Coatings are often used as a means of protecting aluminum alloy and steel structures in industry. The assessment of corrosion under these coatings can be challenging. Corrosion sensing coatings can exhibit properties that allow undercoating corrosion to be identified before it can be seen with the naked eye. This would be very advantageous and could potentially result in tremendous savings in time and money when structures undergo routine maintenance. Our work involved the study of corrosion sensing coatings with incorporated fluorescent indicators that can be used to sense the undercoating corrosion on metal substrates. The fluorescent indicator in the coated-aluminum system was a negative indicator, i.e. the indicator in the coating was initially fluorescent and subsequently non-fluorescent due to the reduced pH at the anodic sites of corrosion. The fluorescent indicator in coated-steel system was positive, in the sense that the coating changed from non-fluorescent to fluorescent over the cathodic areas due to increased pH. The corrosion sensing coating was composed of commercial epoxy-polyamide and the indicator: 7-amino-4-methylcoumarin (7-AMC) for the coated-aluminum alloy system and 7-diethylamino-4-methylcoumarin (7-DMC) for the coated-steel system. The feasibility of using 7-AMC for sensing early undercoating corrosion was demonstrated by using fluorescent observations, Electrochemical Impedance Spectroscopy (EIS), Scanning Electron Microscope (SEM) and Energy Dispersive Spectroscopy (EDS) tests. EIS results estimated that with continuous immersion the undercoating corrosion occurred within 24 hours after immersion in the salt solution. When corrosion occurred, the corrosion was invisible under natural light. However, small spots appeared in the fluorescent image, changing from initially fluorescent to non-fluorescent where the anodic sites were identified by SEM and EDS. In other words, the fluorescent indicator could sense the early undercoating corrosion, although blistering can be a competing mechanism associated with corrosion under some conditions. The sensitivity of the 7-AMC corrosion detection system was tested by applying anodic current to the metal and measuring the charge at which fluorescence quenching was detected. The critical charge for a detectable pit under the coating was approximately 2x10⁻⁵ C, which implied a critical radius of a single corrosion spot or set of spots of approximately 10 [mu]m. The fluorescent properties of 7-AMC, its effect on the protectiveness, its sensitivity to pH and its concentration in the coating are explored as well. Fourier transform spectroscopy (FTIR) was used to characterize the structure of the coating with and without 7-AMC. The results suggested that there is no structure change occurring after adding 7-AMC into the coating. Fluorescence behavior, electrochemical behavior, microscopic evidence, and visual observations of coated steel specimens with 7-DMC are compared based on exposure to saltwater conditions. Some of the challenges associated with the use of these types of coatings will be presented. This includes the interference from the increased production of ferrous and ferric ions. All of this information is aimed at the development of corrosion sensing coatings that can reveal undercoating corrosion before it is visible to the naked eye. / text

The equation for the conservation of momentum in the mushy zone during solidification is derived using the volume averaging technique. The conditions under which the momentum equation reduces to Darcy's law are elucidated. Permeabilities for flow of interdendritic liquid in Al-Cu alloys with equiaxial structures are measured using a simple, cost-effective permeameter. Center-to-center distance between grains (180 μm to 450 μm), specific surface (3.21 x 10⁻² μm⁻¹ to 3.095 x 10⁻¹ μm⁻¹), and volume fraction liquid (0.166 to 0.434) are the structural parameters studied in this investigation. Permeability in Al-Cu alloys with equiaxial grains is structure sensitive. For example, permeabilities for globular structures (nondendritic) are approximately one order of magnitude greater than permeabilities for the dendritic-globular structures, when the volume fraction liquid is approximately 0.3. To better understand the dependence of permeability on structure morphology, structure evolution during the permeability testing was studied in isothermal coarsening experiments. Dimensionless permeabilities based on specific surface, and center-to-center distance between grains are presented along with the theoretical results for flow through different arrays (simple cubic, body-centered cubic and face-centered cubic) of uniform spheres. With dimensionless permeability defined as KSᵥ², where Sᵥ is the specific surface of the solid, the empirical data compare reasonably well with theoretical curves for flow through arrays of uniform spheres. Numerical experiments are performed to obtain permeabilities for flow parallel to primary dendrites in columnar structures with high volume-fraction liquid where physical experiments may fail. The results of numerical experiments are presented along with the analytical results for flow parallel to cylinders arranged in square and triangular packing, analytical results for flow through periodically constricted tubes and the available empirical data. The results indicate that there is a transition in the behavior of permeability in the neighborhood of volume fraction liquid equal to 0.65.

In this work, three aluminum sheet alloys, AA5754, AA5182 and AA6111, which are prime candidates for replacing mild steel in automobile structures, are tested in tension at quasi-static and high strain rates. <br /><br /> In order to characterize the constitutive response of AA5754, AA5182 and AA6111 at high strain rates, tensile experiments were carried out at strain rates between 600 s^-1 and 1500 s^-1, and at temperatures between ambient and 300??C, using a tensile split Hopkinson bar (TSHB) apparatus. As part of this research, the apparatus was modified in order to provide an improved means of gripping the sheet specimens. Quasi-static experiments also were conducted using an Instron machine. <br /><br /> The experimental data was fit to the Johnson-Cook and Zerilli-Armstrong constitutive models for all three alloys. The resulting fits were evaluated by numerically simulating the tensile experiments conducted using a finite element approach.

Aluminum-lithium alloys have been under development for lightweight - high strength aerospace structures but implementation has been slowed significantly because of poor short transverse fracture toughness and brittle intergranular delamination cracking. The alloy AF/C458 (now designated AA 2099) has been designed to exhibit decreased mechanical anisotropy and improved fracture toughness while maintaining ductility and strength levels. This thesis examines the application of Friction Stir Processing (FSP) of AF/C458 as an approach to refine and homogenize the grain structure and enhance mechanical properties. FSP of peak-aged material results in refined, equiaxed grains but with reduced hardness due to the heat input of the process. The effect of post-FSP heat treatment has been established and the influence of FSP on tensile and fatigue properties has been determined.

No description available.

O objetivo deste trabalho foi o de otimizar a adição de estrôncio em liga A356 visando obter as melhores propriedades mecânicas de ductilidade. Foram estudados diferentes níveis de adição de estrôncio em ligas A356 com dois níveis de fósforo residual. Além disto, foi estudado o efeito de adições crescentes de magnésio na morfologia do silício em liga Al-7%Si modificada. Para a realização deste estudo, foram produzidos corpos de prova de tração segundo ASTM B108 com velocidade de resfriamento de 8°C/s. Os corpos de prova foram endurecidos por precipitação via tratamento térmico e tracionados. Além de uma avaliação quantitativa das propriedades mecânicas, amostras de todas as condições passaram por uma avaliação metalográfica qualitativa. Foi feito também ataque profundo para observação das morfologias das partículas de silício em microscópio eletrônico. O efeito da adição crescente de estrôncio na liga A356 em um intervalo de 0 a 256 ppm de estrôncio foi o de aumento do alongamento até teores de 50 a 60 ppm, seguido de uma diminuição do mesmo até 256 ppm. O teste de adição crescente de estrôncio foi repetido para uma liga A356 com teor residual de fósforo de aproximadamente 10 ppm. A curva de alongamento segue o mesmo formato da curva levantada para amostras que não continham fósforo, embora tenha sido encontrada uma sensível queda nos valores de alongamento na presença de fósforo. A presença de magnésio em ligas Al-Si modificadas por estrôncio foi responsável por uma mudança na morfologia de crescimento das partículas de silício nas regiões de contornos de células eutéticas, além do aparecimento de partículas intermetálicas nesta mesma região. Deste trabalho, concluiu-se que as melhores propriedades mecânicas de ductilidade foram obtidas para a adição de estrôncio de 50 a 60 ppm. / This work has, as its main objective, the optimization of the strontium addition in A356 alloy, in order to obtain the best ductility results. The addition of several different strontium amounts in alloys containing two phosphorous amounts was studied. Besides, the effect of increasing magnesium content on the morphology of the silicon particles of Al-7%Si modified alloy was also studied. Test bars were produced from ASTM B108 cooled at a rate of 8°C/s. The samples were heat treated and then tested. The mechanical properties were evaluated and the microstructures were analyzed. The silicon morphology was observed in deep etched samples at SEM. Strontium additions of 0 to 256 ppm increased the elongation up to 50-60 ppm. Above 75 ppm, the addition of strontium caused the elongation to decrease up to 256 ppm. The same test was reproduced for an alloy containing approximately 10 ppm P and, although the best results were achieved at strontium additions of 50-60 ppm, the elongation results were clearly lower. The presence of magnesium in Al-7%Si modified alloys was responsible for a change in the growth morphology of the silicon particles, especially near grain boundaries, and also for the formation of intermetallic particles in those areas. From this work, it was possible to conclude that the best ductility properties are achieved for strontium additions of 50-60 ppm.

A resistência à corrosão das ligas de alumínio está relacionada ao meio de exposição, composição química, presença de intermetálicos e microestrutura do metal, entre outras. Neste trabalho investigou-se a corrosão nas ligas de alumínio 3105 H16 e 5052 H34, comumente utilizadas na indústria de carrocerias de ônibus, em meio aquoso continham íons agressivos, tais como cloretos, sulfatos e hidroxilas. Avaliou-se comparativamente o comportamento destas ligas com os revestimentos de proteção de Nanocerâmico, Cromo VI, Cromo III e Sistema de Pintura em exposição atmosférica acelerada e imersão em diferentes meios agressivos. Estudos mais aprofundados restringiram-se às ligas sem tratamento, para as quais foram realizados ensaios de exposição acelerada em névoa salina neutra, névoa salina acética, câmara de umidade e exposição atmosférica natural. Microscopia eletrônica de varredura por emissão de campo foi empregada para caracterizar a superfície das ligas antes e após os ensaios de névoa salina neutra e acética. O comportamento eletroquímico das ligas sem tratamento foi determinado através do monitoramento do potencial de circuito aberto, curvas de polarização potenciodinâmica anódicas e espectroscopia de impedância eletroquímica. Os resultados mostraram que o tratamento de Cromo VI foi o que obteve melhor desempenho na proteção de ligas de alumínio, particularmente para a liga 5052. De um modo geral, a liga 5052 apresentou maior resistência à corrosão nos meios testados em presença ou não de tratamentos superficiais. Na exposição à névoa salina, a corrosão manifestou-se principalmente na forma de pites. Ficou comprovado que o efeito do íon Cl- é importante, porém o fator preponderante do comportamento à corrosão das ligas de alumínio está relacionado ao pH do meio de exposição, sendo este recomendado para avaliar revestimentos protetores. Além das condições do meio ao qual o metal será exposto, na seleção de tratamentos anticorrosivos é importante considerar as particularidades de cada liga, uma vez que suas características composicionais e microestruturais exercem relevante influência no desempenho à corrosão. / The corrosion resistance of aluminum alloys is related to the exposure medium, chemical composition, presence of intermetallic particles and metallic microstructure, among others. This work investigated corrosion of 3105 H16 and 5052 H34 aluminum alloys commonly used in the bus body industry in aqueous media containing aggressive ions, such as chlorides, sulfates and hydroxyls. The behavior of these alloys with the protective coatings of Nanoceramic, Chromium VI, Chromium III and Paint System in accelerated atmospheric exposure and immersion in different aggressive media was evaluated comparatively. Further studies were restricted to untreated alloys for which accelerated exposure tests were performed on neutral salt spray, acetic salt spray, moisture chamber and natural atmospheric exposure. Field scanning electron microscopy was used to characterize the alloys surface before and after neutral and acetic salt spray tests. The electrochemical statement of the untreated alloys was determined by monitoring the open circuit potential, anodic potentiodynamic polarization curves and electrochemical impedance spectroscopy. Results have shown that the treatment with Chromium VI was the one that obtained better performance in the protection of the aluminum alloys, particularly for 5052 alloy. In general, 5052 aluminum alloy presented greater resistance to corrosion in all tested media, with or without surface treatments. Under salt spray exposure, the corrosion attack appeared mainly in the form of pitting. It has been proven that the effect of Cl- ion is important, but the predominant factor on the corrosion behavior of aluminum alloys is related to the pH of the exposure medium, which is recommended to evaluate protective coatings. Besides the conditions of the medium to which the metal will be exposed, in the selection of anticorrosive treatments it is important to consider the particularities of each alloy, since its compositional and microstructural characteristics exert a relevant influence on the corrosion performance.

Aluminum alloys are the subject of increasing interest (in the automotive industry, as well as aircraft industry), aiming to reduce the weight of components and also allowing a profit in term of energy saving. Concerning the assembly, riveting has been widely used in the aircraft industry, whereas welding seems to be promising in the car industry in the case of aluminum alloys. Nevertheless, welding can generate defects, such as porosity or hot cracking, which could limit its development. One of the major problems associated with the welding of aluminum alloys is the formation of gas porosity. Aluminum alloy cleanliness remaining one of the aluminum industry's primary concerns, this project focuses on the formation and distribution of porosity in Al-Si welds. A literature review has been performed, to identify the mechanisms of porosity formation in welds and castings. Porosity distribution in welds has been investigated, based on three different welding techniques: hybrid Laser/MIG welding process, the electron beam welding process, and the MIG dual wire welding process. Porosity distribution results provide information on to the porosity formation mechanisms involved during welding. A complete microstructure, microhardness and EDX analysis have been carried out, to describe and quantify the solidification process within the welds.

Orientador: Marcelo dos Santos Pereira / Banca: Manoel Cleber de Sampaio / Banca: Alves Rosinei Batista Ribeiro / Resumo: O processo de rebitagem é largamente utilizado na indústria aeronáutica para fabricação de fuselagens de aviões. Durante esse processo deformações locais são introduzidas nas estruturas por meio da expansão dos rebites devido sua conformação. A deformação plástica causa uma expansão no rebite e consequentemente na estrutura circundante onde o mesmo foi inserido. Este trabalho tem como objetivo analisar o efeito da anisotropia na propagação da deformação induzida em corpos de prova de ligas 2024 que passaram pelo processo de rebitagem, em chapas de alumínio termicamente tratadas. O experimento avaliou como a geometria do grão, relacionadas ao tamanho e forma dos mesmos, assim como o efeito do tratamento térmico, influenciam na expansão diametral. Foram empregados corpos de prova de liga de alumínio 2024 com tratamento térmico T3 e TO, comumente utilizadas pela indústria aeronáutica, em diferentes direções de grãos, longitudinal e transversal, onde foram cravados rebites e avaliado o alongamento dos corpos de prova pelo efeito da rebitagem. Os resultados obtidos comprovam que a anisotropia exerce uma influência significativa no fator expansão e que a deformação plástica na direção transversal de laminação foi aproximadamente 60% maior que na direção de laminação para os dois tratamentos térmicos analisados. Também foi constatado que o tratamento térmico do material influencia no fator expansão. Verificou-se que a expansão dos corpos de prova recozidos foi o dobro nas direções t... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: The riveting process is wide used at Aerospace industry during airplane fuselage construction. During this process, local deformations are introduced in the structures by the rivet expansion, due the plastic deformation. The plastic deformation makes the rivet expand inside the hole and consequently, the structure around the rivet expand too. The goal of this research is to analyses the anisotropy effect in the squeezing force propagation in specimens of 2024 alloys that were submitted to the riveting process, in aluminum plates heated treatment. The research analyzed the grain geometry related to size and form, and how the heat treatment effect influences the hole diameter expansion. It was used specimens of aluminum alloy 2024 T3 and TO, commonly used in aerospace industry, in different grains directions, longitudinal and transversal. Rivets were installed and the specimen stretching was analyzed. The results prove that the anisotropy have a significative influence in the expansion factor, the plastic deformation in the transversal rolled direction was about 60% bigger than rolled direction for the two heat treatment analyzed. Also, it was verified that the material heat treatment influences the factor expansion. According the results the expansion in the relieved specimens condition were the double in the transversal and longitudinal direction than the aging specimens condition / Mestre

Abstract not available