Uma das finalidades do pré-aquecimento na soldagem é reduzir a taxa de resfriamento da junta a ser soldada, com consequente minimização da formação de fases frágeis. Esta prática é usualmente realizada em uma região relativamente extensa no entorno da junta, eventualmente causando alterações indevidas nas propriedades mecânicas e metalúrgicas do metal base, além de desperdiçar energia e tempo. Entretanto, o aquecimento localizado na junta também tem a função de auxiliar na fusão do metal base, fazendo com que este alcance temperaturas próximas à fusão do material. Esse pré-aquecimento pode favorecer o aumento da penetração do cordão de solda. Em juntas de chapas mais espessas, pode ser descartada a usinagem de chanfro em alguns casos, e podem ser alcançadas maiores velocidades do processo de soldagem. Desta forma, neste trabalho foi utilizado um equipamento de aquecimento indutivo para aquecer localmente a zona a ser soldada, visando avaliar a microestrutura formada e o perfil de durezas encontrado para os parâmetros variados. Os parâmetros de montagem e de operação foram avaliados quanto à sua influência na geometria do cordão de solda. A utilização do pré-aquecimento se mostrou efetiva na redução da taxa de resfriamento e consequentemente da proporção de fases frágeis e microdureza máxima das juntas. O trabalho mostra que a penetração e largura do cordão de solda foram aumentadas com o aumento do pré-aquecimento, e reduziram com o aumento da velocidade de soldagem, sendo a velocidade de soldagem o fator com maior influência nestas respostas. / One of the purposes of welding preheating is to decrease cooling rate of the joint to be welded, with consequent minimization of brittle phases formation. This practice is usually performed in a relatively large area around the joint, eventually causing undue changes in base metal mechanical and metallurgical properties, beyond to waste energy and time. However, the heat located in the joint also has the function of assisting in the melting of the base metal, so that it reaches temperatures close to the melting point of the material. This preheating may increase the penetration of the weld bead. In thicker plates may be discarded bevel machining in some cases and can be achieved higher welding speeds. Therefore, in this work an inductive heating equipment was used to locally heat the zone to be welded, aiming to evaluate the formed microstructure and the hardness profile found for the varied parameters. The assembly and operating parameters were evaluated for their influence on the geometry of the weld bead. The use of preheating was effective in reducing cooling rates and consequently in the proportion of brittle phases and maximum microhardness of the welded joint. The work shows that penetration and weld bead width increase with the increasing of the preheating, and reduces with the increase in welding speed, being the welding speed the factor with the greatest influence on this responses.

Uma das finalidades do pré-aquecimento na soldagem é reduzir a taxa de resfriamento da junta a ser soldada, com consequente minimização da formação de fases frágeis. Esta prática é usualmente realizada em uma região relativamente extensa no entorno da junta, eventualmente causando alterações indevidas nas propriedades mecânicas e metalúrgicas do metal base, além de desperdiçar energia e tempo. Entretanto, o aquecimento localizado na junta também tem a função de auxiliar na fusão do metal base, fazendo com que este alcance temperaturas próximas à fusão do material. Esse pré-aquecimento pode favorecer o aumento da penetração do cordão de solda. Em juntas de chapas mais espessas, pode ser descartada a usinagem de chanfro em alguns casos, e podem ser alcançadas maiores velocidades do processo de soldagem. Desta forma, neste trabalho foi utilizado um equipamento de aquecimento indutivo para aquecer localmente a zona a ser soldada, visando avaliar a microestrutura formada e o perfil de durezas encontrado para os parâmetros variados. Os parâmetros de montagem e de operação foram avaliados quanto à sua influência na geometria do cordão de solda. A utilização do pré-aquecimento se mostrou efetiva na redução da taxa de resfriamento e consequentemente da proporção de fases frágeis e microdureza máxima das juntas. O trabalho mostra que a penetração e largura do cordão de solda foram aumentadas com o aumento do pré-aquecimento, e reduziram com o aumento da velocidade de soldagem, sendo a velocidade de soldagem o fator com maior influência nestas respostas. / One of the purposes of welding preheating is to decrease cooling rate of the joint to be welded, with consequent minimization of brittle phases formation. This practice is usually performed in a relatively large area around the joint, eventually causing undue changes in base metal mechanical and metallurgical properties, beyond to waste energy and time. However, the heat located in the joint also has the function of assisting in the melting of the base metal, so that it reaches temperatures close to the melting point of the material. This preheating may increase the penetration of the weld bead. In thicker plates may be discarded bevel machining in some cases and can be achieved higher welding speeds. Therefore, in this work an inductive heating equipment was used to locally heat the zone to be welded, aiming to evaluate the formed microstructure and the hardness profile found for the varied parameters. The assembly and operating parameters were evaluated for their influence on the geometry of the weld bead. The use of preheating was effective in reducing cooling rates and consequently in the proportion of brittle phases and maximum microhardness of the welded joint. The work shows that penetration and weld bead width increase with the increasing of the preheating, and reduces with the increase in welding speed, being the welding speed the factor with the greatest influence on this responses.

Uma das finalidades do pré-aquecimento na soldagem é reduzir a taxa de resfriamento da junta a ser soldada, com consequente minimização da formação de fases frágeis. Esta prática é usualmente realizada em uma região relativamente extensa no entorno da junta, eventualmente causando alterações indevidas nas propriedades mecânicas e metalúrgicas do metal base, além de desperdiçar energia e tempo. Entretanto, o aquecimento localizado na junta também tem a função de auxiliar na fusão do metal base, fazendo com que este alcance temperaturas próximas à fusão do material. Esse pré-aquecimento pode favorecer o aumento da penetração do cordão de solda. Em juntas de chapas mais espessas, pode ser descartada a usinagem de chanfro em alguns casos, e podem ser alcançadas maiores velocidades do processo de soldagem. Desta forma, neste trabalho foi utilizado um equipamento de aquecimento indutivo para aquecer localmente a zona a ser soldada, visando avaliar a microestrutura formada e o perfil de durezas encontrado para os parâmetros variados. Os parâmetros de montagem e de operação foram avaliados quanto à sua influência na geometria do cordão de solda. A utilização do pré-aquecimento se mostrou efetiva na redução da taxa de resfriamento e consequentemente da proporção de fases frágeis e microdureza máxima das juntas. O trabalho mostra que a penetração e largura do cordão de solda foram aumentadas com o aumento do pré-aquecimento, e reduziram com o aumento da velocidade de soldagem, sendo a velocidade de soldagem o fator com maior influência nestas respostas. / One of the purposes of welding preheating is to decrease cooling rate of the joint to be welded, with consequent minimization of brittle phases formation. This practice is usually performed in a relatively large area around the joint, eventually causing undue changes in base metal mechanical and metallurgical properties, beyond to waste energy and time. However, the heat located in the joint also has the function of assisting in the melting of the base metal, so that it reaches temperatures close to the melting point of the material. This preheating may increase the penetration of the weld bead. In thicker plates may be discarded bevel machining in some cases and can be achieved higher welding speeds. Therefore, in this work an inductive heating equipment was used to locally heat the zone to be welded, aiming to evaluate the formed microstructure and the hardness profile found for the varied parameters. The assembly and operating parameters were evaluated for their influence on the geometry of the weld bead. The use of preheating was effective in reducing cooling rates and consequently in the proportion of brittle phases and maximum microhardness of the welded joint. The work shows that penetration and weld bead width increase with the increasing of the preheating, and reduces with the increase in welding speed, being the welding speed the factor with the greatest influence on this responses.

[pt] Bloqueio total de linhas submarinas de produção de petróleo devido ao depósito de parafina é um problema relevante para a indústria. Esse problema tem levado a perdas significativas associadas à diminuição de produção e à substituição de linhas obstruídas. O presente trabalho é um estudo sobre a viabilidade técnica de um procedimento para remoção de bloqueios ocasionados por depósitos de parafina. Nesse procedimento, a seção da linha de petróleo obstruída com parafina é aquecida por indução utilizando-se uma bobina externa posicionada sobre a linha no fundo do mar. O objetivo do trabalho é estimar o nível de potência elétrica necessária para amolecer a obstrução de parafina dentro da linha. Com esta finalidade, foi empregado um modelo numérico para simular o processo de condução de calor transiente para prever a distribuição de temperatura na parede da linha e na parafina sólida. Essa informação foi usada para estimar as dimensões básicas da seção da bobina de aquecimento e isolamento térmico empregado para minimizar as perdas de calor para o ambiente gelado da água do mar. Um estudo experimental de laboratório com uma seção de um duto submarino bloqueado com parafina foi conduzido para verificar as previsões do modelo numérico e para testar o desempenho da bobina de indução de aquecimento. Os resultados mostraram que as soluções numéricas obtidas apresentaram boa concordância com o experimento. Ainda, foi observado que os níveis de temperatura necessários para produzir o amolecimento da parafina na região bloqueada somente serão obtidos se toda a extensão da região bloqueada for aquecida pela ferramenta de indução. / [en] Total blockage of subsea petroleum production lines due to wax deposition is a relevant problem for the industry. This problem has led to significant capital losses associated with the loss of production and the substitution of plugged lines. The present work is a study of the feasibility of a remediation procedure aimed at helping the removal of wax plugs. In this procedure, the section of the oil line plugged with wax is inductively heated by means of an external coil positioned over the line at sea bed.The objective of the work is to estimate the level of electrical power required to soften the wax plug inside the line. To this end, a transient heat conduction model was employed to predict the temperature distribution in the line wall and solid wax. This information was employed to estimate the basic dimensions of the heating coil section and thermal insulation employed to minimize the heating losses to the cold sea water environment. A laboratory experimental study with a subsea pipeline section plugged with wax was conducted to verify the numerical model predictions and to test the performance of the inductive heating coil.The results showed that the numeric solutions obtained presented good agreement with the experiments. It was also observed that the necessary temperature levels to produce the paraffin softening in the blocked region will only be attained if the whole extension of the blocked region is heated by the induction tool.

Railway turnout heating is essential during the winter because snow and ice can hinder the movement of the switch. In Sweden, heating has traditionally been done using resistive heating wires mounted to the stock rail, but the technology is outdated and generally exhibits low efficiency and performance. Inductive heating systems such as Indheater, described in this exam work, has in previous studies shown great potential in reduction of the power consumption. Real world data comparing a resistive system and an Indheater system confirms this, with an energy consumption of the latter reaching 37,3 % of the resistive system’s consumption over two winter seasons. To achieve high efficiency and reliability, the heating system control algorithm is important, and during the work described in this report, fault detection was implemented to the programmable logic controller (PLC). Alarms will be triggered if the peak power is too low, which could indicate a heater malfunction. Additionally, detection of faulty switch position sensors and temperature sensors is also described. Given the dynamic nature of the Indheater system, calculations were performed to assess the electrical performance under both balanced and unbalanced load scenarios. Various sizes of phase compensating capacitors were compared. It is recommended to select a capacitor that provides a high power factor for a wide range of different loads, while still reducing the current enough at full load.

Le présent travail est réalisé dans le cadre de l’étude d’un procédé industriel de densification de matériaux composites carbone/carbone (C/C) destinés aux freins d’avion. Une préforme poreuse de fibres de carbone baigne dans un précurseur liquide et elle est chauffée par induction électromagnétique radio-fréquence. Le précurseur porté à ébullition dans l’espace poral crée un dépôt de carbone dans les zones les plus chaudes ; ce dépôt constitue la matrice du composite. On propose une modélisation physico-chimique de ce procédé afin d’en assurer le contrôle et l’optimisation. Le travail a consisté à développer un solveur couplant l’induction électromagnétique avec les transferts de masse, de chaleur, de mouvement et d’espèces chimiques, en incluant l’ébullition et le dépôt chimique. Le modèle inclut le circuit électrique complet permettant d’effectuer le chauffage : il permet donc de suivre en temps réel et de façon non destructive l’avancement de la densification par l’évolution des grandeurs électriques. Une formulation originale adaptée à la représentation simultanée du liquide, du gaz et de la zone en ébullition a été développée et implémentée avec succès dans un logiciel commercial d’éléments finis. Les résultats de la simulation sont comparés avec les données obtenues sur le moyen expérimental, avec un bon accord. Enfin, la simulation est utilisée pour proposer des pistes d’amélioration du procédé, en altérant la géométrie du dispositif de chauffage par induction et en modifiant la stratégie de pilotage en puissance. / This work has been carried out in the frame of the study of an industrial process for the manufacturing of carbon/carbon (C/C) composite aircraft brake discs. A porous preform made of carbon fibres is immersed in a liquid precursor and is heated by Radio-Frequency electromagnetic induction. The boiling precursor enters the porous preform and yields a carbon deposit in the hottest zones; this deposit will be the carbon matrix of the composite. A physico-chemical process model is proposed in the aim of ensuring its control and optimisation. The work consisted in developing a numerical solver coupling electromagnetic induction heating with heat, mass and species balances accounting for boiling, diffusion and chemical deposition reactions. The model includes the complete electrical circuit of the heating device: it therefore allows real-time, non-destructive monitoring of the infiltration progress through the evolution of the electrical properties. An original formulation has been designed to simultaneously describe the liquid, the gas and the boiling zone; it has been implemented in a commercial Finite Element software package and validated physically with respect to experimental data, with a good agreement. Finally, the simulation software has been used to propose directions for process improvements, through alterations of the inductive heating device geometry or of the heating power supply program.

Ce travail montre la mise en œuvre d'une technique originale pour le chauffage rapide et bien contrôlé de catalyseurs sous forme de films minces déposés sur un structurant métallique. L'utilisation d'un système à induction électromagnétique adapté à un réacteur catalytique de type annulaire nous a permis d'étudier un certain nombre de matériaux catalytiques, déposés sur acier inoxydable, dans une perspective d'oxydation totale en CO2 et H2O de composés organiques volatiles (COV) présents dans l'air. La combustion de l'isopropanol et du toluène par l'oxygène de l'air a été étudiée en utilisant différents catalyseurs déposés sous forme de films minces: 1%Pt/Al2O3, 0,3%Pt/SnO2, 1%Pt/SnO2 et 1%Pt/YSZ. Les solides ont été préparés par imprégnation des oxydes correspondants par H2PtCl6 puis ont été déposés sur le support d'acier inoxydable par électrophorèse. Les principaux paramètres relatifs au mode de chauffage ont été étudiés de même que l'influence sur la conversion des COV de différents facteurs tels que la quantité de catalyseur, le pourcentage de platine ou la nature du support oxyde employé. Les informations fournies par ce système innovant ont également été comparées pour validation à celles obtenues à l'aide d'un système classique (microréacteur en quartz à lit traversé chauffé de manière conventionnelle) pour une réaction de référence qui est l'oxydation de CO en CO2. Le système décrit dans cette étude présente d'une part un intérêt pratique pour le traitement rapide de contaminations accidentelles de l'air ambiant, mais est aussi un très bon moyen d'obtenir des paramètres cinétiques fiables dans le domaine des catalyseurs en films minces utilisés dans de nombreux réacteurs structurés / This study shows the development of an innovative technique for a fast and well-controlled heating of catalysts deposited as thin films on a metallic support. The use of an electromagnetic induction system fitted to an annular catalytic reactor enabled us to study some catalytic materials deposited on stainless steel. The target application was the abatement of volatile organic compounds (VOCs) in the air. Isopropyl alcohol and toluene combustion by the oxygen was studied on various thin films catalysts, i.e. : 1%Pt/Al2O3, 0,3%Pt/SnO2, 1%Pt/SnO2 et 1%Pt/YSZ. Solids were prepared by wet impregnation of the corresponding oxides by H2PtCl6 and were deposited on the stainless steel support using an electrophoretic deposition technique. The main parameters of the heating system were investigated as well as the influence on VOCs abatement of various parameters such as the thickness of catalyst film, the platinum amount and the nature of the oxide. For validation purpose, the data provided by this innovative system were also compared to the ones provided by a classical one (quartz plug-through microreactor heated in a conventional way) in a reference reaction which was CO oxidation into CO2. The system described in this study shows on the one hand a real practical interest for fast remediation of indoor air polluted by VOCs, and on the other hand is a very powerful tool for obtaining kinetic data about thin layer catalysts used in many structured reactors

Die vorliegende Arbeit beschäftigt sich mit der Auswirkung der induktiven Erwärmung beim Austenitisieren eines walzprofilierten Erzeugnisses vor dem Abschrecken auf seine mechanischen Eigenschaften und Mikrostruktur. Zur Beschreibung der Entwicklung von mechanischen Eigenschaften werden verschiedene empirische, semi-empirische sowie auf den experimentell ermittelten Kennwerten basierte physikalische Werkstoffmodelle herangezogen. Der Einfluss der schnellen induktiven Erwärmung auf die Gefüge¬entwicklung und die Einleitung der Entfestigungsprozesse wird dargelegt. Deren Auswirkung auf erzeugten Eigenspannungen wird simulativ abgebildet. Anhand der erzielten Ergebnisse wird eine Empfehlung zur Auslegung des Prozessfensters gegeben.:1 Einleitung 2 Stand der Technik 3 Zielsetzung und Aufgabenstellung 4 Versuchseinrichtungen und eingesetzte Methoden 5 Ergebnisse 6 Diskussion 7 Zusammenfassung und Ausblick / The present work focuses on the effect of inductive heating during austenitizing of a roll formed product before quenching on its mechanical properties and microstructure. To describe the development of mechanical properties various empirical, semi-empirical and physical material models based on the experimentally determined characteristic values are used. The influence of rapid inductive heating on the microstructure development and the initiation of softening processes is described. Their effect on generated residual stresses is simulated. Based on the obtained results, a recommendation for the design of the process window is given.:1 Einleitung 2 Stand der Technik 3 Zielsetzung und Aufgabenstellung 4 Versuchseinrichtungen und eingesetzte Methoden 5 Ergebnisse 6 Diskussion 7 Zusammenfassung und Ausblick

Der Forschungsgegenstand der vorliegenden Arbeit ist die kontinuierliche Herstellung eines profilförmigen Bauteils aus dem Bor-Mangan-Stahl 22MnB5 mit lokal bzw. global definierten mechanischen Eigenschaften. Dabei laufen die Formgebung und Wärmebehandlung (WBH) parallel ab. Die Hauptformgebung erfolgt zunächst im Lieferzustand, an die sich die Wärmbehandlung und die finale Formgebung anschließen. Während der WBH wird das ferritische Anfangsgefüge beim Erwärmen in Austenitgefüge und anschließend durch eine rasche Abkühlung größer 30 K/s in Martensitgefüge umgewandelt. Die Induktorform, -frequenz und die -leistung beeinflussen hierbei maßgeblich die Aufheizrate und das Erwärmungsbild. Durch kontinuierliche Formgebung und die gezielte WBH sind Profilbauteile mit Bauteilfestigkeiten bis 1500 MPa effizient herstellbar. Im Anschluss an eine Machbarkeitsstudie werden experimentelle und simulative Untersuchungen durchgeführt und die gewonnenen Ergebnisse miteinander verglichen. Dadurch kann die prinzipielle Eignung des FE-Modells nachgewiesen werden. Im Weiteren erfolgt der Vergleich von drei verschiedenen Fertigungsrouten, wobei das Hauptaugenmerk auf der erforderlichen Umformkraft und der erreichbaren Formgenauigkeit liegt. Auf Basis der Simulationsergebnisse kann festgehalten werden, dass mittels der untersuchten Technologie höchstfeste und formgenaue Profilbauteile mit definierten mechanischen Eigenschaften herstellbar sind. Der Einsatz der Technologie birgt somit ein enormes Leichtbaupotenzial. Dennoch gibt es Hemmnisse die Technologie einzusetzen, da „Wärme“ in den traditionell kalt ablaufenden Umformprozess eingebracht wird. Die Arbeit soll dazu beitragen, diese Barriere abzubauen.:1 EINLEITUNG 2 STAND DER FORSCHUNG UND ENTWICKLUNG 3 HANDLUNGSBEDARF, ZIELSETZUNG UND LÖSUNGSWEG 4 VERSUCHSPLANUNG 5 VERWENDETE WERKSTOFFE SOWIE ANLAGEN- UND WERKZEUGTECHNIK ZUR ENTWICKLUNG EINER TECHNOLOGIE ZUR HERSTELLUNG EINTEILIGER, EIGENSCHAFTSSKALIERTER PROFILBAUTEILE 6 REFERENZVERSUCHE V-GESENKBIEGEN UND KALTWALZPROFILIEREN EINES HUTPROFILS AUS 22MNB5 7 STATIONÄRES AUFHEIZVERHALTEN EINES RINGINDUKTORS UND ABSCHRECKEN MITTELS UNTERSCHIEDLICHER KÜHLMEDIEN 8 INTEGRATION EINER WÄRMEBEHANDLUNG IN DEN KONTINUIERLICHEN WALZPROFILIERPROZESS 9 ZUSAMMENFASSUNG 10 AUSBLICK / The research object of the present work is the continuous production of an open profile component made of the manganese-boron steel 22MnB5 with locally or globally defined mechanical properties. The shaping and heat treatment (SHT) take place in one process. The main shaping is first carried out in the as-delivered condition, followed by heat treatment and final shaping. During the heat treatment, the initial ferritic microstructure is transformed into an austenitic state during heating and then into a martensitic microstructure by rapid cooling at a rate of more than 30 K/s. The geometry of the induction coil, the frequency and the heating power have a significant influence on the heating rate and the heating effect. Through continuous shaping and controlled SHT, profile components with strengths of up to 1500 MPa can be produced efficiently. Following a feasibility study, experimental and simulative investigations were carried out and the results obtained were compared with each other. In this way, the principle suitability of the FE model could be demonstrated. In further steps, three different production routes were com-pared, whereby the main focus was on the required forming force and the achievable forming accuracy. Based on the obtained results, it can be stated that the investigated technology can be used to produce high-strength and dimensionally accurate profile components and defined mechanical properties with high output rate. The use of this technology thus offers a huge lightweight potential. However, as additional heat is introduced into the traditionally cold forming process, the process is more complexity and this constitutes a barrier to the use of the technology. This work is intended to overcome this barrier.:1 EINLEITUNG 2 STAND DER FORSCHUNG UND ENTWICKLUNG 3 HANDLUNGSBEDARF, ZIELSETZUNG UND LÖSUNGSWEG 4 VERSUCHSPLANUNG 5 VERWENDETE WERKSTOFFE SOWIE ANLAGEN- UND WERKZEUGTECHNIK ZUR ENTWICKLUNG EINER TECHNOLOGIE ZUR HERSTELLUNG EINTEILIGER, EIGENSCHAFTSSKALIERTER PROFILBAUTEILE 6 REFERENZVERSUCHE V-GESENKBIEGEN UND KALTWALZPROFILIEREN EINES HUTPROFILS AUS 22MNB5 7 STATIONÄRES AUFHEIZVERHALTEN EINES RINGINDUKTORS UND ABSCHRECKEN MITTELS UNTERSCHIEDLICHER KÜHLMEDIEN 8 INTEGRATION EINER WÄRMEBEHANDLUNG IN DEN KONTINUIERLICHEN WALZPROFILIERPROZESS 9 ZUSAMMENFASSUNG 10 AUSBLICK