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The need for clean and renewable fuel such as hydrogen is driven by a growing worldwide population and increasing air pollution from fossil fuels. One of the major barriers for the use of hydrogen in automotive industry is the storage of hydrogen. Physisorption is the most promising storage technique due to its high storage density, reversibility and rapid sorption kinetics besides being safe and volume-efficient. A major challenge for physisorption is the need to manage the heat of adsorption at cryogenic temperatures. In this thesis, a 6061 aluminum microchannel cooling plate is designed to remove the equivalent heat flux required by the adsorption of hydrogen within an adsorption bed. Therefore, the objective of this thesis is to determine whether laser welding and heat treating strategies can be developed for a 6061 aluminum microchannel cooling plate as part of a larger hydrogen storage thermal management system. Key manufacturing process requirements include controlling the hermeticity, strength and dimensional stability of the heat-treated weld joint. A hermetic microchannel cooling plate was successfully laser welded and heat treated using free convection in air to quench the solution heat treatment. The weld strength and warpage obtained were within acceptable limits. Experimental testing of the fabricated microchannel cooling plate showed acceptable percent error with an experimental heat removal rate within 13.4% of computational fluid dynamics (CFD) analyses and an average pressure drop error of 25%. Calculations show that the cooling plate developed could support a hydrogen storage thermal management system taking up 5.0% and 10.3% of the system displacement volume and mass, respectively. / Graduation date: 2013

Este trabalho tem como objetivo analisar as vibrações no processo de torneamento interno utilizando um porta ferramentas com a relação comprimento/diâmetro alta. Ferramentas com alto comprimento em balanço são susceptíveis a ocorrência de vibrações regenerativas durante a usinagem, alterando a estabilidade dinâmica do processo e gerando um acabamento superficial indesejado. Testes realizados para a obtenção de dados foram feitos utilizando equipamentos de medição como microfone e plataforma para medição das forças. A proposta foi de analisar a influência de parâmetros de usinagem como rotação e profundidade de corte na estabilidade dinâmica do processo de torneamento interno da liga de alumínio 6351-T6. Para isso utilizou-se os dados gerados na elaboração de uma carta de estabilidade do processo. Simultaneamente efetuou-se as simulações no software Matlab utilizando um modelo pré-estabelecido e comparando com os resultados experimentais obtidos. Para a análise dos dados coletados pelo microfone utilizou-se uma placa de aquisição de sinais, um microcomputador e um software para análise, o ITA-Toolbox. Baixas velocidades de corte propiciam maiores profundidades de corte limite devido ao efeito de amortecimento. Os resultados mostraram que este fenômeno começa a ser significativo quando a relação entre a frequência de vibração e a frequência de rotação é de aproximadamente 30 e aumenta consideravelmente para uma relação de 60. Os resultados também mostraram que para profundidades de corte abaixo do raio de ponta da ferramenta tem-se cortes instáveis porém de acordo com os modelos existentes na literatura, para um valor suficientemente abaixo da profundidade de corte o processo é sempre estável. / This work aims to analyze the vibrations in the boring process using a tool holder with high overhang. Tools with high overhang are susceptible to the occurrence of regenerative vibrations during machining, altering the dynamic stability of the process and generating an undesired surface finish. Tests performed to obtain data were made using measuring equipment such as microphone and platform for measuring forces. The proposal was to analyze the influence of machining parameters such as cutting speed and depth of cut in the dynamic stability of the aluminium alloy 6351-T6 boring process. For this purpose, the data generated in the process stability chart was used. Simulations were performed in the Matlab software using a previous model and compared with the experimental results. For the analysis of the data collected were used a microphone, a signal acquisition board, a microcomputer and a software for analysis, the ITA-Toolbox .In the end, the results showed that the depth of cut and the cutting speed have great influence on the vibration and on the stability of the boring process. Low cutting speeds provide greater cut depth of cut due to the damping effect. The results showed that this phenomenon begins to be significant when the relation between the frequency of vibration and the frequency of rotation is of approximately 30 and increases considerably to a ratio of 60. The results also showed that for depths of cut below the tool nose radius has unstable cuts but according to the models in the literature, for a value sufficiently below the depth of cut the process is always stable.

A busca pela qualidade radiográfica com a menor dose de radiação absorvida é uma constante na comunidade radiológica. Juntamente com o princípio ALARA (As Low As Reasonably Achievable), os filtros de alumínio são peças fundamentais para barrar os fótons de baixa energia que não contribuem para a imagem e depositam dose de radiação para o paciente. De acordo com a Portaria n°453, a Agência Nacional de Vigilância Sanitária decretou que todos os equipamentos de raios X odontológicos intrabucais devem possuir a filtração adicional. Nesse sentido, os filtros são peças fundamentais para a proteção radiológica do paciente. Este estudo tem por objetivo caracterizar a composição elementar dos filtros de raios X de equipamentos de raios X odontológicos intrabucais. O estudo também relaciona a composição elementar com a qualidade das imagens radiográficas. A análise dos filtros foi realizada por meio do método de Espectroscopia de Fluorescência de raios X por Energia Dispersiva (EDXRF). Foram analisados, qualitativa e quantitativamente, dez filtros de alumínio. Para avaliar a qualidade das imagens, foram realizadas 30 radiografias periapicais dos dentes molares com 0,3 s de tempo de exposição (dez radiografias) e incisivos com 0,2 s e 0,3 s (vinte radiografias) com os diferentes filtros em um equipamento com os parâmetros de 66 kV e 6,5 mA. Os filtros e as radiografias foram identificadas, para que fosse possível distinguir a que filtro cada radiografia pertencia no momento das avaliações. Todas as radiografias foram feitas sob as mesmas condições. As radiografias foram submetidas à análise das densidades óticas por um densitômetro e posteriormente, enviadas a cirurgiões dentistas radiologistas que fizeram a análise subjetiva. Foram selecionadas três regiões para análise do densitômetro (diferenciadas entre dentes molares e incisivos) e uma região para análise subjetiva (diferentes regiões para dentes molares e incisivos). Os dados obtidos foram correlacionados com a avaliação dos efeitos da composição elementar dos filtros na qualidade das imagens radiográficas. Os elementos encontrados na análise dos filtros foram: Al, S, Cl, Ti, Mn, Fe, Cu, Zn e Zr. Os filtros apresentaram maiores concentrações de alumínio, com mais de 96% sendo os outros elementos contaminantes ou elementos que foram adicionados para melhorar a estabilidade mecânica do filtro. As densidades óticas das radiografias seguiram um padrão nas regiões analisadas, exceto as regiões enegrecidas do filme. A análise subjetiva revelou que muitas das radiografias realizadas poderiam ser aceitas para diagnóstico. Porém, imagens consideradas com baixo contraste obtiveram o mesmo valor de densidade ótica. Os resultados mostraram que a composição elementar dos filtros não modificou a qualidade da imagem. Por conseguinte, os filtros convencionais pesquisados oferecem uma opção aceitável para a produção de imagens de qualidade em radiologia odontológica, apesar das diferenças na composição das ligas. / The quest for radiographic quality with the lowest dose of radiation absorbed is a constant in the radiology community. Along with the ALARA principle (As Low As Reasonably Achievable), the aluminum filters are essential parts to bar the low energy photons do not contribute to the image and cause radiation dose to the patient. According to standard Portaria No. 453, the Agência Nacional de Vigilância Sanitária decreed that all equipment intraoral dental X-rays must have an additional filtration. Acording this, the filters are essential parts to radiological protection of patients. This study aims to characterize the elemental composition of filters used in intraoral X-ray equipment. We also intend to relate them to the quality of the radiographic images. The analysis of the filters was made using the method Energy Dispersive X-ray Fluorescence (EDXRF). Ten aluminum filters were analyzed (qualitatively and quantitatively). To evaluate the quality of images, 30 periapical radiographs of molars to 0.3 s (ten radiographs) and the incisor teeth 0.2 and 0.3 s (twenty radiographs) were performed with different filters. All filters and all radiographs were identified, it was possible to distinguish which folder each radiograph belonged at the time of the evaluations. All radiographs were performed under the same conditions. Radiographs were subjected to analysis of optical density by a densitometer and later, two dentists radiologists realized a subjective analysis. Three regions for analysis of the densitometer (differentiated between molars and incisors) and a region for subjective analysis (for different regions molars and incisors) were selected. The data were correlated with the assessment of the effects of the elemental composition of all filters in the quality of radiographic images. From the results, the elements of the filters in the analysis were: Al, S, Cl, Ti, Mn, Fe, Cu, Zn and Zr. The filters had higher aluminum concentrations (over 96%), other elements were contaminants or components that are added to improve the mechanical stability of the filter. The optical densities of radiographs followed a pattern for the regions analyzed except blackened regions of the film. Subjective analysis revealed that many of the radiographs were accepted for diagnosis. But considered low-contrast images obtained the same value of optical density. Therefore, it is concluded that the elemental composition of filters do not change the image quality. Consequently, conventional filters were evaluated option to produce an acceptable image quality in dental radiology, despite differences in the composition of the alloys.

Várias ligas de Al em cavacos, com diferentes granulometrias foram dissolvidas de modo convencional, com ataque por água régia. Este tipo de decomposição resulta, muitas vezes, em resíduos sólidos, cujas quantidades dependem dos teores de silício. A fim de se comparar os resultados, procedeuse, com esses resíduos, de dois modos distintos: ou foram desprezados ou foram decompostos com ácido fluorídrico, eliminando-se o silício, dissolvendo-se o restante com ácido nítrico e agrupando-o à primeira solução para a determinação de Fe, Cu, Mn, Mg, Cr, Ni, Zn, Pb, Sn, Ti e Zr por ICP-OES. Foi avaliada a influência de quantidades crescentes de Al na determinação destes elementos e, também, a provável interferência espectral de Cu na determinação do Zn (com e sem separação eletrolítica de Cu). A dissolução eletrolítica de ligas de alumínio em cavacos foi estudada pressionando-os contra um eletrodo de platina para que se comportassem como se fossem o próprio ânodo e a eletrólise ocorresse. Uma célula foi construída utilizando-se um tubo (corpo de seringa de 2,5 mL) com perfurações ao redor da base aberta, onde foi colocada uma malha sintética (perlon) no fundo e, sobre esta, a amostra. Na parte superior foi introduzido um pequeno tarugo de acrílico com um fio de platina passando pelo seu interior e com um orifício por onde passava o fluxo (4,5 mL min.-1) da solução eletrolítica (ácido nítrico diluído). Na extremidade inferior, prendeu-se, com o fio, uma plaquinha, também de platina, que pressionava a amostra. A solução saía pelos orifícios inferiores para um béquer de onde era recirculada e onde estava colocado o cátodo, um fio de Pt (de forma de losango), sendo novamente captada e introduzida na parte superior do tarugo do ânodo. Com esse circuito, foram obtidos bons resultados utilizando-se ácido nítrico 1 mol L-1, corrente de 0,6A e tempo de eletrólise de 10 minutos. Sendo a dissolução parcial, é necessário que se conheçam as porcentagens dos elementos por dissolução ácida total de uma liga de composição similar ou por um material de referência certificado. Normalizaram-se os dados pelas porcentagens conhecidas dos constituintes das ligas. Compararam-se os cálculos feitos dos seguintes modos: 1-) pela razão entre a concentração do elemento com a do Al, também determinada; 2-) pela a razão entre a concentração do elemento com a soma das concentrações de todos os elementos determinados, inclusive o Al; 3-) pela razão entre a concentração do elemento e a soma das concentrações só dos outros elementos, sem o Al. O desvio padrão e o erro relativo para os elementos Fe, Cu, Mg, Ni e Cr, quando em teores > 0,1%, foram < 10%; para teores de Zn < 0,2%, foram menores de 10% e para teor de 4,8% foram < 15%. Já para o Mn, quando em teor > 0,2% foram <10% (exceto para a liga B.C.S.268/1). O desvio padrão relativo para o Zr, com teor ao redor de 0,002% foi <10%. Os resultados para o elemento Pb nas ligas B.C.S. 216/1 e 380 tiveram desvio padrão e erro relativo <10%, mas o mesmo não ocorreu na liga B.C.S. 268/1. O elemento Sn apresentou resultados piores, ao redor de 20%. O elemento Ti só deu bons resultados quando em teor de cerca de 0,2%. Para estas determinações foram avaliadas as dissoluções químicas dos metais nas ligas pelo ácido nítrico em diferentes concentrações e temperaturas. Além disso, foram avaliadas duas outras células para a verificação da possibilidade de dissolução eletrolítica das ligas de Al on-line com a determinação por ICP-OES. / Several aluminum alloys with different chips size were dissolved using aqua regia (HCl:HNO3,3:1). The residues of the dissolution procedure were either rejected or used in silicon volatilization with hydrofluoric acid before determination of Fe, Cu, Mn, Mg, Cr, Ni, Zn, Pb, Sn, Ti and Zr by ICP-OES. The influence caused by crescent amounts of aluminum in the determination of other elements and the probable spectral interference by Cu in determination of Zn (with or without electrolytic separation of Cu) was evaluated. The electrolytic dissolution of aluminum alloys was performed by pressing chips against a platinum electrode for the electrolysis to occur, so that way the chips behaved as the anode. A tube (body of syringe of 2.5mL) with perforations around the open base was used to contain the sample and Pt electrode. The alloy was placed on synthetic wool (perlon) in this tube. An acrylic dowel with a platinum wire across its interior was fixed in the superior part a tube with Teflon film, with an orifice through which the electrolytic solution flowed (HNO3 1 mol L-1; 4.5mL min-1). A platinum dish was fixed at the inferior extremity of the platinum wire to press the sample. The solution came out through the inferior orifices of the tube to a flask, from where it was again captured (with a peristaltic pump) to go into the superior part of the tube. In this flask, a Pt wire cathode was also placed. A current of 0,6A and ten minutes of electrolysis provided good results. Due to the partial dissolution, the knowledge of percentages of previous elements analyzed after total dissolution, or using certified reference material are necessary. The results were normalized by known percentages. The calculations were made by: 1-) the ratio between the concentration of the element determind, with the determined concentration of aluminum; 2-) the ratio between concentration of the element and the sum of the concentrations of the elements determined, including Al; 3-) the ratio between the concentration of element and the sum of the concentrations of the elements determined, without the aluminum. The relative standard deviations and accuracy were <10% for the elements Fe, Cu, Mg, Ni and Cr when the concentrations were >0.1%; for the Zn were 15%, when the concentration >0.2%, and <10% for concentration <0.2%. For Ti with concentration of about 0.1%, were 15%. Relative standards deviations for the Zr, with concentration of 0.002%, were always <10%. The element Pb, Sn and Mn didnt provide good results. For these determinations, the chemical dissolution of the elements with different nitric acid concentrations and temperature was evaluated. Two other cells for the electrolytic dissolution of Al alloys followed by online ICP-OES determination were examined.

A soldagem por fricção (Friction Stir Welding - FSW) é um processo eficiente de unir ligas de alumínio de alta resistência evitando defeitos que são usualmente criados quando técnicas convencionais de soldagem são utilizadas. A indústria aeronáutica tem mostrado grande interesse neste método de soldagem, tanto para a união de ligas similares como dissimilares. Entretanto, este processo causa modificações microestruturais dependentes das condições de tratamento térmico ou termomecânico. Contato elétrico entre zonas de microestruturas diferentes, por sua vez, pode resultar em acoplamento galvânico. No presente estudo, a soldagem por FSW foi usada para unir duas ligas de alumínio dissimilares, AA2024-T3 e AA7475-T651 e o efeito desta soldagem na resistência à corrosão das juntas soldadas e na microestrutura das ligas foi avaliada. Na investigação da resistência à corrosão foram utilizados ensaios eletroquímicos, especificamente, medidas de potencial de circuito aberto (OCP) em função do tempo de exposição ao meio corrosivo, ensaios de polarização e de espectroscopia de impedância eletroquímica, global (EIS) ou local (LEIS), em duas soluções, seja 0,1 M Na2SO4 ou 0,1 M Na2SO4 + 1 mM NaCl. Os ensaios eletroquímicos evidenciaram efeito de acoplamento galvânico nas juntas soldadas. A caracterização microestrutural foi realizada por microscopia ótica, microscopia eletrônica de varredura, microscopia eletrônica de transmissão e por calorimetria diferencial. As zonas afetadas pela solda tiveram importantes modificações na microestrutura indicadas pela precipitação e dissolução de precipitados que afetam a resistência à corrosão localizada. A resistência à corrosão intergranular e a resistência à esfoliação das juntas soldadas também foram avaliadas e comparadas com as das ligas AA2024-T3 e AA7475-T651 não soldadas. Os resultados mostraram aumento da suscetibilidade das juntas soldadas a estas formas de corrosão em comparação com as ligas não soldadas sendo observado ataque mais severo na liga AA7475-T651. A identificação das áreas anódicas e catódicas resultantes do acoplamento galvânico nas juntas soldadas foi realizada por teste que consistiu na deposição de camada de gel (ágar-ágar) com indicador universal na superfície das ligas soldadas. A liga AA2024-T3 atuou como cátodo, enquanto a AA7475-T651, como ânodo no par galvânico. Além disso, evolução de hidrogênio foi observada na região de interface entre a zona termomecanicamente afetada e a termicamente afetada da liga AA7475-T651 mostrando que reações catódicas também ocorreram localmente nesta última liga. Resultados de LEIS obtidos nas diferentes zonas das duas ligas soldadas por FSW mostraram acoplamento galvânico na interface entre elas para tempos curtos de ensaio e deslocamento da região mais ativa com o tempo de ensaio para a liga AA7475-T651, mais precisamente para a interface entre a zona termomecanicamente afetada e a térmicamente afetada desta liga. / Friction Stir Welding (FSW) is an efficient process of joining high strength aluminum alloys avoiding defects that are usually created when conventional welding techniques are used. The aircraft industry has shown great interest in this welding method, both for welding of similar or dissimilar alloys. However, this process causes microstructural changes that are dependent on the thermal or thermomechanical conditions applied. Electrical contact between zones of different microstructures, in turn, can result in galvanic coupling. In the present study, FSW was used to join two dissimilar aluminum alloys, AA2024-T3 and AA7475-T651 and the effect of this process on the corrosion resistance of the welded joints and on the microstructure of the alloys was evaluated. For corrosion resistance evaluation, electrochemical tests were used, specifically, open circuit potential measurements (OCP) as a function of time of exposure time to the corrosive environment, polarization tests, and electrochemical impedance spectroscopy, global (EIS) or local (LEIS), in two solutions, either 0.1 M Na2SO4 or 0.1M Na2SO4 + 1 mM NaCl. The electrochemical tests showed galvanic coupling effects in the welded joints. Microstructural characterization was carried out by optical microscopy, scanning electron microscopy, transmission electron microscopy and differencial scanning calorimetry. The welded affected zones showed significant microstructural changes indicated by precipitation and dissolution of precipitates that affect the localized corrosion resistance. Intergranular and exfoliation corrosion resistance of the welded joints were also evaluated and compared to those of unwelded AA2024-T3 and AA7475-T651 alloys. The results showed increased susceptibility of welded joints to these forms of corrosion in comparison with the unwelded alloys with more severe attack associated to the AA7475-T651 alloy. Identification of anodic and cathodic areas due to galvanic coupling in the welded joints was evaluated by a test consisting in depositing a gel layer (ágar-ágar) with universal indicator on the surface of the welded alloys. The AA2024-T3 alloy worked as cathode, while the AA7475-T651 as anode in the galvanic coupling. Furthermore, hydrogen evolution was observed at the interface region between the thermomechanically affected zone and the heat affected alloy AA7475-T651 showing that cathodic reactions also occurred on this last alloy. LEIS results obtained in different zones of the two FSW welded alloys showed galvanic coupling at the interface between them for short test times and displacement of the most active region to the AA7475-T651 alloy, at longer periods of test, specifically to the interface between the thermomechanically affected and the heat affected zones of this last alloy.

Le matériau étudié est un alliage Al A356, utilisés pour produire des têtes de cylindres pour l'industrie automobile par fonderie. Le matériau présente une microstructure dendritique assez grossière dans une matrice eutectique, avec une taille moyenne de grains de 25 microns, des précipités intermetalliques et des porosités. Les propriétés de traction sont fortement affectées par la température d'essai, avec une baisse assez sensible du module de Young, de la limite d'élasticité lorsque la température augmente. La durée de vie de fatigue isotherme chute de façon marquée (approximativement d'un facteur 10) lorsque la température d'essai est portée de 120 à 280 °C, en déformation imposée. Du essais thermomecaniques cycliques en phase, avec une température variant de 120 à 280 °C, on montré que la durée de vie en anisotherme est assez similaire à celle obtenue en conditions isothermes à 280 oC. Dans ce cas, les dommages causés par le chargement thermomécanique cyclique se produisent à la température la plus élevée du cycle. Les essais de relaxation ont montré l'existence de deux comportements distincts. À basse température, le matériau présente de l'écrouissage cyclique tandis qu'il s'adoucit cycliquement à des températures plus élevées. A partir des résultats de croissance des fissures de fatigue, on a observé que la température et la forme du cycle de fatigue a une forte influence sur la vitesse de fissuration par fatigue ainsi que sur le facteur d'intensité des contraintes seuil. Une loi de comportement élastique visco-plastique non-isotherme a été identifiée pour le matériau. Les paramètres de comportement mécanique sont statistiquement distribués du fait de la fabrication du matériau par fonderie. Toutefois, il a été démontré que le modèle était capable de se reproduire, avec une approximation raisonnable, les essais contrainte-déformation à des températures différentes, pour le cas isotherme et anisotherme. / The studied material is an A356 Al alloy, used to produce engine cylinder heads for the automotive industry by die casting process. The material displays a quite coarse dendritic microstructure in a eutectic matrix, with a mean grains size of 25 microns, intemetallic precipitates and porosities. The tensile properties are strongly affected by testing temperature, with a quite sensitive drop of the Young's modulus, the Yield stress as the temperature was raised. The isothermal fatigue life dropped of markedly (approximately 10 times) when the testing temperature is raised from 120 to 280 °C, under strain control. From the themomechanical in-phase cyclic tests, with temperature varying from (120 to 280 oC), it was possible to observe that life is quite similar to the isothermal fatigue test at 280 oC. In this case, the more sensitive damage caused the in-phase mechanical and thermal cycle take place at the highest temperature. Relaxation tests indicated two distinct behaviors, with the temperature of 240°C being a threshold. At lower temperatures, the material hardens cyclically whereas it softens cyclically at higher temperatures. From the fatigue crack growth results, it was observed that temperature and wave shape has a strong influence on the crack growth rate as well as on the stress intensity threshold. Considering sinusoidal wave shape (10 Hz), as the temperature increased the DKth decreased and the crack propagation rate increased. However, the rate as da/dN change with temperature is quite similar, as an indicative that the micromechanism of crack growth has not changed due to the high frequency used, and it was due only to loss of mechanical strength. An elastic-visco-plastic non-isothermal constitutive law was identified for the material. For the cast material studied in this work, the mechanical behavior parameters are statistically distributed. However, it was shown that the model was able to reproduce, with a reasonable approximation, the stress – strain relationship at different temperatures, for the isothermal and anisothermal cases. / Para caracterizar componentes usados em aplicações de alta responsabilidade não basta apenas conhecer a composição química e os resultados de ensaios de tração, impacto e dureza, pois estes podem não fornecer os subsídios necessários que permitam prever, de maneira confiável, o comportamento dos componentes nas condições reais de trabalho. Exemplo disto são os cabeçotes de motor automotivos, submetidos a tensões térmicas e mecânicasrelativamente altas durante seu uso normal e altíssimo em condições extremas. Durante longos tempos de funcionamento e eventuais falhas na refrigeração e ou lubrificação a temperatura pode chegar a valores próximos de 300ºC. Esta variação de temperaturas provoca choques térmicos que podem gerar trincas e/ou uma grande quantidade de deformação plástica em regiões próximas aos pistões. Desconsiderando a presença de choques térmicos provocadospor falhas, ainda assim, uma pequena quantidade de ciclos de acionamento e parada do motor, é considerada como os principais causadores de pequenas trincas. Isso indica que o surgimento de trincas em cabeçotes de motor deve ser considerado um problema de fadiga termomecânica de baixo ciclo. Outro problema é a heterogeneidade microestrutural no componente devido ao processo de fundição, levando a propriedades mecânicas e físicas diferentes em uma mesma peça. Além da presença de porosidade gerada por bolhas de gás e vazios de solidificação, que podem adquirir tamanho tal que se aproximem de pequenas trincas, diminuindo a vida para a nucleação e assim mudando o foco do problema para o de propagação de trinca por fadiga. A proposta deste trabalho foi a de determinar as propriedades de fadiga isotérmica e termomecânica através de ensaios de fadiga de baixo ciclo, bem como as propriedades de propagação de trinca por fadiga, relaxação, caracterização microestrutural e modelagem do comportamento mecânico por elementos finitos para a liga de alumínio utilizada na fabricação de cabeçotes de motores automotivos pela indústria nacional. Todos os ensaios e análises computacionais foram realizados nos laboratórios da Universidade de São Paulo (EESC-USP) e da École Normale Supérieure de Cachan (ENS-LMT). Os ensaios de fadiga isotérmica foram realizados nas temperaturas de 120ºC e 280ºC e os ensaios termomecânicos foram realizados em fase entre as temperaturas de 120ºC e 280ºC. Os ensaios de relaxação foram realizados em várias temperaturas com carregamento de onda trapezoidal, enquanto que os ensaios de propagação de trinca por fadiga foram realizados nas temperaturas de 120ºC, 200ºC e 280ºC para arregamentos de onda senoidal e trapezoidal em controle de carga e de deslocamento. Foi feita também análise microestrutural nos corpos de prova, após os ensaios de fadiga, por microscopia óptica e por microscopia eletrônica de varredura MEV.Os resultados destes ensaios mostraram que os defeitos de fundição e a falta de homogeneidade no material, aliados a longos tempos de exposição a carregamentos e em altas temperaturas, constituem um fator crítico no desempenho do componente. Estes resultados ajudarão a estabelecer modelos precisos de previsão de vida para os cabeçotes de motor.

A large number of advanced structural materials are based on metallic materials where alloying additions play a key role in imparting the required properties. Most of the commercially important aluminium alloys are classified by the nature of the alloying additions. Among them the 2219, 2618, 5086, and 7075 are important class of lightweight alloys that plays critical role in modern engineering application. However, despite having a series of commercially useful aluminum alloys for commercial applications the increasing need of improved performance requires newer development in particular for applications that require high strength at elevated temperatures and performance at extreme environments. Precipitations of the intermetallic compounds containing copper during thermal treatments play a very important role in developing high strength aluminium alloys. Although,these precipitates are stable at fairly high temperatures, the rapid coarsening of these second phase precipitates (e.g. Al2Cu), leads to loss of strength at elevated temperature. Several approaches are explored to overcome this problem. One of them is to utilize non-equilibrium solidification route, which can increase solid solubility and hence increasing the precipitate density. Nonequilibrium processing can also alter the selection pathway of the competitive phases and evolution of the microstructure. Recently, non–equilibrium solidification by suction casting technique is becoming increasingly popular for casting of metallic materials of any shape. In this technique solidification is effected by sucking the molten alloy into water cooled copper mold using a suction force resulting from the differences between the melting chamber in Argon gas pressure and casting chamber under vacuum. The present thesis aims to develop a set of newer alloys with small amount of alloying additions primarily based on nickel that can retain reasonable strength at high temperature by utilizing the non-equilibrium solidification route. In addition to Ni (≤ 0.10at.%), the thesis present results of the effect of minor addition of Sc and Zr as ternary and quaternary additions. Following a short review in chapter 2, Chapter 3 presents the experimental techniques adopted for both preparation of alloys and their characterization. Chapter 4 deals with the results of alloying of aluminum with minor amount of nickel. The Ni in the range of 0.05-0.20at% was used to develop a high temperature template, containing a set of hardening intermetallic compounds to increase the strength of the host matrix. The microstructural investigations of the suction cast alloys reveal a characteristic feathery microstructure. At higher magnification the microstructure reveals the presence of fine dispersions of a second phase. Both x-ray and transmission electron microscopy confirms the phase in the dispersions to be primarily crystalline Al9Ni2 phase having a monoclinic crystal structure. This phase does not exist in equilibrium phase diagram. Only at higher concentration one can observe equilibrium Al3Ni (Orthorhombic) particles. The size of the particle ranges from 50-200nm. Beyond~0.5at%Ni, the microstructure changes to normal cellular type solidification morphology with interdendritic space decorated by the eutectic network of Al-Al3Ni having a rod eutectic morphology. A careful observation of alloys with small amount of Ni reveals that the feathery structure is associated with the thin cells, which have grown by continuously splitting the tip yielding a fractal like dendritic morphology. The dispersoids form at the intercellular regions. We have presented clear evidence of their origin from the interdendritic liquid, which most likely underwent Rayleigh instability. The random distribution reflects the nature of the dendritic growth. We have argued that these inter-dendritic liquid droplets, which are enriched with Ni, get undercooled. The metastable Al9Ni2 phase nucleates and grows in this liquid. In order to confirm this scenario, we have carried out a phase field simulation for dendritic growth of aluminium solid solution in the alloy melt both under the condition of constraint growth and free growth. The observed distribution of the dispersoid is well reflected in the phase field simulation. The chapter also report the response of effect of direct ageing of suction cast alloy as one expect an extension solid solubility of Ni in Al. A small increase in hardness could be observed during ageing treatment. In order to determine the thermal stability of the intermetallic particles, the samples of the suction cast alloys were exposed at 200°C for 200h and 500°C for 100h respectively. No change in the microstructure could be observed excepting a slight coarsening indicating the dispersed particles are thermally stable. After exposure at two different temperatures the maximum retained hardness was measured to be 350MPa. We have also attempted to correlate the hardness with coarsening behavior of particles. The feathery morphology of the cast structures and fine dispersion of the intermetallic phase is expected to improve the tensile strength of the alloy. The tensile yield strength of cast alloys was determined to be 150MPa ± 20 for Al- 0.09at%Ni alloy. We have tried to estimate the expected strength of the alloy from quantitative microstructural parameters using possible hardening mechanism. The estimates are in good agreement to the observed values. The chapter 5 reports attempts to develop thermally stable precipitation strengthened aluminum alloys by retaining the dispersion template developed earlier alloyed with Ni. Then, the binary alloys were added with extremely low diffusivity element Zr. The element Zr is traditionally added in the aluminium alloys as grain refiner and as a powerful agent for inhibiting recrystallization especially for high strength aluminium alloys. However, in this work we have alloyed Zr for imparting precipitation hardening. An amount of 0.15at%Zr was added to the suction cast alloys of Al-0.05, 0.09 and 0.20at%Ni. The first two alloys exhibit the formation of metastable phase Al9Ni2 during solidification stage. Increase the concentration of the alloy to Al-0.20at% Ni with 0.15at%Zr additions exhibits combination of both stable Al3Ni and Al9Ni2 metastable phases. Microstructures of these alloys show columnar cells of ~200μm with dispersions of spherical nodules of Al9Ni2 and Al3Ni with varying size ranges from 200-500nm. Particle size distribution of Zr containing aluminium alloys with 0.05at% Ni is 595nm ± 20 while the alloy having the 0.09 at% Ni has the optimum size of 290nm. Further increase of Zr composition above 0.20at % led to columnar to equiaxed transition. The as cast alloys containing Zr does not show the improvement with limited yield strength of the order of 150MPa. The equivalent hardness of the samples has been measured to be about 370-420MPa. Heat-treated alloys however show the presence of Al3Zr (L12) precipitates with ~20nm size that are coherent with the matrix. Binary suction cast Al-0.15at%Zr alloy after ageing exhibits tensile yield strength of ~200MPa. With ternary aluminium alloy with minor additions Ni and Zr, The strength increases to ~300MPa. Additionally, the alloy continue retain a maximum hardness of 870-920MPa even after long hours of aging. The Zr containing alloys were proved to be stable. When the tests were carried out on a nominally alloyed sample of Al-0.09at%Ni-0.15at%Zr peak aged and exposed to 250°C for 200h, the yield strength under compression tests was found to be 280MPa. The chapter 6 of the thesis discusses the role of Sc with the ternary Al-alloys with Ni and Zr. Addition of small quantities 0.1 and 0.2at%Sc substantially reduces the inter-particle distance of precipitates by increasing volume fraction and number of nano-sized particles. It has been observed and presented in this thesis that the Sc addition provides the highest incremental strengthening per atom percent of any alloying element. Chill-suction cast samples show equiaxed cells in the samples with dispersions of particles inside and some segregated particles at the cell boundaries. To achieve a further increase in the number density of precipitates we processed the suction cast alloys with additional heat treatment at 375 and 450°C. All the suction cast alloys with varying Ni content and keeping the Sc and Zr constant at 0.10 and 0.15at% respectively exhibit formation of Al9Ni2 phase. The alloy Al-0.20at%Ni-0.10at%Sc-0.15at%Zr also contain stable phase of Al3Ni with an eutectic morphology. The DSC experiments in the dynamic mode with heating rate of 10°C min-1 exhibit two distinct exothermic peaks due to precipitates from solution at 375 and 450°C. The TEM analysis using STEMEDX has further confirmed the existence of nano-sized particles 30-50 nm of both phases of Al3Sc and Al3 (Sc, Zr). The tensile yield strength of the as cast alloy show 200MPa while after precipitation treatment, we observe improved yield strength 350-450MPa. Thermal stability of the alloys were tested after peak aged condition and exposed to 200°C for 250h. The results show that the yield strength is unaffected implying the coarsening resistance of the precipitate particles. Overall the thesis establishes that with minimum alloying additions, it is possible to design alloys that are expected to perform for high temperature applications by the formation of set of dispersions of Al9Ni2 (monoclinic) and precipitates of ordered cubic phases of (L12) structure of Al3Zr, Al3Sc and Al3 (Sc, Zr) with required number density of particles.

This diploma thesis focuses on improvement of the existing technology of the flange part in cooperation with the company Znojemské strojírny, s r.o. The theoretical part describes the technologies used in machining of the component. Subsequently, cutting materials and aluminum alloys are dealt with. A detailed analysis of the existing technology is performed in the practical part of the thesis followed by rationalization of the production process, which was carried out with respect to time and financial savings. A new technological procedure is developed after the improvement of the current production process. Finally, a technical-economic evaluation of the design improvement process is carried out.

The theoretical part of the thesis deals with materials used in the aircraft industry with a focus on aluminium alloys. Then it describes high speed machining, its characteristics and its comparison with conventional machining. The following chapters describe strategies of machining thin-walled parts and a description of vibration that occurs during machining. The practical part deals with selection appropriate tool geometry, machining of thin-walled parts and evaluation of their deflection during machining.