Orientador: Itamar Ferreira / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-04T09:29:09Z (GMT). No. of bitstreams: 1 Sandor_LeonardoTaborda_M.pdf: 9634671 bytes, checksum: 3b7603db85e265d8bd0e3fc244928942 (MD5) Previous issue date: 2005 / Resumo: Este trabalho propõe um modelo para avaliar pontualmente as variações de tenacidade à fratura ao longo da camada cementada de um aço SAE 5115. A pequena espessura dessas camadas impede a retirada de corpos de prova nas dimensões especificadas pelas normas de ensaios de tenacidade à fratura. Assim, para simular uma camada cementada retirou-se corpos de prova de tração e de tenacidade à fratura de amostras de aços SAE 5115, 5140, 5160 e 52100 assumindo a influência local apenas da variação do teor de carbono e considerando que os teores dos demais elementos de liga são essencialmente constantes. Os corpos de prova após eletrodeposição de cobre foram tratados termicamente numa carga industrial de cementação, têmpera e revenimento para serem submetidos aos efeitos térmicos sem absorção de carbono. Os resultados da análise microestrutural, dos ensaios de microdureza, de tração e de tenacidade à fratura foram agrupados em um único gráfico e comparados com o perfil de cementação de peças de aço SAE 5115 tratadas nas mesmas condições. Foi confirmado que a tenacidade à fratura varia inversamente proporcional à microdureza (HV1) e que a previsão do comportamento de uma trinca numa camada cementada pode ser feita por meio de equação ou diagrama que relacionam a miicrodureza HV1 com a tenacidade à fratura (K1c ou CTODc) / Abstract: The purpose of this work is to propose a model for evaluating the fracture toughness along the SAE 5115 steel carburized layer. Due to the small thickness of those layers, it is impossible to machine specimens from those layer in accordance with standards. For simulating the microstructures of the carburized layer in order to get samples for tensile and the fracture toughness testing, specimens of SAE 5115, 5140, 5160, and 52100 steels assuming the local influence just of the variation of the content of carbon and considering that the contents of the other alloy elements are essentially constant. The specimens after electroplated copper layer were heat treated in an industrialload of carburizing, quenching, and tempering for they be submitted to the thermal effects without absorption of carbono The results of the microstructure analysis and microhardness, tension, and fracture toughness tests were placed in a single graph and compared with the profile of the carburizing of the steel SAE 5115 heat treated in the same conditions. It was confirmed that the fracture toughness varies inversely proportional to the microhardness (HV1) and that the forecast of the behavior of a crack in a carburized layer can be made through equation or it designs that relate the microhardness (HV1) with the fracture toughness (KIC or CTODc) / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

There are great energy savings to be made by recycling aluminium; as little as 5% of the energy needed for primary aluminium production may be required. Striving to produce high quality aluminium castings requires knowledge of microstructural imperfections, which is extra important when casting recycled aluminium that generally contains higher levels of imperfections compared to primary aluminium. Imperfections include amongst others Si, Fe, and Mn as well as oxides. Si is needed for castability, but it may also initiate fracture. There are different types of Fe-rich intermetallics influencing properties of castings, generally in a negative direction. Oxides constitute cracks and they are elusive because they are difficult to quantify. This thesis aims to increase knowledge about imperfections in recycled aluminium castings originating from alloying elements and the melt. Experiments were performed in advanced laboratory equipment, including X-radiographic imaging during solidification and in-situ tensile testing in a scanning electron microscope. Experiments were also performed at industrial foundry facilities. The experiments showed that the nucleation temperature of primary α-Fe intermetallics increased with higher Fe, Mn, and Cr contents. Primary α-Fe are strongly suggested to nucleate on oxides and to grow in four basic morphologies. Lower nucleation frequency of α-Fe promoted faster growth and hopper crystals while higher nucleation frequency promoted slower growth rates and massive crystals. Results also showed that a decrease in the size of the eutectic Si and plate-like β-Fe intermetallics improved tensile properties, foremost the elongation to fracture. In β-Fe containing alloys the transversely oriented intermetallics initiated macrocracks that are potential fracture initiation sites. In alloys with primary α-Fe foremost clusters of intermetallics promoted macrocracks. In fatigue testing, a transition from β-Fe to α-Fe shifted the initiation sites from oxides and pores to the α-Fe, resulting in a decrease of fatigue strength. Oxides in Al-Si alloys continue to be elusive; no correlations between efforts to quantify the oxides and tensile properties could be observed. / Genom att återvinna aluminium kan stora energibesparingar göras eftersom återvinning kan förbruka så lite som 5% av den energi som behövs för produktion av primär aluminium. Vid gjutning av högkvalitativa aluminiumprodukter krävs förståelse för defekter i mikrostrukturen och denna kunskap är extra viktig vid användning av återvunnen aluminium, som i regel innehåller mer defekter än primär aluminium. Defekterna består bland annat av Si, Fe och Mn samt oxider. Si behövs för gjutbarhet men kan också initiera brott. Järnrika intermetaller kan ha olika morfologier som generellt påverkar gjutna komponenter negativt. Oxider, som kan utgöra sprickor, är gäckande då de är svåra att kvantifiera. Denna avhandlings syfte är att öka kunskapen om defekter i gjutna komponenter av återvunnen aluminium. Experiment utfördes med avancerad laborationsutrustning så som röntgenfotografering av prover under stelning och dragprovning i svepelektronmikroskop. Experiment utfördes också i industrimiljö. Experimenten visade att kärnbildningstemperaturen steg för primära α-Fe intermetaller med ökade andelar av Fe, Mn och Cr. Resultaten tyder starkt på att primär α-Fe kärnbildas på oxider och att de växer i fyra olika morfologier. Lägre kärnbildningstäthet av α-Fe främjade snabbare tillväxt av kristaller med håligheter men högre kärnbildningstäthet främjade långsammare tillväxt av massiva kristaller. Resultaten visade också att minskad storlek av eutektiskt Si och β-Fe intermetaller ledde till förbättring av dragprovsresultaten, främst brottförlängningen. I legeringar med β-Fe ledde transversellt orienterade intermetaller till makrosprickor vilka kan initiera brott. I legeringar med primär α-Fe var det främst kluster av intermetaller som orsakade makrosprickor. I utmattningsprovning orsakade modifiering av β-Fe till α-Fe förflyttning av sprickinitieringen från oxider och porer till α-Fe, vilket resulterade i en reducerad utmattningshållfasthet. Oxiderna i Al-Si-legeringar fortsätter att gäcka; ingen korrelation mellan försök att kvantifiera oxiderna och draghållfasthet kunde påvisas.

Nickel based superalloys are currently being investigated for high temperature applications in advanced steam power plant operating at temperatures of 700˚C and above. Three nickel-based superalloys Inconel 617, Inconel 625 and Nimonic 263 alloys, which are of primary interest for boiler technology components such as furnace walls, superheater tubes, header and steam pipes, etc and for steam turbine technology components such as HP &IP cylinders, rotor forgings, casing and valve chest, blading, etc., have been evaluated for long and short term creep performance. Creep deformation processes occurring at high temperatures and stresses lead to the evolution of microstructures in the form of precipitation, precipitate coarsening and recovery effects. The deterioration in mechanical properties as a result of this microstructural change has been evaluated by hardness testing. This work discusses the microstructural evolution occurring in alloys in samples that have been creep exposed at a series of temperatures from 650°C to 775°C and for durations from 1000 to 45,000 hours using advanced FEGSEM, TEM, XRD and phase extraction techniques. The fractions and morphology of different phases, their locations during exposure to higher temperatures and probable creep fracture mechanism in these alloys are illustrated and discussed.

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 subject of this master’s thesis was to find the causes of impact toughness scattering of forgings of the test disk with dimension range of 540 – 170 mm. The experimental samples were developed from steel A694 F60. To reach the main aim light microscopy, electron microscopy, EBSD technique, fractographic analysis and hardness measurement HV10 were utilized.

Dissertation thesis deals with basic research in the field of materials from pure Zn powders and Mg, Zn, and Ca binary mixtures prepared by powder metallurgy. General powder metallurgy principles and methods, a brief description of Mg, Zn, and Ca structure and properties, and the latest research in the field of bulk materials preparation from these elements via powder metallurgy are summarized in the theoretical part of the thesis. The experimental part focuses on the preparation of materials from finer and coarser Zn powder particles by hot pressing at 300 and 400 °C using the pressure of 100, 200, 300, 400, and 500 MPa. Binary mixtures based on Mg with the addition of Zn or Ca were prepared by hot pressing in the solid-state (300 °C) and hot pressing in the semi-solid state (400 °C, 450 °C in the case of Mg-Ca system) using the pressure of 500 MPa. Binary mixtures based on Zn with the addition of Mg or Ca were prepared by hot pressing in the semi-solid state (400 °C) using the pressure of 500 MPa. The prepared materials were evaluated in terms of microstructure, elemental and phase composition, microhardness, flexural strength, and fractography. The results showed that in the case of processed from pure Zn powders, a better combination of the flexural strength and displacement was achieved in the case of the finer Zn powder, namely in the material prepared at a temperature of 400 °C and a pressure of 500 MPa. In the case of mixtures, the best connection between the powder particles was achieved in the case of a material based on finer Zn powder with 0.5 wt.% of Mg, which had a significant effect on the achieved values of flexural strength and displacement. The amount of minor powder in the mixture had a significant effect on the prepared material structure and phase composition, while the processing conditions influenced the reached strength characteristics and fracture mechanism.

In this work have been identified mechanical and fatigue properties of magnesium alloy AZ31 with 0.5% calcium, which was cast using squeeze casting. In addition, it was observed microstructure of the alloys and made fractographic assessment of fracture surfaces after fatigue loading.

Diploma thesis deals with the determination of fracture toughness values of sintered silicon carbide and casted basalt using both the Single Edge V-Notch Beam (SEVNB) and the Chevron Notched Beam (CNB) methods at room and cryogenic temperatures. The first part of this thesis offers general overview and categorization of ceramic materials. Fracture mechanics of the ceramic materials and available fracture toughness testing methods are discussed in following chapters. The last section in the theoretical part is aimed to the microstructure and properties of the silicon carbide. Experimental part of the work summarizes methods used for characterization of selected materials from the microstructural and fracture point of view. Preparation of samples for microstructural observation and samples for fracture toughness determination are described in details. The results of the fracture toughness data for sintered silicon carbide and cast-basalt obtained at room temperature and at -100 °C are displayed. Consideration of possible measurements errors and application of various fracture toughness testing methods are discussed in the next chapter of this work. The difference in the fracture toughness values with the decrease of testing temperature was found. The difference depends on both, the used method of fracture toughness determination and the material used for the tests. The most important results gained during the experimental work are summarized in the chapter “Conclusions”.

This work is focused on the realization of experiment allowing simultaneous loading under mode II and III in a single circular specimen. Proposed experiment allowed to minimize crack closure during the cyclic loading and obtained values of thresholds of stress intensity range can be considered to be very close to effective values. This was attained by means of an unique experimental devices and procedure of preparation of pre-crack of specimen with circumferential notch, which was made of stainless austenitic steel. The obtained values were compared with theoretical models with the support of molecular dynamics and ab-anitio calculation. Based on observation was found out, that fatigue crack propagation is controlled by decohesion model in austenitic steel. The morphology of fracture surfaces was studied by means of optical chromatographie and 3D stereophotogrammetry, which allowed a comparison of created morphology under shear modes II and III. Morphology of fracture surface formed (static and cyclic loading) by pre-crack was also studied by means of selected roughness parameters. The mechanism of deflection (kink) of crack growth under mode II was defined.

Orientador: Michelli Leali Costa / Resumo: Dentre os setores de aplicações comerciais de materiais compósitos avançados, destaca-se o setor aeroespacial com larga aplicação desses materiais. Entre as técnicas de união aplicadas aos compósitos termoplásticos está a soldagem com grandes vantagens em relação aos outros processos de uniões tais como, redução de custo, agilidade de processamento, redução de elementos acumuladores de tensão, preparações mais simplórias das superfícies a serem soldadas. Mesmo com essas vantagens e, embora o processo já seja utilizado nos setores industriais, a soldagem de compósitos tem como desafio a melhoria de sua resistência, a aplicação do processo para reparos ou processamentos em campo, além da necessidade de avaliação dos efeitos das condições climáticas em juntas soldadas, as quais podem estar submetidas quando em operação em uma aeronave, por exemplo. Mediante a isso, esse trabalho visa produzir e estudar juntas soldadas por resistência elétrica e por tocha acetilênica em compósito PEI/fibra de vidro. Os compósitos obtidos foram submetidos ao condicionamento higrotérmico seguido de ensaios mecânicos de LSS (Lap Shear Strength) e ENF (End-Notched Flexure). O mecanismo de fratura das juntas soldadas foi avaliado por microscopia. A partir das análises e dos resultados obtidos, foi observado que os valores de resistência ao cisalhamento em modo II dos compósitos soldados por resistência elétrica (3270,9 J/m²) são similares aos descritos na literatura para os compósitos PEI/fibra de vid... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: Among the commercial application sectors of advanced composite materials, the aerospace sector with wide application of these materials stands out. Among the joining techniques applied to thermoplastic composites is welding with great advantages over other joining processes such as cost reduction, processing agility, reduction of stress accumulators, little or no preparation required of the surface to be processed. Even with these advantages, and although the process is already used in the industrial sectors, composite welding has the challenge of improving its resistance, the application of the process for field repairs or processing, and the need to evaluate the effects of weather conditions. welded joints, which may be subjected when operating in an aircraft, for example. Therefore, this work aims to produce and study joints welded by electric resistance and acetylene torch in PEI / fiberglass composite. The composites obtained were subjected to hygrothermal conditioning followed by mechanical tests of LSS (Lap Shear Strength) and ENF (End-Notched Flexure). The fracture mechanism of the welded joints was evaluated by microscopy. From the analyzes and results obtained, it was observed that the shear strength values in mode II of the composites welded by electric resistance (3270.9 J / m²) are similar to those described in the literature for PEI / fiberglass composites. However, for the composites welded by the oxyacetylene process, a reduction of approximately 20% in the va... (Complete abstract click electronic access below) / Mestre