Orientador: Tomaz Manabu Hashimoto / Banca: Marcelino Pereira do Nascimento / Banca: Cristina de Carvalho Ares Elisei / Resumo: O presente trabalho estudou as variáveis de fabricação no processo na linha de galvanização contínua por imersão a quente, simulando o processo de conformação e a cura da pintura nas montadoras, visando avaliar as condições de deformação, tempo, temperatura e o envelhecimento desde o tempo de estocagem até a conformação dos aços ultra baixo carbono semi-estabilizado ao Nióbio para obtenção de índices de bake hardening (IBH) satisfatórios, visando o atendimento e a garantia das especificações dos aços BH180 e BH220. Para a execução das análises, utilizou-se o laboratório de controle da qualidade da empresa, onde foram retirados corpos de prova para ensaios de tração e do índice bake hardening seguindo os procedimentos conforme a norma requisitada. O ensaio padrão de bake hardening (BH) consiste em, deformar o corpo de prova até 2%, interromper o ensaio, aquecer o material na estufa por 20 minutos a 170ºC e após resfriamento, dar continuidade ao ensaio. O cálculo do índice de BH foi especificado segundo a norma DIN BS EN 10325. Este trabalho visou a comparação entre dois testes de envelhecimento, um em condição natural e outro artificial. Na condição natural, os corpos de prova foram deixados em temperatura ambiente durante o período de seis meses e, na condição artificial, as variáveis tempo e temperatura foram analisadas. A garantia do tempo de estocagem está sendo discutida entre as montadoras e as usinas. A condição padrão para a simulação do ensaio de aços bake hardening, avaliou a influência de cada variável e verificou que o índice de BH está dentro do especificado em norma, sendo encontrado o valor de 49,0 MPa para o aço BH180 e de 45,0 MPa para o aço BH220. As variáveis mencionadas são importantes para o incremento do índice de BH principalmente a pré-deformação... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: This paper studied the variables in the manufacture process in continous hot dipped galvanizing line, simulating the process of drawing and curing of paint in the automakers, to evaluate the conditions of deformation, temperature, time and aging from storage time to drawing of ultra low carbon steel semi-stabilized to achieve a reasonable bake hardening index (BH) in order to find the specifications and warranty BH180 and BH 220 steels. For the application of tests, it was use the quality control laboratory of the company's, where specimens were removed for tensile tests and bake hardening index (BH) following the standard procedures as required. The bake hardening (BH) pattern test consists of deforming the specimen until 2%, stop the test, after heating the material in an oven for 20 minutes at 170 ° C and after air cooling, continue the trial. The calculation of a reasonable bake hardening index (BH) was specified according to DIN BS EN 10325. This study aimed to compare two aging tests, one in natural and the other one in artificial condition. In natural condition, the specimens were left at room temperature for a period of six months, and in artificial condition, time and temperature variables were analyzed. The warranty of the storage time is being discussed between the automakers and steel plants. The default condition for the simulation of the bake hardening steels test, evaluated the influence of each variable and found out that bake hardening index (BH) is within the specified standard, and with values of 49.0 MPa for BH180 steel and 45.0 MPa for BH220 steel. The variables mentioned are important for increasing the bake hardening index (BH) mainly pre-deformation has a significant influence. The steels studied seem not to have great influence on aging after the production in the time period evaluated. / Mestre

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Initial investigations were conducted to determine the feasibility of applying a post solution heat treatment stress relief stretching operation to near-net-shaped taper rolled aerospace aluminium plate, in terms of the possible process window and the impact on key mechanical properties. Finite element modelling (FEM) and simulations, validated using digital image correlation to measure the strain distribution in flat tapered tensile specimens, have demonstrated the existence of a suitable process window for the production of near-net-shape wing skin blanks. It was revealed that the limits of the available taper geometry are dictated by the work hardening behaviour of the specific aluminium alloy. In addition, in the case of two typical upper wing skin alloys AA2195 and AA7055, tensile and toughness testing revealed that the resultant strain gradient offers the potential for graded mechanical properties suited to this application, with a higher level of toughness at the wing root and an increase in the yield strength of the material at the wing tip. Further, investigations explore the effect of increased tensile pre-stretching, to the maximum achievable before tensile instability, on the strength, microstructure, and precipitation kinetics seen during ageing alloys AA2195 and AA7055. Subsequently, in both alloys, microstructure data have been used to deconvolute and model the effects of increasing pre-strain on the main strengthening components that contribute to the T8 yield strength of the material. In the case of the AA2195 alloy, the T8 yield strength was observed to increase continually as a function of pre-strain to a maximum value of ~670MPa at 15%. It was shown that refinement of the T1 phase continued to the maximum obtainable pre-strain, which was predicted to result in a reduction in the precipitate strengthening contribution. The increase in the T8 yield strength resulting from high levels of pre-strain was attributed to a large increase in residual strain hardening following artificial ageing, owing to a low level of recovery. In the AA7055 alloy, increased pre-strain led to a substantial increase in the T3 yield strength, which was revealed to be due to the dynamic precipitation of GP-Zones. In the T8 temper the yield strength of the alloy increased continually as a function of pre-strain to a maximum of ~607MPa at 24%. Increasing pre-strain was shown to result in a continual and significant increase in the residual strain hardening contribution to the alloys T8 yield strength, due to the occurrence of limited recovery. However, it was also shown that increasing pre-strain led to a progressive reduction in the precipitate strengthening contribution from the eta prime phase, due to an increase in the volume fraction of precipitate free zones (PFZs) with increased dislocation density. Therefore, the increase in the T8 yield strength, as a function of pre-strain, is attributed to an increased residual strain hardening contribution which outweighs a smaller progressive reduction in the precipitate strengthening contribution.

Aluminum-zirconium alloys exhibit superior strength at elevated temperature in comparison to traditional aluminum casting alloys. These alloys are heat-treatable and their strength depends to a large extent on the quenching and aging steps of the heat treatment process. However, measurements show that the critical cooling rate necessary to retain 0.6 wt. pct. zirconium(the minimum amount necessary for significant strengthening) in a super-saturated solid solution with aluminum is 90ºC/s, which is un-attainable with traditional casting processes. On the other hand, the critical cooling rate necessary to retain 0.4 wt. pct vanadium and 0.1 wt. pct. zirconium in a super- saturated solidsolution with aluminum is only 40ºC/s; which suggests that substituting vanadium for zirconium significantly decreases the critical cooling rate of the alloy. This is an important finding as it means that, unlike the Al-0.6Zr alloy, the Al-0.4V-0.1Zr alloy may be processed into useful components by traditional high pressure die-casting. Moreover, measurements show that the hardness of the Al-0.4V-0.1Zr alloy increases upon aging at 400ºC and does not degrade even after holding the alloy at 300ºC for 100 hours. Also, measurements of the tensile yield strength of the Al-0.4V-0.1Zr alloy at 300ºC show that it is about 3 times higher than that of pure aluminum. This increase in hardness and strength is attributed to precipitation of Al3(Zr,V) particles. Examination of these particles with high resolution transmission electron microscopy (HRTEM) and conventional TEM show that vanadium co-precipitates with zirconium and aluminum and forms spherical particles that have the L12 crystal structure. It also shows that the crystallographic misfit between the precipitate particles and the aluminum matrix is almost eliminated by introducing vanadium into the Al3Zr precipitate and thatthe mean radius of the Al3(Zr,V) particles is in the range from 1nm to 7nm depending on the alloy composition and aging practice. Finally, it is found that adding small amounts of silicon to the Al-0.4V-0.1Zr alloy effectively accelerates formation of the Al3(Zr,V) precipitate.

Precipitation hardening of eutectic and hypoeutectic Al-Ni alloys by 2-4 wt pct. manganese is investigated with focus on the effect of the alloys’ chemical composition and solidification cooling rate on microstructure and tensile strength. Within the context of the investigation, mathematical equations based on the Orowan Looping strengthening mechanism were used to calculate the strengthening increment contributed by each of the phases present in the aged alloy. The calculations agree well with measured values and suggest that the larger part of the alloy’s yield strength is due to the Al3Ni eutectic phase, this is closely followed by contribution from the Al6Mn particles, which precipitate predominantly at grain boundaries

Microstructural evolution during heat treatment and the precipitation hardening response of Mg-Ca-Zn alloys were investigated. The binary Mg-2.5Ca alloy was chosen as the base alloy and the effects of adding one and two wt% zinc on the microstructural characteristics and precipitation hardening of the alloy system were studied. The as-cast microstructure of all three alloys showed dendritic solidification of α-Mg and the formation of the eutectic mixtures and/or multiple phases within the interdendritic regions. Homogenization heat treatment of the binary alloy removed the dendritic structure of α-Mg and spherodized the lamellar eutectic of α-Mg+Mg2Ca. Homogenization heat treatment in the ternary Mg-Ca-Zn alloys resulted in the formation of α-Mg grains with Mg2Ca and zinc-containing particles mainly dispersed along the grain boundaries. The EDS analysis suggested that zinc is incorporated in Mg2Ca particles. To study the precipitation hardening response of the alloys, homogenized alloys were aged at 175°C, 200°C and 220°C. At all three isothermal aging temperatures, the binary alloy showed only a slight increase in hardness, i.e. from 50 VHN in the homogenized state to approximately 53 VHN when peak aged. On the other hand, adding zinc was found to promote the age hardening response of the ternary alloys and caused the hardness to increase up to 70 VHN at the peak-aged condition. To further study the precipitation hardening behavior of the alloys, DSC and IC studies were conducted on the homogenized, as–quenched, alloys. The DSC result of the binary alloy showed only one exothermic heat effect, while the ternary alloys showed multiple exothermic peaks. Analysis of the DSC and IC traces, along with the evaluation of the slight increase in microhardness, suggested that non-coherent equilibrium precipitates formed in the aged binary alloy. In addition, it was suggested that the formation of coherent precipitates during aging can be the cause of the pronounced increase in hardness in the aged ternary alloys. The IC traces of the alloys were used to evaluate the kinetics of precipitation in the ternary alloys. It was concluded that increasing aging temperature from 175°C to 220°C greatly increased the precipitation rate. Finally the JMAK model was fit to the experimentally analyzed data for the evolution of the relative volume fraction of precipitates. It was found that the experimentally analyzed data was reasonably well described by the JMAK model. The corresponding JMAK kinetic parameters k and n were relatively close for the two ternary alloys at any aging temperature. The temperature dependence of k was modeled using the Arrhenius-type rate relationship. This analysis resulted in a smaller value for the apparent activation energy in the ternary alloy containing the higher zinc level, i.e. in Mg-2Ca-2Zn alloy.

Microstructural evolution during heat treatment and the precipitation hardening response of Mg-Ca-Zn alloys were investigated. The binary Mg-2.5Ca alloy was chosen as the base alloy and the effects of adding one and two wt% zinc on the microstructural characteristics and precipitation hardening of the alloy system were studied. The as-cast microstructure of all three alloys showed dendritic solidification of α-Mg and the formation of the eutectic mixtures and/or multiple phases within the interdendritic regions. Homogenization heat treatment of the binary alloy removed the dendritic structure of α-Mg and spherodized the lamellar eutectic of α-Mg+Mg2Ca. Homogenization heat treatment in the ternary Mg-Ca-Zn alloys resulted in the formation of α-Mg grains with Mg2Ca and zinc-containing particles mainly dispersed along the grain boundaries. The EDS analysis suggested that zinc is incorporated in Mg2Ca particles. To study the precipitation hardening response of the alloys, homogenized alloys were aged at 175°C, 200°C and 220°C. At all three isothermal aging temperatures, the binary alloy showed only a slight increase in hardness, i.e. from 50 VHN in the homogenized state to approximately 53 VHN when peak aged. On the other hand, adding zinc was found to promote the age hardening response of the ternary alloys and caused the hardness to increase up to 70 VHN at the peak-aged condition. To further study the precipitation hardening behavior of the alloys, DSC and IC studies were conducted on the homogenized, as–quenched, alloys. The DSC result of the binary alloy showed only one exothermic heat effect, while the ternary alloys showed multiple exothermic peaks. Analysis of the DSC and IC traces, along with the evaluation of the slight increase in microhardness, suggested that non-coherent equilibrium precipitates formed in the aged binary alloy. In addition, it was suggested that the formation of coherent precipitates during aging can be the cause of the pronounced increase in hardness in the aged ternary alloys. The IC traces of the alloys were used to evaluate the kinetics of precipitation in the ternary alloys. It was concluded that increasing aging temperature from 175°C to 220°C greatly increased the precipitation rate. Finally the JMAK model was fit to the experimentally analyzed data for the evolution of the relative volume fraction of precipitates. It was found that the experimentally analyzed data was reasonably well described by the JMAK model. The corresponding JMAK kinetic parameters k and n were relatively close for the two ternary alloys at any aging temperature. The temperature dependence of k was modeled using the Arrhenius-type rate relationship. This analysis resulted in a smaller value for the apparent activation energy in the ternary alloy containing the higher zinc level, i.e. in Mg-2Ca-2Zn alloy.

This thesis aims to fabricate the high performance Magnesium/Carbon-Fiber/PEEK five-layer hybrid nanocomposite laminates. The adopted Mg thin sheets are 0.5mm thick. The Carbon-Fiber/PEEK prepregs were stacked into two lay-ups, such as cross-ply [0/90]s and quasi-isotropic [0/45/90/-45], with the adding of nanoparticles SiO2 spreaded among the laminates. After etching of Mg foils by CrO3-base etchants, a five-layered Mg/Carbon-Fiber/PEEK nanocomposite laminate was made according to the modified diaphragm curing process. Then, the mechanical properties, such as stress-strain curve, strength and stiffness were obtained by tensile test at room temperature (25¢J), 50, 75, 100, 125 and 150¢J and the fatigue properties were also obtained under constant stress amplitude tension-tension cyclic loading elevated at room and elevated temperatures 25, 75, 100, 125 and 150¢J. Finally, the Mg sheets and fractured laminates were observed by the SEM and OM. The results according to the experiments were summarized as follows: 1.The slope of stress-strain curve dropped at strain¡Ü0.0015. It can be inferred that fracture occurred in the laminates at this time. Stiffness approached the theoretical value by curve fitting with the strain range of 0 to 0.0015. 2.The mechanical properties decreased with the environmental temperature rise. 3.The resistance to the temperature effect of the quasi-isotropic Magnesium/Carbon-Fiber/PEEK laminate is superior to that of the cross-ply Magnesium/Carbon-Fiber/PEEK laminate. 4.The cross-ply Magnesium/Carbon-Fiber/PEEK laminate is brittler than that of the quasi-isotropic laminate generally. 5.The irregular bright lines were found in the third etched Mg sheet and that resulted in the delamination of Mg sheet after treatment. The unetched part maybe the defect of Mg sheet. 6. It was found that AZ31 has the precipitation hardening effect at 50¢J and 75¢J.