This thesis describes, in a manufacturing context, the development of new waterbased core technology for light alloys. Cores used for steel casting are made from fused silica and are removed using hot sodium hydroxide under refluxing (pressurising hot acids). However, aluminium and other light alloys are attacked by sodium hydroxide. Currently there is no good core system for aluminium and other light alloys. It is therefore desirable to find an alternative material/leaching agent combination for casting aluminium and other light alloys. The recent research review has shown that ceramic cores are mostly made by fused silica with different additives. The previous research has suggested using fused silica (different mesh size) as filling material and using magnesium oxide to control the slurry working life of core mixes. Calcium silicate assists core leaching in dilute acid. The plaster (calcium sulphate) in the form of proprietary plasters (Crystcal R, Fine Casting Plaster) is used to create bond and gives strength to the core. Lithium carbonate acts has an accelerator, improving the strengthening effect of the plaster in the cores. The binder (Ludox® AM) and water act (as added materials) to bind the composition Core compositions were made with different core trials to produce a core, which records suitable strength and quick leaching properties for light alloys. Core trials were individually mixed and poured into a wooden core box. Cores were pre-dried for twenty-four hours. Cores were fired to different temperatures for two hours, followed by two hours cooling. The cores were subjected to computerised three-point bend test to record the Modulus of rupture (MOR). The plain strain fracture toughness and Weibull parameters were calculated. The Weibull parameter was plotted using Minitab analysis software. Using the cores, gravity die casting process were carried out. The subsequent castings was dipped in diluted nitric, citric and acetic acid to leach out the core. Using different core compositions, core trials were mixed, poured, dried, tested and leached. The high amount of plaster in core trials records high MOR when cores were fired between 200°- 400° C and the opposite result when fired between 600°- 800° C. The different grade of plasters(CRP,FCP) do not influence the strength. One percent of magnesium oxide gives a very short working life. High amount of binder(Ludox® AM) in core produce strong cores. Workable MOR results can be obtained depending on composition allowing manual handling or a waxing process. The fracture toughness is typical of a brittle material, with matching Weibull parameters. The casting process suggests that the new materials are sufficiently refractory. The cores are leached out using diluted nitric, acetic and citric acid at rates compatible with commercial manufacture. This methodology has successfully produced a core using fused silica with plaster and magnesium oxide for aluminium and possibly for light alloys. Different core trials can be used depending on the specific industrial application relating to strength and removal with acid attacking the metal. Further work is needed to fine tune optimum leaching conditions.

Pour rendre les véhicules électriques plus attractifs, les recherches actuelles se portent sur l'augmentation de l'autonomie de la batterie. Deux méthodes existent pour le réaliser : travailler sur les technologies de batterie ou alléger le véhicule. Une voie classique d'allègement est de remplacer les matériaux des pièces existantes par d'autres matériaux plus légers. Dans le cas des alliages d'aluminium, les matériaux de remplacement possibles sont les polymères ou les alliages de magnésium. Dans cette étude, l'alliage de magnésium commercial AZ91 a été modifié par ajout d'éléments d'alliages supplémentaires. Des échantillons d'alliages modifiés coulés sable ont été étudiés pour en comparer la microstructure et les comportements mécaniques et face à la corrosion. Des observations de coupes métallographiques avec analyse quantitative d'image ont été couplées avec de la microanalyse X , de la diffraction des rayons X et avec de l'analyse thermique , pour analyser les changements de microstructure et de séquence de précipitation dues aux ajouts. La réponse aux traitements thermiques a aussi été quantifiée. Des essais mécaniques ont été réalisés pour classer les différents alliages de magnésium selon leurs performances. Enfin, l'AZ91D est connu pour son bon comportement en corrosion par rapport aux autres alliages de magnésium. L'influence des ajouts d'éléments sur la performance en corrosion a également été étudiée par des méthodes conventionnelles d'électrochimie et par des essais industriels. / To make electric vehicles more attractive, researches to increase the autonomy of electric vehicles are underway on the battery technology and on the lightening of many vehicle parts. For the second approach, one way is to replace aluminum by magnesium without loosing mechanical and corrosion resistance performance. The AZ91 commercial alloy was modified with additional elements to meet the mechanical requirements for the power electronic casings. Sand casting samples were studied for the comparison of microstructure and properties. First, metallographic observations were performed with an optical microscope and a SEM combined with microanalysis (epma) coupled with quantitative image analysis, then the solidification sequence was analysed using thermal analysis in order to identify the changes in microstructure when alloying. Combined with DTA, X-ray diffraction and micro probe analysis, these techniques are useful to understand the solidification sequence of the complex alloys and their response to heat treatments. Tensile and hardness tests were then performed in order to quantify the mechanical strength of the different samples. Fractographic observations were also done to characterize the rupture of the specimens. AZ91D is known for its good corrosion resistance. Corrosion behaviour of modified alloys was assessed by electrochemical and non-electrochemical methods.

Hoje em dia na indústria automobilística há uma grande necessidade em diminuição de custos e de peso no carro e isso pode ser o diferencial na concorrência da indústria automobilística. A substituição de materiais pesados por materiais mais leves é uma tendência mundial na indústria automobilística, além disso, existe também a necessidade de diminuir as etapas de processo. O tratamento térmico é uma etapa que tem um gasto muito grande de energia consequentemente é uma etapa muito cara do processo e ligas não tratáveis termicamente pode acarretar em economia de processo. O cabeçote de motor é uma parte importante do carro e o uso é em altas temperaturas em tempos elevados, esta peça é uma peça fundida sobre pressão para motores movido a álcool ou/e gasolina e geralmente feita de liga de alumínio com tratamento térmico, este trabalho estudou uma liga de alumínio com alto teor de cobre, para isso foi necessário a caracterização da liga com envelhecimento a temperaturas de trabalho do motor e verificou-se o que acontece com as propriedades mecânicas da peça. / Nowadays, there is a huge need in reduce the costs and the weight of cars, which could be a differential in the competition of the automotive industry. The substitution of heavy materials for lighter materials is a world tendency in the automotive industry, besides that, there is a need in reduce the stages of the process. The thermal treatment is a stage that has a high cost of energy, consequently, it is the more expensive stage of the process and alloys, that cannot be treated thermally, can result in economy of process. The cylinder head is an important part of the car and it is used in high temperatures for a long period. This piece is fused on pressure for engines that use ethanol or/and gasoline, generally, it is made by aluminum alloys with thermal treatment, this project was made by the study of an aluminum alloy with high content of copper, to make it happen, was necessary the characterization of the alloy with aging to temperatures of engine\'s work, it was found what happens to the mechanics properties of the piece.

O objetivo principal desse trabalho é estudar o processo de solidificação e da formação de fases de uma liga de magnésio contendo elemento Terras Raras (Mg-6Al-3La-1Ca), submetida a diferentes níveis de superaquecimento. Para isso, foi utilizado um sistema de solidificação unidirecional ascendente com atmosfera controlada. Termopares foram utilizados para monitorar a evolução térmica dos lingotes, que foram resfriados de forma lenta (convecção natural) e de forma rápida (convecção forçada com água refrigerando a base). Pôde-se, então, determinar as temperaturas de transformação da liga (temperaturas solidus e liquidus). Além disso, foram identificadas as formações da matriz α-Mg, dos compostos de forma acicular Al11La3, e dos eutéticos Mg2Ca e (Al,Mg)2Ca, além de uma fina estrutura dispersa pela matriz indicando ser provavelmente Al2Ca. O superaquecimento mostrou forte influência na morfologia quando aliado ao resfriamento rápido. Para maiores valores de superaquecimento a formação de fases contendo Lantânio foi majorada e a formação de estruturas eutéticas contendo Cálcio foi retardada. Equações correlacionando parâmetros struturais e térmicos foram geradas mostrando conformidade com a literatura. / This work aimed to study the solidification process and phase formation of a magnesium alloy containing rare earth elements (Mg-6Al-3La-1CA) subjected under different values of superheating. For this, it was used an unidirectional solidification system with a controlled atmosphere. Thermocouples were used to follow up the thermal evolution of the ingots, in both, slow cooling condition (using natural convection) and fast cooling condition (using water in the base to cooling the ingots). So it was then determined the transformation temperatures of the alloy (solidus and liquidus temperatures). Furthermore, it was identified the formations of α-Mg matrix, the compounds of Al11La3 (acicular form), and the eutectic Mg2Ca and (Al, Mg)2Ca, and a fine structure dispersed through the specimen indicating, probably, to be Al2Ca. Superheating has showed strong influence on morphology when combined with rapid cooling. For larger values of superheating the formation of phases containing lanthanum was increased and the formation of eutectic structures containing calcium was delayed. Correlation between thermal parameters and microstructure were made and the results agreement with the literature.

O objetivo principal desse trabalho é estudar o processo de solidificação e da formação de fases de uma liga de magnésio contendo elemento Terras Raras (Mg-6Al-3La-1Ca), submetida a diferentes níveis de superaquecimento. Para isso, foi utilizado um sistema de solidificação unidirecional ascendente com atmosfera controlada. Termopares foram utilizados para monitorar a evolução térmica dos lingotes, que foram resfriados de forma lenta (convecção natural) e de forma rápida (convecção forçada com água refrigerando a base). Pôde-se, então, determinar as temperaturas de transformação da liga (temperaturas solidus e liquidus). Além disso, foram identificadas as formações da matriz α-Mg, dos compostos de forma acicular Al11La3, e dos eutéticos Mg2Ca e (Al,Mg)2Ca, além de uma fina estrutura dispersa pela matriz indicando ser provavelmente Al2Ca. O superaquecimento mostrou forte influência na morfologia quando aliado ao resfriamento rápido. Para maiores valores de superaquecimento a formação de fases contendo Lantânio foi majorada e a formação de estruturas eutéticas contendo Cálcio foi retardada. Equações correlacionando parâmetros struturais e térmicos foram geradas mostrando conformidade com a literatura. / This work aimed to study the solidification process and phase formation of a magnesium alloy containing rare earth elements (Mg-6Al-3La-1CA) subjected under different values of superheating. For this, it was used an unidirectional solidification system with a controlled atmosphere. Thermocouples were used to follow up the thermal evolution of the ingots, in both, slow cooling condition (using natural convection) and fast cooling condition (using water in the base to cooling the ingots). So it was then determined the transformation temperatures of the alloy (solidus and liquidus temperatures). Furthermore, it was identified the formations of α-Mg matrix, the compounds of Al11La3 (acicular form), and the eutectic Mg2Ca and (Al, Mg)2Ca, and a fine structure dispersed through the specimen indicating, probably, to be Al2Ca. Superheating has showed strong influence on morphology when combined with rapid cooling. For larger values of superheating the formation of phases containing lanthanum was increased and the formation of eutectic structures containing calcium was delayed. Correlation between thermal parameters and microstructure were made and the results agreement with the literature.

O objetivo principal desse trabalho é estudar o processo de solidificação e da formação de fases de uma liga de magnésio contendo elemento Terras Raras (Mg-6Al-3La-1Ca), submetida a diferentes níveis de superaquecimento. Para isso, foi utilizado um sistema de solidificação unidirecional ascendente com atmosfera controlada. Termopares foram utilizados para monitorar a evolução térmica dos lingotes, que foram resfriados de forma lenta (convecção natural) e de forma rápida (convecção forçada com água refrigerando a base). Pôde-se, então, determinar as temperaturas de transformação da liga (temperaturas solidus e liquidus). Além disso, foram identificadas as formações da matriz α-Mg, dos compostos de forma acicular Al11La3, e dos eutéticos Mg2Ca e (Al,Mg)2Ca, além de uma fina estrutura dispersa pela matriz indicando ser provavelmente Al2Ca. O superaquecimento mostrou forte influência na morfologia quando aliado ao resfriamento rápido. Para maiores valores de superaquecimento a formação de fases contendo Lantânio foi majorada e a formação de estruturas eutéticas contendo Cálcio foi retardada. Equações correlacionando parâmetros struturais e térmicos foram geradas mostrando conformidade com a literatura. / This work aimed to study the solidification process and phase formation of a magnesium alloy containing rare earth elements (Mg-6Al-3La-1CA) subjected under different values of superheating. For this, it was used an unidirectional solidification system with a controlled atmosphere. Thermocouples were used to follow up the thermal evolution of the ingots, in both, slow cooling condition (using natural convection) and fast cooling condition (using water in the base to cooling the ingots). So it was then determined the transformation temperatures of the alloy (solidus and liquidus temperatures). Furthermore, it was identified the formations of α-Mg matrix, the compounds of Al11La3 (acicular form), and the eutectic Mg2Ca and (Al, Mg)2Ca, and a fine structure dispersed through the specimen indicating, probably, to be Al2Ca. Superheating has showed strong influence on morphology when combined with rapid cooling. For larger values of superheating the formation of phases containing lanthanum was increased and the formation of eutectic structures containing calcium was delayed. Correlation between thermal parameters and microstructure were made and the results agreement with the literature.

Hoje em dia na indústria automobilística há uma grande necessidade em diminuição de custos e de peso no carro e isso pode ser o diferencial na concorrência da indústria automobilística. A substituição de materiais pesados por materiais mais leves é uma tendência mundial na indústria automobilística, além disso, existe também a necessidade de diminuir as etapas de processo. O tratamento térmico é uma etapa que tem um gasto muito grande de energia consequentemente é uma etapa muito cara do processo e ligas não tratáveis termicamente pode acarretar em economia de processo. O cabeçote de motor é uma parte importante do carro e o uso é em altas temperaturas em tempos elevados, esta peça é uma peça fundida sobre pressão para motores movido a álcool ou/e gasolina e geralmente feita de liga de alumínio com tratamento térmico, este trabalho estudou uma liga de alumínio com alto teor de cobre, para isso foi necessário a caracterização da liga com envelhecimento a temperaturas de trabalho do motor e verificou-se o que acontece com as propriedades mecânicas da peça. / Nowadays, there is a huge need in reduce the costs and the weight of cars, which could be a differential in the competition of the automotive industry. The substitution of heavy materials for lighter materials is a world tendency in the automotive industry, besides that, there is a need in reduce the stages of the process. The thermal treatment is a stage that has a high cost of energy, consequently, it is the more expensive stage of the process and alloys, that cannot be treated thermally, can result in economy of process. The cylinder head is an important part of the car and it is used in high temperatures for a long period. This piece is fused on pressure for engines that use ethanol or/and gasoline, generally, it is made by aluminum alloys with thermal treatment, this project was made by the study of an aluminum alloy with high content of copper, to make it happen, was necessary the characterization of the alloy with aging to temperatures of engine\'s work, it was found what happens to the mechanics properties of the piece.

Este trabalho tem o intuito de analisar a junção realizada pelo processo de soldagem por fricção-mistura (FSW) pelo do teste de Arcan. É apresentada inicialmente uma revisão bibliográfica dos estudos já realizados nessa área e da teoria relevante. Foram realizados ensaios para avaliar a falha da junta sob carregamento multiaxial quando comparada à falha do material base. Para a realização dos ensaios utilizouse uma máquina de tração com capacidade de 50 kN. Foi projetado e construído um dispositivo de Arcan modificado, que permite a variação do ângulo com o qual a força de tração é aplicada. Os resultados práticos demonstraram as características de resistência da junção por FSW quando sujeita à forças de tração e cisalhamento. Os resultados obtidos servem como base para comparação entre junções feitas por FSW e por métodos convencionais como a utilização de rebites (prática muito comum na indústria aeronáutica). / The aim of this work is to analyze the junction made by Friction Stir Welding (FSW) using the Arcan test. Initially is presented a review of the studies carried out in this area and the relevant theory for the project. Tests were executed in order to evaluate the failure of the welding under multiaxial loading when compared to the failure of the base material. In order to execute the Arcan Tests, a tensile test machine with nominal capacity of 50 kN was used. A modified Arcan device, that allows an angle variation of the force applied, was developed and fabricated. The practical results demonstrate the FSW joint resistance characteristics when subjected to normal and shear forces. The results obtained serve as basis to compare the junctions made using FSW and conventional joint methods like rivets (very common practice in the aeronautical industry).

Refill Friction Stir Spot Welding (RFSSW) is a new solid-state joining technology, which is suitable for joining similar and dissimilar overlap sheets connections, particularly in aluminium and magnesium alloys. This welding method is expected to have wide applications in joining of body parts in the automotive industry. In the present study, RFSSW has been used to join 1.0 mm gauge sheets of two material combinations: similar AA6111-T4 automotive aluminium alloy joints and a dissimilar aluminium AA6111-T4 to magnesium AZ31-H24 alloy combinations. The performance of the joints was investigated in terms of the effect of the welding parameters (including tool rotation rate, sleeve plunge depth, and welding time etc.) to improve current understanding and allow optimisation of the process for short welding-cycles when joining similar and dissimilar light alloys. The results of the investigations on similar AA6111 welds showed the ability to use a wide window of process parameters that resulted in joints with a successfully refilled keyhole and flat weld surface, even when using a welding time as short as 0.5 s. The joints in the as-welded condition showed strengths as high as 4.2 kN, when using welding parameters of 1500 rpm, 1.0 mm with a range of welding times from 0.55 to 2.0 s. All joints showed a nugget pull-out failure mode when using a sleeve plunge depth of 0.8 mm or more, as a result of increasing the joint area. The strength of the joints further improved and reached peak loads of 5.15 and 6.43 kN after natural and artificial ageing, respectively, for welds produced using optimised welding parameters of a 2500 rpm tool rotation rate, a 1.5 s welding time and a 1.0 mm plunge. This improvement in strength resulted from the improvement in the local mechanical properties in the HAZ and other regions, which results from a minimal HAZ due to the rapid weld cycle and the re-precipitation of GPZs and clustering on natural ageing, or β on artificial ageing. A modification to the RFSSW process was developed in this project to solve the problems faced when dissimilar welding Mg to Al. This modified process involved adding a final brief pin plunge stage to consolidate refill defects and it was successful in producing nearly defect-free joints with improved mechanical properties, using a wide range of the process parameters. The average peak load of the joints increased with increasing tool rotation rate, to reach a maximum value at 2500 rpm due to eliminating the weld defects by increasing the material plasticity. However, increasing the tool rotation rate further to 2800 rpm led to a decrease in the average peak failure load due to eutectic melting at the weld interface. The optimum welding condition was thus found to be: 2500 rpm, 1.0 s, and 1.0 mm, which gave an average peak failure load of 2.4 kN and average fracture energy of 1.3 kN.mm. These values represent an improvement of about 10 % and 27 %, respectively, compared to welds produced with the conventional RFSSW process, and about 112 % and 78 % of the Mg-Mg similar joints produced using the same welding conditions. A FE model developed in this project was successful in increasing understanding of the behaviour of the RFSSW joints when subjected to lap tensile-shear loading. The stress and strain distribution in the modelled samples showed that the highest concentration occurring in the region of the confluence of the SZ with the two sheets. With increasing extension, these regions of highest stress and strain propagated to the outer surfaces of the two sheets and then annularly around the weld nugget. This annular ring of high strain concentration agreed well with the failure path and results in the full plug pull-out fracture mode shown by the experimentally tested samples. The predicted force-extension curves showed high agreement with the experimental results, especially when including the effect of the hook defect and correction of compliance in the experimental results.

Este trabalho tem o intuito de analisar a junção realizada pelo processo de soldagem por fricção-mistura (FSW) pelo do teste de Arcan. É apresentada inicialmente uma revisão bibliográfica dos estudos já realizados nessa área e da teoria relevante. Foram realizados ensaios para avaliar a falha da junta sob carregamento multiaxial quando comparada à falha do material base. Para a realização dos ensaios utilizouse uma máquina de tração com capacidade de 50 kN. Foi projetado e construído um dispositivo de Arcan modificado, que permite a variação do ângulo com o qual a força de tração é aplicada. Os resultados práticos demonstraram as características de resistência da junção por FSW quando sujeita à forças de tração e cisalhamento. Os resultados obtidos servem como base para comparação entre junções feitas por FSW e por métodos convencionais como a utilização de rebites (prática muito comum na indústria aeronáutica). / The aim of this work is to analyze the junction made by Friction Stir Welding (FSW) using the Arcan test. Initially is presented a review of the studies carried out in this area and the relevant theory for the project. Tests were executed in order to evaluate the failure of the welding under multiaxial loading when compared to the failure of the base material. In order to execute the Arcan Tests, a tensile test machine with nominal capacity of 50 kN was used. A modified Arcan device, that allows an angle variation of the force applied, was developed and fabricated. The practical results demonstrate the FSW joint resistance characteristics when subjected to normal and shear forces. The results obtained serve as basis to compare the junctions made using FSW and conventional joint methods like rivets (very common practice in the aeronautical industry).