The master´s diploma thesis elaborated as the master's degree M-STG Manufacturing Technology solves surfacing problems in the simulations of surfacing turbine rotors pinot pins. The work was seen as a preparatory work before the real surfacing. Topic commissioned by Siemens Industrial Turbomachinery Ltd. For welding plates test has been used the method of SAW and the base material was identical to turbine rotor material, X22CrMoV 12-1. Additional material was Fluxocord 42. Simulations were carried out in programs SYSWELD and Visual - WELD. The output of the simulation software are temperature and stress fields, material structures and creations of the CCT diagrams at the base material, filler material, and mixed area.

Military aircraft that require high maneuverability, durability, ballistic protection, reparability, and energy efficiency require structural alloys with low density, high toughness, and high strength. Also, repairs to these aircraft demand a production process that has the flexibility to be relatively in-situ with the same high-performance output. Materials produced by the cold spray process, a thermo-mechanical powder consolidation technique, meet many of the requirements. In accordance with President Obama’s 2011 Materials Genome Initiative, the focus of this effort is to design customized aluminum alloy powders which exploit the unique behavior and properties of the materials created by the cold spray process. Analytical and computational models are used to customize microchemistry, thermal conditioning, and solidification behavior of the powders by predicting equilibrium and non-equilibrium microstructure and resulting materials properties and performance. Thermodynamic, kinetic, and solidification models are used, including commercial software packages Thermo-Calc, Pandat™, and JMatPro®, and TC-PRISMA. Predicted powder properties can be used as input into a cold spray process impact model to determine the consolidated materials’ properties. Mechanical properties of powder particles are predicted as a function of powder particle diameter and are compared to experimental results.

Este trabalho tem por objetivo caracterizar e comparar as microestruturas de diferentes regiões de uma chapa de aço microligado para tubo API 5L X65, empregado no transporte de gás natural e petróleo, como recebido e submetido a tratamentos térmicos de austenitização e resfriamento contínuo sob diferentes taxas de resfriamento. O aço em estudo apresenta uma linha de segregação central, originada durante o processo de produção do aço. Corpos de prova de dilatometria foram usinados da região central e de outras regiões da chapa. As amostras foram previamente austenitizadas a 1200°C e temperadas em água, visando solubilizar grande parte dos precipitados presentes no aço. Após este tratamento, as amostras foram austenitizadas em um dilatômetro de têmpera a 950°C por 180s, e em seguida resfriadas nas seguintes taxas de resfriamento: 0,5°C/s, 1°C/s, 5°C/s, 10°C/s, 20°C/s, 30°C/s, 40°C/s, 50ºC/s e 60ºC/s. Valores de temperatura e tempo correspondentes a inflexões da curva dilatométrica foram obtidas e correlacionadas com a microestrutura, para cada taxa de resfriamento. Com base nesta análise foi traçado um diagrama de Transformação por Resfriamento Contínuo (TRC) do material. / This work aims to characterize and compare the microstructures of different regions of a plate of microalloyed pipeline steel that conforms to API 5L X65, employed in the transportation of natural gas and oil, as received and after being subjected to heat treatments of austenitization and continuous cooling under different cooling rates. The steel under study presents a central line of segregation that was originated during production. Specimens for dilatometry were machined from the central region and from different regions of the plate. The samples were austenitized at 1200°C and in quenched in water, with the purpose of solubilizing most of the precipitates in the steel. After the preliminary heat treatment, the specimens were austenitized at 950°C for 180s and cooled under the cooling rates: 0.5°C/s, 1°C/s, 5°C/s, 10°C/s, 20°C/s, 30°C/s, 40°C/s, 50ºC/s and 60ºC/s in a quench dilatometer. Values of temperature and time correspond of transformation for each rate of cooling were used for the determination of the Continuous Cooling Transformation (CCT) diagram.

Non-metallic inclusions in steels are generally considered to be detrimental for mechanical properties. However, it has been recognized that certain inclusions, such as Ti-oxide and TiN, can serve as potent nucleation sites for the formation of intragranular ferrite (IGF) in low-alloy steels. The formation of IGF could improve the toughness of the coarse grained heat affected zone (CGHAZ) of weld metals. Thus, the present thesis mainly focuses on the effect of size of nucleation sites on the IGF formation. Quantitative studies on the composition, size distribution and nucleation probability for each size of the inclusions as well as the area fraction, starting temperature and morphology of an IGF have been carried out. In the present work, the Ti-oxide and TiN powders were mixed with metallic powders. The mixed powders were heated up to the liquid state and cooled with a slow cooling rate of 3.6 ºC/min. These as-cast steels with Ti-oxide and TiN additions were used to simulate the IGF formation in the CGHAZ of weld metals. Specifically, the inclusion and microstructure characteristics in as-cast steels have been investigated. The results show that the nucleant inclusion was identified as a TiOx+MnS phase in steels with Ti2O3 additions and as a TiN+Mn-Al-Si-Ti-O+MnS phase in steels with TiN additions. In addition, the TiOx and TiN phases are detected to be the effective nucleation sites for IGF formation. It is clearly shown that an increased inclusion size leads to an increased probability of IGF nucleation. This probability of IGF nucleation for each inclusion size of the TiOx+MnS inclusions is clearly higher than that of the complex TiN+Mn-Al-Si-Ti-O+MnS inclusions. In addition, the area fraction of IGF in the steels with Ti2O3 additions is larger than that of the steels with TiN additions. This result agrees with the predicted tendency of the probability of IGF nucleation for each inclusion size in the steels with Ti2O3 and TiN additions. In order to predict the effective inclusion size for IGF formation, the critical diameters of the TiO, TiN and VN inclusions, which acted as the nucleation sites of IGF formation, were also calculated based on the classical nucleation theory. The critical diameters of TiO, TiN and VN inclusions for IGF formation were found to be 0.192, 0.355 and 0.810 μm in the present steels. The calculation results were found to be in agreement with the experiment data of an effective inclusion size. Moreover, the effects of the S, Mn and C contents on the critical diameters of inclusions were also calculated. It was found that the critical diameter of the TiO, TiN and VN inclusions increases with an increased content of Mn or C. However, the S content doesn’t have a direct effect on the critical diameter of the inclusions for IGF formation. The probability of IGF nucleation for each inclusion size slightly decreases in the steel containing a higher S content. This fact is due to that an increased amount of MnS precipitation covers the nucleant inclusion surface. In the as-cast experiment, it was noted that an IGF can be formed in steels with Ti2O3 and TiN additions with a cooling rate of 3.6 ºC/min. In order to control the microstructure characteristics, such as the area fraction and the morphology of an IGF, and to investigate the starting temperature of IGF and grain boundary ferrite (GBF) formation, the dynamic transformation behavior of IGF and GBF was studied in-situ by a high temperature confocal laser scanning microscope (CLSM). Furthermore, the chemical compositions of the inclusions and the morphology of IGF after the in-situ observations were investigated by using scanning electron microscopy (SEM), electron backscatter diffraction (EBSD) and electron probe microanalysis (EPMA) which equipped wavelength dispersive spectrometer (WDS). The results show that the area fraction of IGF is larger in the steels with Ti2O3 additions compared to the steels with TiN additions, after the same thermal cycle has been imposed. This is due to that the TiOx phase provides more potent nucleation sites for IGF than the TiN phase does. Also, the area fraction of IGF in the steels is highest after at an intermediate cooling rate of 70 ºC/min, since the competing phase transformations are avoided. This fact has been detected by using a hybrid methodology in combination with CLSM and differential scanning calorimetry (DSC). In addition, it is noted that the morphology of an IGF is refined with an increased cooling rate. / <p>QC 20150325</p>

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior / The joining of metals is often associated to metallurgical problems. Specifically, metallurgical transformations in the HAZ (Heat Affected Zone) can occur, what lead to undesirable microestructural changes. The HAZ is a difficult region for studying due to its small dimensions and high thermal gradientes. Thus, in order to overcome this limitation of the HAZ study, there are in the literature different proposes of HAZ-simulator machines (physical simulation), which uses the Joule effect for heating specific coupons that cool down by conduction and convection. This approach intends to simulate the thermal cycle in a real HAZ obtained in a real welding. However, the use of traditional coupons with cylindrical geometry presents restrictions of portraying the real case, i.e., the welding. In the cylindrical geometry option, the obtained thermal cycles do not present temperature gradients closer to the ones in real weldments. Hence, to overcome this limitation, finite elements modeling was carried out and different coupon geometries were simulated. The objective is to reach thermal cycles as close as possible to the ones obtained in a real situation, for a subsequent physical simulation. This approach showed proper and the physical and numerical present coherent results. The next step is the physical simulation validation by comparing to real weldments. This would be the most intuitive way. However, it was proposed to conduct this validation by determining CCT (Continuous Cooling Transformation) diagrams. This approach has the advantage of reaching important technological results at the same time of validating the physical simulation, since CCD diagrams dedicated to welding are very difficult to find in literature. It is possible to concluded that the physical simulation does represent the HAZ and can be used to build up CCT diagrams / Freqüentemente a união de materiais metálicos está associada a problemas metalúrgicos. Especificamente, podem ocorrer modificações metalúrgicas na ZAC (zona afetada pelo calor), levando a alterações microestruturais não adequadas. Contudo esta é uma região de difícil estudo devido a sua pequena dimensão e grandes gradientes térmicos. Assim, a fim de superar esta limitação com relação ao estudo da ZAC, existem na literatura proposições de máquinas de simulação física, que fazem uso do Efeito Joule para o aquecimento de determinados corpos de prova, que se resfriam por condução e convecção, de forma a simular o ciclo térmico obtido por soldagem real. Entretanto, o uso de corpos de provas cilíndricos apresenta restrições em retratar o caso real. Nesta opção de geometria cilíndrica, os ciclos térmicos não apresentam gradientes de temperatura que sejam fiéis àqueles encontrados em uma soldagem. Desta forma, foram realizadas simulações numéricas em elementos finitos, variando-se a geometria dos corpos de prova, de forma a obter ciclos térmicos o mais próximos da realidade para uma posterior simulação física. Esta abordagem de variação da geometria do corpo de prova calculada via simulação numérica mostrou-se adequada, onde os resultados obtidos pela simulação física e numérica mostraram-se coerentes. Como forma de validar os resultados finais obtidos via simulação física, ao invés de se conduzir soldagens reais, o que seria mais intuitivo, optou-se pelo levantamento de Diagramas CCT (Transformação em Resfriamento Contínuo) dedicados à soldagem. Este direcionamento tem a vantagem de se, concomitantemente à validação da simulação física, atingir resultados tecnologicamente muito importantes que são as curvas CCT de difícil acesso na literatura. Conclui-se pela viabilidade da simulação física em retratar a ZAC e pela viabilidade em se conseguir Diagramas CCT para soldagem. / Mestre em Engenharia Mecânica

Este trabalho tem por objetivo caracterizar e comparar as microestruturas de diferentes regiões de uma chapa de aço microligado para tubo API 5L X65, empregado no transporte de gás natural e petróleo, como recebido e submetido a tratamentos térmicos de austenitização e resfriamento contínuo sob diferentes taxas de resfriamento. O aço em estudo apresenta uma linha de segregação central, originada durante o processo de produção do aço. Corpos de prova de dilatometria foram usinados da região central e de outras regiões da chapa. As amostras foram previamente austenitizadas a 1200°C e temperadas em água, visando solubilizar grande parte dos precipitados presentes no aço. Após este tratamento, as amostras foram austenitizadas em um dilatômetro de têmpera a 950°C por 180s, e em seguida resfriadas nas seguintes taxas de resfriamento: 0,5°C/s, 1°C/s, 5°C/s, 10°C/s, 20°C/s, 30°C/s, 40°C/s, 50ºC/s e 60ºC/s. Valores de temperatura e tempo correspondentes a inflexões da curva dilatométrica foram obtidas e correlacionadas com a microestrutura, para cada taxa de resfriamento. Com base nesta análise foi traçado um diagrama de Transformação por Resfriamento Contínuo (TRC) do material. / This work aims to characterize and compare the microstructures of different regions of a plate of microalloyed pipeline steel that conforms to API 5L X65, employed in the transportation of natural gas and oil, as received and after being subjected to heat treatments of austenitization and continuous cooling under different cooling rates. The steel under study presents a central line of segregation that was originated during production. Specimens for dilatometry were machined from the central region and from different regions of the plate. The samples were austenitized at 1200°C and in quenched in water, with the purpose of solubilizing most of the precipitates in the steel. After the preliminary heat treatment, the specimens were austenitized at 950°C for 180s and cooled under the cooling rates: 0.5°C/s, 1°C/s, 5°C/s, 10°C/s, 20°C/s, 30°C/s, 40°C/s, 50ºC/s and 60ºC/s in a quench dilatometer. Values of temperature and time correspond of transformation for each rate of cooling were used for the determination of the Continuous Cooling Transformation (CCT) diagram.