterações das condições de spray; e, por fim, a terceira avaliou a distribuição de soluto na microestrutura, neste caso, outras ligas de alumínio foram estudadas (2024 e 7050). A discussão dos fenômenos foi realizada a partir de um modelo de solidificação para materiais conformados por spray que divide o processo em duas etapas distintas, sendo a solidificação final ocorrendo a uma taxa de resfriamento relativamente lenta. Os resultados mostraram que através do controle das condições de spray é possível mitigar a formação do intermetálico β-Al9Fe2Si2, assim como alterar a morfologia do eutético Al-Si. A terceira etapa indicou a manutenção de certos elementos em solução sólida em regiões adjacentes aos contornos de grão. Pôde-se concluir que o modelo de solidificação utilizado foi adequado para explicar os fenômenos descritos nas etapas realizadas. / CNPq: 135810/2015-9

Este trabalho procurou identificar o defeito que ocorria no teste de estanqueidade de uma peça e apresentar a correlação entre o nível de porosidade encontrado no produto fundido com a liga de alumínio A356 e os processos de fusão e de manutenção sob temperaturas controladas, o teor de hidrogênio, o sistema de enchimento e de alimentação, obedecendo ao princípio de solidificação direcional e o posicionamento do modelo em relação à linha de divisão. Foram efetuadas algumas experiências com diferentes tempos de introdução de nitrogênio para a purificação do metal, com a inversão do modelo em relação ao plano de partição do molde, com a modificação das dimensões do sistema de enchimento, com a substituição dos massalotes laterais por outros com luvas exotérmicas e utilizando-se resfriadores. Tentou-se verificar os benefícios que os filtros cerâmicos proporcionam aos fundidos, principalmente quanto à diminuição do nível de porosidade, menor turbulência e maior capacidade de reter as inclusões e parte dos filmes de óxidos. Para comprová-los, propôs-se a fundição de peças, em moldes confeccionados pelo processo de areia à verde, com diferentes tipos de filtros cerâmicos nos canais de distribuição. As amostras foram analisadas no Laboratório Metalográfico do Departamento de Engenharia Metalúrgica e de Materiais da Escola Politécnica da Universidade de São Paulo e no Laboratório de Metalurgia e de Materiais Cerâmicos do Instituto de Pesquisas Tecnológicas de São Paulo. Após a análise dos resultados em microscópio óptico, microscópio eletrônico de varredura e em espectrômetro por emissão de energia observou-se que o problema está relacionado principalmente com a alimentação e a solidificação direcional e não somente com o teor de hidrogênio. / The objective of this work is to study the type of defect identified during the pressure tightness test of aluminum parts and to establish a relationship between porosity level of an A356 aluminum alloy and the production processes, hydrogen level, feeding system, and directional solidification. Different nitrogen blowing times, inversion of the mould pattern, relative to the partition line, changing of the feeding system dimensions, replacement of the lateral feeding by exothermic gloves and the use of chills where tested. Ceramic filters were also tested, in order to evaluate their influence on the formation of porosities and on the porosity level, through a decrease of turbulence and an increase in the capacity of retaining non-metallic inclusions and part of the oxide films. Casting was performed by the green sand process using different ceramic filters. The obtained parts were metallographicaly analyzed through optical and scanning electronic microscopy using also EDS analysis. The results showed that porosity is related with the feeding conditions and directional solidification besides the hydrogen content of the alloys.

Orientador: Amauri Garcia / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-04T22:38:42Z (GMT). No. of bitstreams: 1 Santos_NewtonSilva_M.pdf: 11404473 bytes, checksum: e3fa93c65cc03106c6ee4c62e3694589 (MD5) Previous issue date: 2005 / Resumo: O presente trabalho descreve o desenvolvimento de um simulador físico estático do processo de lingotamento contínuo rotativo, como parte de uma metodologia experimental auxiliada por um modelo matemático para a determinação de coeficientes transitórios globais de transferência de calor metal/molde ao longo da solidificação. Através desta metodologia, investigou-se a influência da formação do gap de ar entre as paredes do molde e o metal, na cinética total do processo. O simulador fisico foi construído na mesma escala do processo industrial e constitui-se de um trecho de um equipamento de lingotamento contínuo rotativo Properzi. O simulador é equipado com um sistema de refrigeração à água por bicos pulverizadores, canal de vazamento e termopares acoplados a um sistema de aquisição de dados, onde foram realizados experimentos com ligas utilizadas na indústria de condutores elétricos de alumínio. Para a determinação dos coeficientes transitórios de transferência de calor, após o mapeamento experimental das temperaturas, empregou-se o método de comparação teórico-experimental de perfis térmicos (método IHCP) através de um modelo numérico baseado na técnica de diferenças finitas, aplicada em um volume de controle do sistema experimental. Os resultados obtidos demonstraram consistência da metodologia, permitindo a caracterização destes coeficientes e com isso a possibilidade de se prever a evolução da solidificação em processos industriais / Abstract: The present study describes the development of a static experimental set-up representing the solidification system of a Rotary Continuous Caster, as part of a metholology, which connected to a numerical model permits to determine transient global metal/mold heat transfer coefficients along solidification. By using this methodology the influence of air gap formation between mold walls and metal surface on process kinetics has been investigated . The static simulator has the same escale of an industrial caster and is constituted of a Properzi copper wheel sector, equipped with a spray cooling system, a pouring system and a thermocouple arrangement connected to a data aquisition system. Experiments were performed using aluminum alloys of the electrical conductors industry. The heat transfer coefficients were obtained by using a method base don com pari sons of numerically calculated and experimental thermal profiles (lHCP method). The used numerical model is based on a finite difference technique and applied on a control volume from the experimental system. The results have shown that the used methodology is consistent, permitting the characterization of metal/mold heat transfer coefficients and as a consequence, to predict the solidification evolution in industrial processes / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

Materiais compostos de matriz metálica (CMM) vêm sendo estudados para diversas aplicações. Entretanto, pouco estudo é apresentado na sua confecção a partir de materiais reciclados. Este trabalho teve como objetivo a caracterização de um material composto de matriz metálica (CMM), utilizando material reciclado como matéria prima. Foram usados aparas de chapas de liga de alumínio 2024 descartados para a matriz e carbeto de silício (SiC) como reforço, sendo a produção realizada através do processo de fabricação com base na técnica de conformação por spray para possível aplicação em componentes automotivos. Foi realizado o tratamento térmico do material e a caracterização, determinando as propriedades de dureza, resistência mecânica, resistência ao desgaste, MEV e EDS. Foram ensaiadas amostras do material composto fundido e extrudado, bem como de ferro fundido de uma peça automotiva e da liga de alumínio 2024. Observou-se que o CMM ainda precisa de melhorias no processo de produção para obter propriedades de dureza e resistência que permitam que ele possa ser usado como um substituto para o ferro fundido, porém o mesmo apresentou melhores propriedades quando comparado com o material da matriz. / Metal matrix composites (MMC) have been studied for several applications. However, little study is presented in its manufacture from recycled materials. This study aimed to characterize a metal matrix composite (MMC), using recycled material as raw material. Were used aluminum alloy 2024 plates clippings discarded for the matrix and silicon carbide (SiC) as reinforcement, being the production accomplished through the manufacturing process based on the technique of spray forming for possible application in automotive components. The thermal treatment and the characterization of the materia was accomplished, determining the properties of hardness, mechanical strength, wear resistance, SEM and EDS. Were tested samples of the cast and extruded composite material, as well as cast iron of an automotive part and aluminum alloy 2024. It was observed that the MMC still needs improvements in the production process to obtain properties of hardness and strength that allows it to be used as a substitute forcast iron, but it presented better properties when compared with the matrix material.

Aspersão térmica é um processo de produção de revestimentos com ampla aplicação industrial, utilizado na proteção de superfícies contra a corrosão e/ou o desgaste. Os setores aeronáutico e de moldes plásticos estão entre os que utilizam essa técnica para ampliação da vida útil de seus componentes. Este trabalho teve como objetivo avaliar a influência do processo de deposição de revestimentos metálicos (1248 T - Co-28,5%Mo-17,5%Cr-3,4%Si e 1256 F - Co-28%Cr-4%W-3%Ni-3%Fe), cerâmicos (CRO 192 - Cr2O3-5%SiO2-3%TiO2 e 25030 - TiO2-8%Al2O3) e composto (1342 - WC-12%Co), aspergidos pelas técnicas de combustão por chama convencional (cerâmicos) e HVOF (metálicos e composto), no substrato constituído de uma liga de alumínio AA 7475 endurecida por precipitação, visando o melhoramento de suas características tribológicas (desgaste e corrosão), sem alterar as propriedades mecânicas. A influência do processo no substrato foi avaliada por meio de ensaios de microdureza Vickers, microestruturais e de composição química. A resistência ao desgaste foi avaliada por meio de ensaios de desgaste microabrasivo com esfera, com o uso de uma solução abrasiva de alumina (Al2O3). A avaliação da resistência à corrosão de revestimentos e substrato foi realizada por meio de ensaios de polarização potenciodinâmica em meio de NaCl 3,5%. A deposição dos revestimentos por aspersão térmica não afetou significativamente a dureza, composição química e microestrutura do substrato constituído pela liga de alumínio, tornando viável a aplicação dessa técnica a essa classe de ligas. Os revestimentos foram altamente eficientes na proteção do substrato contra o desgaste microabrasivo, sendo que o revestimento constituído de WC-Co (1342) apresentou o melhor desempenho dentre eles. Quanto à corrosão, todos os revestimentos apresentaram resistênciassuperiores a do substrato, tendo o revestimento Co-Cr-W-Fe-Ni (1256 F) apresentado o melhor desempenho geral. Portanto, os revestimentos produzidos por aspersão térmica são alternativas altamente promissoras para o melhoramento tribológico das ligas de alumínio envelhecidas, sem o comprometimento de suas características mecânicas. / The thermal spray process is used in the production of coatings with a wide range of industrial application such as protection of surfaces against corrosion and/or wear. The aircraft and plastic molds industries are among the ones that use this technique to increase the useful life of components. This work aimed to evaluate the influence of the deposition process of metallic (1248 T Co-28.5%Mo-17.5%Cr-3.4%Si and 1256 F Co-28%Cr-4%W-3%Ni- 3%Fe), ceramic (CRO 192 Cr2O3-5%SiO2-3%TiO2 and 25030 TiO2-8%Al2O3) and composite (1342 WC-12%Co) coatings, deposited by flame spray (for the ceramic) and HVOF (for the metallic and composite) techniques, on the substrate of precipitation-hardened AA 7475 aluminum alloy, intended to improve the tribological characteristics (wear and corrosion), without changing its mechanical properties. The influence of the process on the substrate was measured by Vickers microhardness, microstructural tests and chemical analyses. The wear resistance was evaluated by the calowear microabrasive test, using abrasive slurry of alumina (Al2O3). The corrosion resistance evaluation of coatings and substrate was carried out using the potentiodynamic polarization test in NaCl 3.5%. The coating deposition by thermal spray did not significantly affect the hardness, chemical composition and microstructure of the aluminum alloy substrate, establishing the feasibility of using this technique on this class of alloys. Coatings were highly efficient in protecting the substrate against microabrasive wear, where of the WC-Co (1342) coating showed the best performance among them. Also, the corrosion resistance of all coatings was higher than that of the substrate of which the Co-Cr-W-Fe-Ni (1256 F) coating presented the best overall performance. Therefore, the coatings produced by thermal spray are a highly promising alternative for the improvement of the tribological properties of aged aluminum alloys, without compromising its mechanical characteristics.

Orientadores: Maria Helena Robert, Elisa Maria Ruiz Navas / Tese (doutorado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecânica / Made available in DSpace on 2018-08-19T00:27:43Z (GMT). No. of bitstreams: 1 BravoSalazar_JaimeAlejandro_D.pdf: 9695376 bytes, checksum: d35ebfbcaf1dac8c6665392b7d784d23 (MD5) Previous issue date: 2007 / Resumo: Este trabalho estuda o processo de fabricação de compósitos de matriz de alumínio AA6061 reforçado com TiCN por metalurgia do pó, envolvendo as etapas de mistura de pós, compactação uniaxial e sinterização com fase líquida. Para efeitos de comparação foram produzidos e caracterizados compactados da liga AA6061 sem adição de reforços. Foram investigados os parâmetros de processo: teores de reforço (5% e 10% massa), teor de aditivos Pb e Sn (0,1, 0,15, 0,2 e 0,4% massa), pressão de compactação (400, 600 e 800 MPa), tempos (15, 30, 45 e 60 min) e temperatura de sinterização (590, 600, 610 e 620 ºC). Em cada etapa do processo foram caracterizados os produtos (mistura de pós e compactados); o produto final obtido, após sinterização, foi caracterizado com relação à sua microestrutura, propriedades físicas (densificação e variação dimensional) e mecânicas (resistência à flexão e dureza). Os resultados obtidos mostraram uma grande eficiência do processo na obtenção de compósitos; a adição do teor de reforço de 5%TiCN foi eficiente na promoção de rupturas das camadas de óxidos do pó da liga de alumínio compactado à pressão de 400 MPa, auxiliando a sinterização por difusão da fase líquida formada a partir da fusão de Al+Mg2Si, melhorando a densificação e diminuindo a variação dimensional dos produtos sinterizados. Do ponto de vista metalúrgico, os materiais compósitos obtidos apresentaram microestruturas homogêneas, com uma boa distribuição dos reforços na matriz e relativa diminuição de poros. A adição de Pb e Sn promovem maior eficiência de ativação de mecanismos de sinterização; para compactados produzidos à pressão de 800 MPa, a adição de 0,1% desses elementos já apresentou significativa influência na sinterização. Com relação às propriedades mecânicas e físicas observou-se que a adição de TiCN aumentou quase no dobro de seus valores obtidos quando são comparados com a liga AA6061 / Abstract: This work investigates the process of production of composites of the alloy AA6061 reinforced with TiCN particles, by powder metallurgy involving the steps: conventional mixture of powders, compaction by uniaxial cold pressing and sintering with formation of a liquid phase. For comparative analysis it was also produced sintered AA6061 without addition of reinforcements. The following processing parameters were studied: reinforcing particles content (5 and 10 wt%); content of trace elements Pb and Sn (0.1, 0.15, 0.2 0.4 wt%); compaction pressure (from 400, 600 and 800 MPa); time and temperature of sintering (15, 30, 45, 60 min and 590, 600, 610, 620 oC). In each step products were characterized (powder mixture and green compacts); the final sintered product was characterized related to microstructure, physical (densification and dimensional changes) and mechanical (hardness and bending strength) properties. Obtained results showed high efficiency of the applied process to produce reliable composite products; the addition of 5 wt% TiCN was efficient to promote fracture of the oxide layer in the aluminum particles surface during pressing. At sintering temperatures liquid phase is formed by Al+Mg2Si melting and is distributed among particles through the fractures of the oxide layer, improving the material densification and its mechanical properties. Microstructures obtained showed homogeneous distribution of TiCN and reduced porosity, whereas AA6061 alloy microstructure showed higher porosity. Addition of Pb and Sn promoted higher efficiency of sintering mechanisms in compacts submitted to high pressures, leading to enhanced physical and mechanical properties in those materials. / Doutorado / Materiais e Processos de Fabricação / Doutor em Engenharia Mecânica