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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.

Made available in DSpace on 2014-12-17T14:07:08Z (GMT). No. of bitstreams: 1 WagnerLT_TESE.pdf: 4295737 bytes, checksum: feb949970c7901b7da571339c28198a9 (MD5) Previous issue date: 2012-02-29 / Conselho Nacional de Desenvolvimento Cient?fico e Tecnol?gico / Ceramic filters are cellular structures that can be produced by various techniques, among which we highlight the replication method, or method of polymeric sponge. This method consists of impregnating polymeric foam with ceramic slurry, followed by heat treatment, where will occur decomposition of organic material and the sinter of the ceramic material, resulting in a ceramic whose structure is a replica of the impregnated sponge. Ceramic filters have specific properties that make this type of material very versatile, used in various technological applications such as filters for molten metals and burners, make these materials attractive candidates for high temperature applications. In this work we studied the systems Al2O3-LZSA ceramic filters processed in the laboratory, and commercial Al2O3-SiC ceramics filters, both obtained by the replica method, this work proposes the thermal and mechanical characterization. The sponge used in the processing of filters made in the laboratory was characterized by thermogravimetric analysis. The ceramic filters were characterized by compressive strength, flexural strength at high temperatures, thermal shock, permeability and physical characterization (density and porosity) and microstructural (MEV and X-rays). From the results obtained, the analysis was made of the mechanical behavior of these materials, comparing the model proposed by Gibson and Ashby model and modified the effective area and the tension adjusted, where the modified model adapted itself better to the experimental results, representing better the mechanical behavior of ceramic filters obtained by the replica method / Filtros cer?micos processados pelo m?todo da r?plica tem sido objeto de crescentes pesquisas pela versatilidade da t?cnica. O m?todo consiste na impregna??o de uma esponja polim?rica em uma suspens?o cer?mica, seguido de tratamento t?rmico, onde ocorre a decomposi??o do material org?nico e a sinteriza??o do material cer?mico, resultando em um corpo cer?mico, cuja estrutura macrosc?pica ? uma r?plica da esponja impregnada. Filtros cer?micos possuem propriedades especificas que os tornam muito vers?teis, com diferentes aplica??es tecnol?gicas, tais como filtros para metais fundidos e queimadores, tornando esses materiais fortes candidatos para aplica??es ?s altas temperaturas. Neste trabalho foram estudados e desenvolvidos filtros cer?micos dos sistemas Al2O3-LZSA processados em laborat?rio, e de Al2O3-SiC comerciais, ambos obtidos pelo m?todo da r?plica, e caracterizados t?rmica e mec?nicamente. A esponja utilizada no processamento dos filtros feitos em laborat?rio foi caracterizada atrav?s de an?lises t?rmicas (ATG e DrATG). Os filtros cer?micos foram caracterizados mediante an?lises de resist?ncia a compress?o, resist?ncia ? flex?o a altas temperaturas, choque t?rmico, permeabilidade e caracteriza??o f?sica (densidade e porosidade), e microestrutural (MEV e raios X). A partir dos resultados obtidos, foi feita a an?lise do comportamento mec?nico desses materiais, comparando-se o modelo proposto por de Gibson e Ashby e o modelo modificado com a ?rea efetiva e a tens?o corrigida, onde o modelo modificado se adequou melhor aos resultados experimentais, representando melhor o comportamento mec?nico dos filtros cer?micos obtidos pelo m?todo da r?plica

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.

Made available in DSpace on 2014-12-17T14:57:49Z (GMT). No. of bitstreams: 1 FernandoBMS.pdf: 3386932 bytes, checksum: 168cdc99a75d4f1724f61a337a6c9569 (MD5) Previous issue date: 2008-09-29 / Coordena??o de Aperfei?oamento de Pessoal de N?vel Superior / Porous ceramics have many applications: thermal insulation, catalytic support, materials to fire protection, filters, and others. There are many techniques to production of ceramic filters. One technique to obtain ceramic filters is the replication method. This method consists in the impregnation of polymeric foam with ceramic slurry followed by a heating treatment that will burn out the organic elements and sintering of the material, resulting of a replication of the original foam. To perform their functions ceramic filters must satisfy mechanical requirements and permeability parameters (darcian k1 and no-darcian k2). The permeability and the strength of the ceramic material are dependent of the pore size and pore distribution. To the use at high temperatures the evaluation of mechanical properties in these temperatures is necessary. In this work the mechanical behavior of two commercial porous ceramics (10 and 40 poros per inch) was studied these materials were submitted to compression and four-point flexure test (room temperature, at 1000 ?C, after thermal shock). Density and porosity measurements, permeability tests and microstructural analysis by scanning electronic microscopy (SEM) were realized. The Results showed that the decrease of mechanical strength of these materials, when submitted to thermal shock, occur for propagation of new cracks from cracks pre-existing and the permeability depends of the pore size / As cer?micas porosas possuem uma vasta gama de aplica??es, tais como: isoladores t?rmicos, suporte catal?tico, materiais para prote??o contra fogo, filtros, dentre outras. Existem v?rias t?cnicas para a produ??o de filtros cer?micos, dentre as quais pode-se destacar o m?todo da r?plica, o qual consiste basicamente na impregna??o de uma esponja polim?rica ou natural com uma barbotina cer?mica, seguindo-se um tratamento t?rmico deste material, onde ocorrer? a decomposi??o do material org?nico e sinteriza??o do material cer?mico, resultando em um corpo cer?mico que consiste em uma r?plica da estrutura da esponja impregnada inicialmente. Al?m de par?metros de permeabilidade (darciana k1 e n?o darciana k2), os filtros cer?micos t?m que atender a requisitos mec?nicos, para que assim possam desempenhar bem as suas fun??es. A resist?ncia mec?nica e a permeabilidade dependem do tamanho e da distribui??o dos poros no material. Para utiliza??o em altas temperaturas, a avalia??o das propriedades mec?nicas a estas temperaturas se faz necess?ria. Neste trabalho foi estudado o comportamento mec?nico de duas cer?micas porosas comerciais (10 e 40 poros por polegada linear) ap?s serem submetidas a ensaios de resist?ncia ? compress?o e ? flex?o em 4 pontos (temperatura ambiente, 1000 ?C e ap?s choque t?rmico). Foram realizadas medidas densidade e porosidade, permeabilidade e an?lise da microestrutura destes materiais por microscopia eletr?nica de varredura. Os resultados mostram que os valores de resist?ncia mec?nica destes materiais s?o dependentes dos defeitos pr?-existentes nos filamentos que comp?em a estrutura do material e a permeabilidade ? fun??o do tamanho dos poros

Магистерская диссертация посвящена созданию предприятия по производству вспомогательных материалов для литейного производства, таких как керамические фильтры и экзотермические прибыли. Магистерская диссертация состоит из введения, 6 глав, заключения, списка литературы и приложений. Чтобы обеспечить высокое качество отливок, необходимо очистить металл от неметаллических включений, таких как оксидная пленка. Оксидные пленки образуются при течении металла в литниковой системе на легкоокисляемых сплавах, включая нержавеющие стали, алюминиевые сплавы. Для очистки расплава используются керамические фильтры. Была разработана линейка керамических фильтров, рассчитан состав и технология фильтров для различных сплавов, изготовлены опытные образцы. Чтобы снизить себестоимость производства отливок в рамках технологии использования химически твердеющих смесей, необходимо уменьшить размеры форм. Для этого используются экзотермические прибыли. Они нагревают расплав, позволяя уменьшить размер прибыли и, соответственно, высоту формы. Разработана линейка экзотермических прибылей, рассчитан состав и технология производства, изготовлены и испытаны опытные образцы. Проанализирована спрос на производимую продукцию. Цена продукции рассчитывается исходя из экономического эффекта от производства. Показана экономическая эффективность предприятия. / Master’s thesis is devoted to establish an enterprise for the production of supporting materials for foundry, such as ceramic filters and exothermic metal head. Master’s thesis consists of an introduction, 6 chapters, conclusion, references list and appendixes. To ensure the high quality of castings, it is necessary to clean the metal from non-metallic inclusions, such as oxide film. Oxide films occurs during the flow of metal in the feeding gate system in easily oxidizable alloys, including stainless steels, aluminum alloys. Ceramic filters are used to clean the melt. A line of ceramic filters has been developed, the composition and technology of filters for various alloys have been calculated, and prototypes have been produced. To reduce the production cost of castings within the technology of chemically bonded sand, it is necessary to reduce the size of the molds. Exothermic metal heads are used for this. It heat the melt, allowing to reduce the size of the metal head, and accordingly, the height of the mold. A line of exothermic metal heads has been developed, the composition and technology of the production have been calculated, prototypes have been produced and tested. The demand for manufactured products is analyzed. The price of products is calculated from the economic effect on production. The economic efficiency of the enterprise is shown.

Die Sicherheit von Straßen-, Schienenfahrzeugen sowie von Flugzeugen erfordert hochbelastbare Bauteile aus Stahl, Eisen, Aluminium und Magnesium. Während des Herstellungsprozesses können Verunreinigungen in der Metallschmelze auftreten, die zu Defekten in Form von Einschlüssen führen. Die Reduzierung oder Entfernung dieser Einschlüsse ist schwierig oder manchmal sogar unmöglich. Der Sonderforschungsbereich 920 „Multifunktionale Filter für die Metallschmelzefiltration – ein Beitrag zu Zero Defect Materials“ konzentrierte sich auf die Erforschung einer neuen Generation von Metallqualitäten – auch beim Recycling – durch Schmelzefiltration mit überlegenen mechanischen Eigenschaften für höchstbeanspruchbare Komponenten in Sicherheits- und Leichtbaukonstruktionen. Der SFB 920 wurde von 2011 bis 2023 an der Technischen Universität Bergakademie Freiberg von der Deutschen Forschungsgemeinschaft (DFG) gefördert (Projektnummer 169148856 – SFB 920) und nach 12 Jahren intensiver Forschungsarbeit erfolgreich beendet. Der Abschlussbericht des SFB 920 fasst die wichtigsten Publikationen und ausgewählte Ergebnisse zusammen.:1 Zusammenfassung / Summary 1 2 Die 50 wichtigsten veröffentlichten Ergebnisse 2 2.1 Publikationen mit wissenschaftlichen Qualitätssicherung 2 2.2 Weitere Publikationen und öffentlich gemachte Ergebnisse 4 3 Übersicht der Teilprojekte 5 4 Wissenschaftliche Entwicklung des Sonderforschungsbereichs 7 4.1 Einleitung, Vision und Thesen 7 4.2 Ausgewählte Ergebnisse 8 4.2.1 „Stahlschmelze-Filtration“ 8 4.2.2 „Aluminiumschmelze-Filtration“ 16 4.2.3 „Magnesiumschmelzefiltration“ 17 4.2.4 Beiträge der Simulation 18 4.2.5 Harz- und pechfreies Bindemittel für umweltfreundliche, reaktive Filter 20 4.2.6 Generatives Hybrid-Flammspritzverfahren 20 4.2.7 Transferprojekte 21 4.2.8 Zusammenfassende Bemerkungen 22 4.2.9 Management der Forschungsdaten 24 4.2.10 Literatur 24 4.3 Wissenschaftliche Veranstaltungen und Wissenschaftskommunikation 26 4.4 Nationale und internationale Kooperationen 28 5 Schwerpunktbildung und internationale Sichtbarkeit 31 / The safety of road and railway vehicles as well as aircrafts requires highly stressable components made of steel, iron, aluminum and magnesium. During the production process, contaminations can occur in the metal melt, which lead to defects in the form of inclusions. Reducing or removing these inclusions is difficult or sometimes impossible. The Collaborative Research Center 920 “Multi-functional filters for metal melt filtration – a contribution towards zero defect materials” focussed on research into a new generation of metal qualities - also during recycling - via melt filtration with superior mechanical properties for use in high-demand construction materials and light-weight structures. The CRC 920 was funded by the German Research Foundation (DFG, Deutsche Forschungsgemeinschaft) from 2011 to 2023 at the Technische Universität Bergakademie Freiberg (Project-ID 169148856 – SFB 920) and was successfully completed after 12 years of intensive research work. The final report of the CRC 920 presents the most important publications and selected results.:1 Zusammenfassung / Summary 1 2 Die 50 wichtigsten veröffentlichten Ergebnisse 2 2.1 Publikationen mit wissenschaftlichen Qualitätssicherung 2 2.2 Weitere Publikationen und öffentlich gemachte Ergebnisse 4 3 Übersicht der Teilprojekte 5 4 Wissenschaftliche Entwicklung des Sonderforschungsbereichs 7 4.1 Einleitung, Vision und Thesen 7 4.2 Ausgewählte Ergebnisse 8 4.2.1 „Stahlschmelze-Filtration“ 8 4.2.2 „Aluminiumschmelze-Filtration“ 16 4.2.3 „Magnesiumschmelzefiltration“ 17 4.2.4 Beiträge der Simulation 18 4.2.5 Harz- und pechfreies Bindemittel für umweltfreundliche, reaktive Filter 20 4.2.6 Generatives Hybrid-Flammspritzverfahren 20 4.2.7 Transferprojekte 21 4.2.8 Zusammenfassende Bemerkungen 22 4.2.9 Management der Forschungsdaten 24 4.2.10 Literatur 24 4.3 Wissenschaftliche Veranstaltungen und Wissenschaftskommunikation 26 4.4 Nationale und internationale Kooperationen 28 5 Schwerpunktbildung und internationale Sichtbarkeit 31

Die vorliegende Dissertation beschäftigt sich mit der thermo-mechanischen Beschreibung und Bewertung von keramischen Filtern für die Metallschmelze-Filtration mithilfe der Finiten-Elemente-Methode. Infolge des zellularen Aufbaus des Werkstoffs handelt es sich um ein Mehrskalenproblem. Grundlegende Aufgaben der Arbeit waren deshalb die geometrische und mechanische Modellbildung sowie die Untersuchung verschiedener effizienzsteigernder Methoden zur Gewinnung einer akkuraten numerischen Lösung. Dabei wurden sowohl verschiedene Verfahren aus der Fachliteratur implementiert und kritisch bewertet, als auch neue Ansätze verfolgt. Die Untersuchungen konzentrierten sich auf das effektive elastische und elastisch-plastische Verhalten von Kelvin-, Weaire-Phelan- und Voronoi-Strukturen. Insbesondere die entwickelten Methoden und Werkzeuge zur automatisierten Modellbildung gestatten in einfacher Weise die Umsetzung von Parameterstudien und Optimierungsaufgaben. Aus darauf aufbauenden Sensitivitätsstudien wurden Empfehlungen hinsichtlich der geometrischen und mechanischen Modellbildung für zellulare Werkstoffe abgeleitet. Diese betreffen auch vielfach eingesetzte Methoden zur Modellreduktion für diese Werkstoffe und tragen somit zukünftig zu einer effizienteren Bewertung von Filterstrukturen bei.

Die vorliegende Dissertation beschäftigt sich mit der thermo-mechanischen Beschreibung und Bewertung von keramischen Filtern für die Metallschmelze-Filtration mithilfe der Finiten-Elemente-Methode. Infolge des zellularen Aufbaus des Werkstoffs handelt es sich um ein Mehrskalenproblem. Grundlegende Aufgaben der Arbeit waren deshalb die geometrische und mechanische Modellbildung sowie die Untersuchung verschiedener effizienzsteigernder Methoden zur Gewinnung einer akkuraten numerischen Lösung. Dabei wurden sowohl verschiedene Verfahren aus der Fachliteratur implementiert und kritisch bewertet, als auch neue Ansätze verfolgt. Die Untersuchungen konzentrierten sich auf das effektive elastische und elastisch-plastische Verhalten von Kelvin-, Weaire-Phelan- und Voronoi-Strukturen. Insbesondere die entwickelten Methoden und Werkzeuge zur automatisierten Modellbildung gestatten in einfacher Weise die Umsetzung von Parameterstudien und Optimierungsaufgaben. Aus darauf aufbauenden Sensitivitätsstudien wurden Empfehlungen hinsichtlich der geometrischen und mechanischen Modellbildung für zellulare Werkstoffe abgeleitet. Diese betreffen auch vielfach eingesetzte Methoden zur Modellreduktion für diese Werkstoffe und tragen somit zukünftig zu einer effizienteren Bewertung von Filterstrukturen bei.