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Wear resistant surfaces with high toughness and impact resistant properties are to be created to improve the life cycle cost of brake discs for trains. A potential solution to this industrial problem is to use an arc cladding process. This work describes the application of gas tungsten arc welding (GTAW) for a structural ceramic Metal Matrix Composite (MMC) on steel. The structure of the two ceramics examined indicates the possibility of development of a wear resistant surface, which would extend the life of the brake disc. Silicon Carbide (SiC) and Tungsten Carbide (WC) ceramics were studied to embed them in a steel matrix by an advanced GTAW method. WC particles penetrated the liquid weld pool and also partially dissolved in the steel matrix, whereas, SiC because of the physical properties never penetrated deeper into the weld pool but segregated on the surface. Successful embedding and bonding of WC led to the decision to exercise an in-depth analysis of the bonding between the WC particles and the matrix. Chemical analysis of the matrix revealed more WC dissolution as compared to particle form within the clad. It was observed that WC reinforcement particles built a strong chemical bond with the steel matrix. This was shown by electron backscatter diffraction (EBSD) analysis. The hard clad layer composed of WC reinforced steel matrix gave an matching friction coefficient to high-strength steel in cold wear conditions through Pin-on-Disc wear and friction testing. A prototype railway brake disc was created with the established GTAW parameters to find out the difficulties of producing industrial scale components.

In a worldwide pursuit for more Accident Tolerant nuclear Fuel (ATF), the quest to obtain and certify alternative nuclear fuel cladding tubes for light-water nuclear power reactors is still a key challenge. One of the facets in this program to develop more ATF is the heat transfer evaluation between the various proposed clad tubes manufactured from suitable replacement materials and the current problematic zirconium-alloy based clad tubes used in nuclear power reactors. For the heat transfer analysis, the accurate measurement of the temperature on the heat transfer surface of heated tubes to be tested was one of the important objectives for the effective analysis of the heat transfer characteristics to the water coolant. After extensive investigations, a suitable technique was developed and validated against recognised forced-convection heat transfer correlations. The results showed that this technique was well suited for external forced convection heat transfer studies from heated surfaces exposed to forced convection water coolants. / Dissertation (MSc)--University of Pretoria, 2019. / Mechanical and Aeronautical Engineering / MSc (Applied Science - Mechanics) / Unrestricted

As recentes descobertas de petróleo e gás na camada do Pré-sal representam um enorme potencial exploratório no Brasil, entretanto, os desafios tecnológicos para a exploração desses recursos minerais são imensos e, consequentemente, têm motivado o desenvolvimento de estudos voltados a métodos e materiais eficientes para suas produções. Os tubos condutores de petróleo e gás são denominados de elevadores catenários ou do inglês \"risers\", e são elementos que necessariamente são soldados e possuem fundamental importância nessa cadeia produtiva, pois transportam petróleo e gás natural do fundo do mar à plataforma, estando sujeitos a carregamentos dinâmicos (fadiga) durante sua operação. Adicionalmente, um dos problemas centrais à produção de óleo e gás das reservas do Pré-Sal está diretamente associado a meios altamente corrosivos, tais como H2S e CO2. Uma forma mais barata de proteção dos tubos é a aplicação de uma camada de um material metálico resistente à corrosão na parte interna desses tubos (clad). Assim, a união entre esses tubos para formação dos \"risers\" deve ser realizada pelo emprego de soldas circunferenciais de ligas igualmente resistentes à corrosão. Nesse contexto, como os elementos soldados são considerados possuir defeitos do tipo trinca, para a garantia de sua integridade estrutural quando submetidos a carregamentos cíclicos, é necessário o conhecimento das taxas de propagação de trinca por fadiga da solda circunferencial. Assim, neste trabalho, foram realizados ensaios de propagação de trinca por fadiga na região da solda circunferencial de Inconel® 625 realizada em tubo de aço API 5L X65 cladeado, utilizando corpos de prova do tipo SEN(B) (Single Edge Notch Bending) com relações entre espessura e largura (B/W) iguais a 0,5, 1 e 2. O propósito central deste trabalho foi de obter a curva da taxa de propagação de trinca por fadiga (da/dN) versus a variação do fator de intensidade de tensão (ΔK) para o metal de solda por meio de ensaios normatizados, utilizando diferentes técnicas de acompanhamento e medição da trinca. A monitoração de crescimento da trinca foi feita por três técnicas: variação da flexibilidade elástica (VFE), queda de potencial elétrico (QPE) e análise de imagem (Ai). Os resultados mostraram que as diferentes relações B/W utilizadas no estudo não alteraram significantemente as taxas de propagação de trinca por fadiga, respeitado que a propagação aconteceu em condições de escoamento em pequena escala na frente da trinca. Os resultados de propagação de trinca por fadiga permitiram a obtenção das regiões I e II da curva da/dN versus ΔK para o metal de solda. O valor de ΔKlim obtido para o mesmo foi em torno de 11,8 MPa.m1/2 e os valores encontrados das constantes experimentais C e m da equação de Paris-Erdogan foram respectivamente iguais a 1,55 x10-10 [(mm/ciclo)/(MPa.m1/2)m] e 4,15. A propagação de trinca no metal de solda deu-se por deformação plástica, com a formação de estrias de fadiga. / Recent oil and gas discoveries in the Pre-Salt layer represent a huge exploration potential in Brazil, however, the technological challenges for the exploitation of these mineral resources are immense and therefore have motivated the development of studies looking for efficient methods and materials for their productions. The oil and gas pipellines, called risers, are elements that are necessarily welded and have fundamental importance in the production chain, since they transport oil and natural gas from the sea bed to the platforms and are subject to dynamic loads (fatigue) during operation. Additionally, one of the central problems in the production of oil and gas in the Pre-Salt reserves is directly associated with a highly corrosive media, such as H2S and CO2. A cheaper way to protect the pipelines from these medias is applying a protective layer of a corrosion resistant metal on the inner diameter of these pipes, creating a cladded pipe. Thus, a joining process of these pipes to form the risers must be carried out by the use of girth welds with a corrosion resistance material similar to the clad metal. As the welded structures are seen as potential location of \"crack like\" defects, to ensure the structural integrity of such component when subjected to repetitive loading conditions, it is necessary to know the fatigue crack growth rates for the girth weld. Therefore, in this work it was carried out fatigue crack propagation tests in the weld region of an API 5L X65 cladded pipe with Inconel® 625, girth welded using Inconel® 625 electrodes. From the welded region, Single Edge Notch Bending specimens, SEN(B), were removed with different thickness and width ratios (B/W= 0.5, 1, and 2). From the fatigue tests, the crack propagation rates (da/dN) as function of the variation of the stress intensity factor (ΔK), were determined for the weld metal, using different crack size measurement techniques: the elastic compliance (EC), electric potential drop (EPD) and image analysis (IA). The results showed that the different B/W ratios used in study did not modified significantly the fatigue crack growth rates, considering that crack propagation took place under small scale yielding conditions. The results of fatigue crack growth tests allowed to obtain the regions I and II of da/dN x ΔK curves for the weld metal. The ΔKth value obtained for the weld metal was around 11,8 MPa.m1/2 and the found values of the experimental constants C and m of Paris-Erdogan\'s equation were respectively equal to 1,55 x10-10 [(mm/cycle)/( MPa.m1/2)m] and 4.15. The micromechanism of fatigue crack growth took place by plastic deformation, with the formation of fatigue striations.

O concreto leve de alto desempenho (CLAD), com argila expandida nacional, é um material alternativo para as concentrações brasileiras, considerando as características climáticas do país e baixo custo do material. Mas atualmente, existe pouca informação disponível sobre a produção e aplicação deste concreto com agregados leves, adições e aditivos nacionais. O objetivo desta dissertação é analisar o comportamento estrutural, por intermédio de ensaios mecânicos (resistência à compressão, resistência à tração por compressão diametral e módulo de deformação) do CLAD, sob ação de altas temperaturas. Para tanto, realiza-se uma análise comparativa da resistência mecânica do concreto em estudo, constituído por agregados leves de argila expandida, com o concreto convencional CAD (concreto de alto desempenho), composto por agregados de brita basáltica, determinando-se assim as respectivas resistências mecânicas, após terem sido expostos a temperaturas externas de até 800 graus centígrados. Através da análise dos resultados obtidos experimentalmente, pode-se comprovar a viabilidade do CLAD, produzido com argila expandida, comparativamente ao CAD, sob à ação de altas temperaturas. / The high performance lightweight aggregate concrete (HPLC), with national expanded clay, is an alternative material for the Brazilian constructions, considering the climatic characteristics of the country and low cost of the material. But now, little available information exists about the production and application of this concrete with lightweight aggregate, additions and addictive national. The aim of this dissertation is to analyze the structural behavior, by mechanical tests (compressive strength, splitting tensile strength and deformation modulus) of HPLC, under action of high temperatures. For so much, it takes place a comparative analysis of the mechanical resistance of the concrete in study, constituted by lightweight aggregate of expanded clay, with the conventional concrete HPC (high performance concrete), composed by crushed basalt coarse aggregate, determining the respective mechanical strength, after they have been exposed to external temperatures of up to 800°C. Through the analysis of the results obtained experimentally, it can be proven the viability of HPLC, produced with expanded clay, comparatively to HPC, under to the action of high temperatures.

La durabilité et l’intégrité des matériaux employés au sein des installations du parc électronucléaire est une préoccupation permanente des exploitants de centrales. Lors de l’irradiation du combustible dans des réacteurs à eau pressurisée (REP), l’ensemble combustible-gaine est sujet à de nombreuses modifications induites par l’irradiation. En particulier, la dilatation des éléments combustibles, concomitante au fluage en compression du gainage, conduit à la mise en contact de ces matériaux, permettant l’oxydation de la surface interne de la gaine, d’abord de manière ponctuelle, affectant à terme la quasi-totalité de la surface interne avec le temps. A fort taux de combustion, on constate une liaison de la périphérie du combustible avec le gainage métallique, constituant le phénomène d’accrochage combustible-gaine et conditionnant les transferts thermiques ainsi que le comportement mécanique des crayons combustibles. L’objectif principal de ce travail de thèse est d’approfondir les connaissances sur l’interaction physico-chimique combustible-gaine, en déterminant notamment l’origine de leur adhésion ainsi que son évolution en fonction du taux de combustion. A cet effet, des études d’inter-diffusion sur des matériaux modèles hors et sous irradiation ionique ont été réalisées, en complément de caractérisations détaillées d’interfaces combustible|gaine d’échantillons irradiés en REP. La comparaison des résultats obtenus sur matériaux modèles avec ceux obtenus sur échantillons irradiés en REP, permettent de formuler de solides hypothèses sur la nature, l’origine et l’évolution de l’accrochage combustible-gaine en REP. / Durability and integrity of materials used in nuclear power plants is a continuous concern of the nuclear power plant owners and developers. During the fuel irradiation in pressurised water reactors (PWR), the whole fuel-clad assembly is subjected to several irradiation-induced modifications. In particular, the fuel element expansion concomitant to the cladding creeping, leads to the contacting of both materials, allowing the oxidation of the inner side of the clad, locally at first, then tending to affect the overall cladding inner surface. At high burnup, a bonding of the fuel periphery with the metallic cladding can be observed, forming the fuel-clad bonding phenomenon, which conditions the thermal transfers and the mechanical behaviour of the fuel rods. The main objective of this PhD, is to further the knowledges of the physic-chemical interaction between fuel and clad, by identifying especially the origin of their bonding and its evolution with burnup. For that purpose, studies on inter-diffusion couples were performed on model materials both under ionic irradiation and not, completing detailed characterisations of the fuel|clad interface of samples irradiated in PWR. Comparison of the results obtained on model materials with those obtained on samples irradiated in PWR, allows making reliable assumptions on the nature, the origin and the evolution of the fuel-clad bonding in PWR.

O concreto leve de alto desempenho (CLAD), com argila expandida nacional, é um material alternativo para as concentrações brasileiras, considerando as características climáticas do país e baixo custo do material. Mas atualmente, existe pouca informação disponível sobre a produção e aplicação deste concreto com agregados leves, adições e aditivos nacionais. O objetivo desta dissertação é analisar o comportamento estrutural, por intermédio de ensaios mecânicos (resistência à compressão, resistência à tração por compressão diametral e módulo de deformação) do CLAD, sob ação de altas temperaturas. Para tanto, realiza-se uma análise comparativa da resistência mecânica do concreto em estudo, constituído por agregados leves de argila expandida, com o concreto convencional CAD (concreto de alto desempenho), composto por agregados de brita basáltica, determinando-se assim as respectivas resistências mecânicas, após terem sido expostos a temperaturas externas de até 800 graus centígrados. Através da análise dos resultados obtidos experimentalmente, pode-se comprovar a viabilidade do CLAD, produzido com argila expandida, comparativamente ao CAD, sob à ação de altas temperaturas. / The high performance lightweight aggregate concrete (HPLC), with national expanded clay, is an alternative material for the Brazilian constructions, considering the climatic characteristics of the country and low cost of the material. But now, little available information exists about the production and application of this concrete with lightweight aggregate, additions and addictive national. The aim of this dissertation is to analyze the structural behavior, by mechanical tests (compressive strength, splitting tensile strength and deformation modulus) of HPLC, under action of high temperatures. For so much, it takes place a comparative analysis of the mechanical resistance of the concrete in study, constituted by lightweight aggregate of expanded clay, with the conventional concrete HPC (high performance concrete), composed by crushed basalt coarse aggregate, determining the respective mechanical strength, after they have been exposed to external temperatures of up to 800°C. Through the analysis of the results obtained experimentally, it can be proven the viability of HPLC, produced with expanded clay, comparatively to HPC, under to the action of high temperatures.

As recentes descobertas de petróleo e gás na camada do Pré-sal representam um enorme potencial exploratório no Brasil, entretanto, os desafios tecnológicos para a exploração desses recursos minerais são imensos e, consequentemente, têm motivado o desenvolvimento de estudos voltados a métodos e materiais eficientes para suas produções. Os tubos condutores de petróleo e gás são denominados de elevadores catenários ou do inglês \"risers\", e são elementos que necessariamente são soldados e possuem fundamental importância nessa cadeia produtiva, pois transportam petróleo e gás natural do fundo do mar à plataforma, estando sujeitos a carregamentos dinâmicos (fadiga) durante sua operação. Adicionalmente, um dos problemas centrais à produção de óleo e gás das reservas do Pré-Sal está diretamente associado a meios altamente corrosivos, tais como H2S e CO2. Uma forma mais barata de proteção dos tubos é a aplicação de uma camada de um material metálico resistente à corrosão na parte interna desses tubos (clad). Assim, a união entre esses tubos para formação dos \"risers\" deve ser realizada pelo emprego de soldas circunferenciais de ligas igualmente resistentes à corrosão. Nesse contexto, como os elementos soldados são considerados possuir defeitos do tipo trinca, para a garantia de sua integridade estrutural quando submetidos a carregamentos cíclicos, é necessário o conhecimento das taxas de propagação de trinca por fadiga da solda circunferencial. Assim, neste trabalho, foram realizados ensaios de propagação de trinca por fadiga na região da solda circunferencial de Inconel® 625 realizada em tubo de aço API 5L X65 cladeado, utilizando corpos de prova do tipo SEN(B) (Single Edge Notch Bending) com relações entre espessura e largura (B/W) iguais a 0,5, 1 e 2. O propósito central deste trabalho foi de obter a curva da taxa de propagação de trinca por fadiga (da/dN) versus a variação do fator de intensidade de tensão (ΔK) para o metal de solda por meio de ensaios normatizados, utilizando diferentes técnicas de acompanhamento e medição da trinca. A monitoração de crescimento da trinca foi feita por três técnicas: variação da flexibilidade elástica (VFE), queda de potencial elétrico (QPE) e análise de imagem (Ai). Os resultados mostraram que as diferentes relações B/W utilizadas no estudo não alteraram significantemente as taxas de propagação de trinca por fadiga, respeitado que a propagação aconteceu em condições de escoamento em pequena escala na frente da trinca. Os resultados de propagação de trinca por fadiga permitiram a obtenção das regiões I e II da curva da/dN versus ΔK para o metal de solda. O valor de ΔKlim obtido para o mesmo foi em torno de 11,8 MPa.m1/2 e os valores encontrados das constantes experimentais C e m da equação de Paris-Erdogan foram respectivamente iguais a 1,55 x10-10 [(mm/ciclo)/(MPa.m1/2)m] e 4,15. A propagação de trinca no metal de solda deu-se por deformação plástica, com a formação de estrias de fadiga. / Recent oil and gas discoveries in the Pre-Salt layer represent a huge exploration potential in Brazil, however, the technological challenges for the exploitation of these mineral resources are immense and therefore have motivated the development of studies looking for efficient methods and materials for their productions. The oil and gas pipellines, called risers, are elements that are necessarily welded and have fundamental importance in the production chain, since they transport oil and natural gas from the sea bed to the platforms and are subject to dynamic loads (fatigue) during operation. Additionally, one of the central problems in the production of oil and gas in the Pre-Salt reserves is directly associated with a highly corrosive media, such as H2S and CO2. A cheaper way to protect the pipelines from these medias is applying a protective layer of a corrosion resistant metal on the inner diameter of these pipes, creating a cladded pipe. Thus, a joining process of these pipes to form the risers must be carried out by the use of girth welds with a corrosion resistance material similar to the clad metal. As the welded structures are seen as potential location of \"crack like\" defects, to ensure the structural integrity of such component when subjected to repetitive loading conditions, it is necessary to know the fatigue crack growth rates for the girth weld. Therefore, in this work it was carried out fatigue crack propagation tests in the weld region of an API 5L X65 cladded pipe with Inconel® 625, girth welded using Inconel® 625 electrodes. From the welded region, Single Edge Notch Bending specimens, SEN(B), were removed with different thickness and width ratios (B/W= 0.5, 1, and 2). From the fatigue tests, the crack propagation rates (da/dN) as function of the variation of the stress intensity factor (ΔK), were determined for the weld metal, using different crack size measurement techniques: the elastic compliance (EC), electric potential drop (EPD) and image analysis (IA). The results showed that the different B/W ratios used in study did not modified significantly the fatigue crack growth rates, considering that crack propagation took place under small scale yielding conditions. The results of fatigue crack growth tests allowed to obtain the regions I and II of da/dN x ΔK curves for the weld metal. The ΔKth value obtained for the weld metal was around 11,8 MPa.m1/2 and the found values of the experimental constants C and m of Paris-Erdogan\'s equation were respectively equal to 1,55 x10-10 [(mm/cycle)/( MPa.m1/2)m] and 4.15. The micromechanism of fatigue crack growth took place by plastic deformation, with the formation of fatigue striations.

Laser cladding is a more recent approach to repair of aviation components within a damage tolerant framework, with its ability to restore not simply the geometric shape but the static and fatigue strength as well. This research analysed the fatigue performance of Ti-6Al-4V that has undergone a laser clad repair, comparing baseline specimens with laser clad repaired, and repaired and heat treated specimens. First an understanding of the microstructure was achieved by use of BSE imagery of the substrate, clad repaired region and post heat treated regions. The substrate of the material was identified with large grains which compared to a repaired clad region with a much finer grain structure that did not change with heat treatment. Next, performance of the specimens under tensile fatigue loading was conducted, with the clad specimens experiencing unexpectedly high fatigue performance when compared to baseline samples; the post heat treated specimen lasting significantly longer than all other specimens. It is theorised that the clad may have contributed to an increase in fatigue resilience due to its fine microstructure, when compared to the softer, more coarse substrate. The heat treatment is likely to have relaxed any residual stresses in the specimens leading to a reduction in any potential undesirable stresses, without impacting the microstructure. Residual stress analysis using EDD was unproductive due to the unexpected coarse microstructure and did not provide meaningful results. Fractography using the marker-band technique was explored with some success, proving a feesable method for measuring fatigue crack growth through a specimen post failure. Unfortunately fatigue crack growth throughout the entire fatigue life was not possible due to the tortuous fracture surface and potentially due to the fine micro-structure of the clad, resulting in interrupted marker-band formation. Future research shall expand on this work with a greater focus on residual stress analysis and its impact on fatigue.

The formation of liquid films is a widely known problem in aluminium heat exchanger materials. The phenomenon results in decreased brazeability along with severely deteriorated mechanical properties which might cause assembly collapse. In addition, low-melting-point elements like tin, bismuth and lead are thought to promote grain boundary sliding which is the main deformation mechanism during brazing. Their melting characteristics are not adequately reported in literature. It is therefore of great importance to examine the behaviour of these elements.The main objectives with this work is melting range determination of fin heat exchanger materials, melting detection of low-melting-point elements and calculation of tin, bismuth and lead solid-solubility in aluminium. This work does also involve distribution analysis of such elements in aluminium matrix after heat treatment.These investigations require development of a differential scanning calorimetry (DSC) technique that is applicable for analysis of aluminium fin heat exchanger material containing low-melting-point elements on ppm level. Optimization of the technique includes parameter control; like heating rate, sample mass, reproducibility and choice of crucible material. Laser ablation inductively coupled plasma mass spectroscopy (LA-ICP-MS) is additionally used in order to analyse solid solubility and distribution of low-melting-point elements in aluminium after heat treatment.The developed DSC technique shows a sensitivity limit in the range of 260-600 ppm. It means that it is not possible to detect melting of phases within and below that range. Solid solubility of tin was calculated for the three heat treatment temperatures, 400°C, 500°C and 625°C. Same procedure was applied on bismuth and lead. However, calculated values did not agree with Thermo-Calc. The distribution analysis indicate an exudation of trace elements i.e. diffusion toward surface during heat treatment.In conclusion, more knowledge regarding liquid films in aluminium fin heat exchanger material was obtained. Future work should be to further optimize the DSC technique for trace element analysis for concentrations below 100 ppm. The LA-ICP-MS technique is likely to improve experimentally unverified binary phase diagrams like Al-Bi, Al-Pb and Al-Sn phase diagrams. It can also be used to study exudation behaviour of liquid films.