Powder metallurgy (PM) steel is produced by near net shape manufacturing, which is used to fabricate alloy steels for many purposes. Designing new powder metal steels that can form a significant fraction of martensite relies on hardenability calculations developed for wrought steels. These proven tools are built upon assumptions for wrought steels that do not hold true for PM steels. One assumption is that the alloying elements are homogenized throughout the material. In admixed powder blends that are industrially sintered this is not the case. Using prealloyed powder is a solution to this issue, yet it places restrictions on alloy design and compressibility. There are tools available to computationally optimize diffusion problems, yet the complexity during the sintering of PM steel is such that a robust model has yet been produced. It is intuitive that with smaller particles of Fe sintering time can be reduced. A direct experimental investigation linking Fe-powders’ sizes and hardenability on Fe-C-Cr-Mn-Mo-Ni PM steel was subject to microstructure analysis and mechanical properties (Jominy test) for comparative analysis. Another assumption that is made for wrought steel is a consistent density of 7.87g/cm3. This is not the case for PM steel as the press and sinter method produces pores, decreasing the density. This directly affects the thermal conductivity and phase transformation of the steel. In an effort to understand how these differences affect Grossmann’s predictions of hardenability, a direct experimental investigation linking the density to hardenability was launched on prealloyed FL-4605 and FL-4605+2%Cu. Specifically the Jominy test was completed on a range of densities, as well as compared to software predictions. The chemical variations in admixed and sintered PM steel produce a unique system where one TTT diagram cannot predict the entire final microstructure. PM steel such as this is observed in industry, and can be created through incorporating larger Fe-particles such that less alloying constituents have a chance to fully alloy these regions. Since the large particles will not have the chance to be alloyed, they will not have the ability to form martensite. Since the regions between large particles will be alloyed, martensite will form, creating a hard matrix surrounding softer particles. This structure is characteristic of a metal matrix composite (MMC), and therefore should be treated as such. There are methods of MMC design that involve numerical methods of predicting strength and toughness. These methods, along with experimental data (tensile and Charpy testing) of Fe-C-Cr-Mn-Mo-Ni PM steels with ranging volume fractions of pearlitic inclusions were compared. / Thesis / Master of Applied Science (MASc)

Thermal spray coatings offer new alternatives in the production of electronic power modules that use alumina ceramic as an isolation layer. Current processes use direct bond copper (DBC) soldered to a nickel plated copper heat spreader. A coefficient of thermal expansion (CTE) mismatch exists between copper and alumina and leads to reliability issues that arise due to product failure during thermal cycling and lifetime operation. The substitution of an AlSiC metal matrix composite (MMC) heat spreader baseplate addresses the problem of CTE mismatch and will reduce the number of product failures related to cracking and delamination caused by this pronounced mismatch in the thermal expansion coefficient.. The substitution of an AlSiC (MMC) heat spreader baseplate also allows the production process to be achieved with a fewer number of metallization layers. Thermal spray can apply alumina ceramic coatings directly to the AlSiC (MMC) baseplates. A reduction in process steps will lead to a reduction in manufacturing costs, the main driving objective in Microelectronics Industries. Thermal spray coatings have a major problem since they have a porous microstructure which can trap undesired moisture. The moisture basically causes the coatings to have a lower dielectric breakdown voltage and a higher leakage current at normal operating voltages. This problem can be eliminated by manufacturing the electronic power modules in a controlled environment and packaging the devices in a hermetically sealed package. This thesis analyzes the data obtained from direct-voltage dielectric breakdown and direct-voltage leakage current tests conducted on coupons manufactured using the thermal plasma spray coating process and the thermal high-velocity oxyfuel (HVOF) coating process. ASTM specifications defining appropriate testing procedures are used in testing the dielectric strength of these coupons. Issues relating to the dielectric strength and dielectric leakage current are evaluated and validated at the Microelectronics Laboratory at Virginia Polytechnic Institute & State University. The objective to conduct this research study using plasma and HVOF alumina coatings as dielectric isolation layers is to support the Microelectronics Industries in developing a product with increased reliability at a lower manufacturing cost. / Master of Science

Silicon carbide and nanostructured ferritic alloy (SiC-NFA) composites have the potential to maintain the outstanding high temperature corrosion and irradiation resistance and enhance the mechanical integrity for nuclear cladding. However, the formation of detrimental silicide phases due to reaction between SiC and NFA remains a major challenge. By introducing a carbon interfacial barrier on NFA (C@NFA), SiC-C@NFA composites are investigated to reduce the reaction between SiC and NFA. In a similar way, the effect of chromium carbide (Cr3C2) interfacial barrier on SiC (Cr3C2@SiC) is also presented for Cr3C2@SiC-NFA composites. Both the coatings were successful in suppressing silicide formation. However, despite the presence of coatings, SiC was fully consumed during spark plasma sintering process. TEM and EBSD investigations revealed that spark plasma sintered SiC-C@NFA and Cr3C2@SiC-NFA formed varying amounts of different carbides such as (Fe,Cr)7C3, (Ti,W)C and graphite phases in their microstructure. Detailed microstructural examinations after long term thermal treatment at 1000oC on the microstructure of Cr3C2@SiC-NFA showed precipitation of new (Fe,Cr)7C3, (Ti,W)C carbides and also the growth of existing and new carbides. The results were successfully explained using ThermoCalc precipitation and coarsening simulations respectively. The oxidation resistance of 5, 15 and 25 vol% SiC@NFA and Cr3C2@SiC-NFA composites at 500-1000oC temperature under air+45%water vapor containing atmosphere is investigated. Oxidation temperature effects on surface morphologies, scale characteristics, and cross-sectional microstructures were investigated and analyzed using XRD and SEM. SiC-C@NFA showed reduced weight gain but also showed considerable internal oxidation. Cr3C2@SiC-NFA composites showed a reduction in weight gain with the increasing volume fraction of Cr3C2@SiC (5, 15 and 25) without any indication of internal oxidation in the microstructure. 25 vol% SiC-C@NFA and 25 vol% Cr3C2@SiC-NFA showed over 90% and 97% increase in oxidation resistance (in terms of weight gain) as compared to NFA. The results were explained using the fundamental understanding of the oxidation process and ThermoCalc/DICTRA simulations. Finally, the irradiation performance of SiC-C@NFA and Cr3C2@SiC-NFA composites was assessed in comparison with NFA using state-of-the-art TEM equipped with in-situ ion irradiation capability. Kr++ ions with 1 MeV energy was used for irradiation experiments. The effect of ion irradiation was recorded after particular dose levels (0-10 dpa) at 300oC and 450oC temperatures. NFA sample showed heavy dislocation damage at both 300oC and 450oC increasing gradually with dose levels (0-10 dpa). Cr3C2@SiC-NFA showed similar behavior as NFA at 300oC. However, at 450oC, Cr3C2@SiC-NFA showed remarkably low dislocation loop density and loop size as compared to NFA. At 300oC, microstructures of NFA and Cr3C2@SiC-NFA show predominantly 1/2<111> type dislocation loops. At 450oC, NFA showed predominantly <100> type loops, however, Cr3C2@SiC-NFA composite was still predominant in ½<111> loops. The possible reasons for this interesting behavior were discussed based on the large surface sink effects and enhanced interstitial-vacancy recombination at higher temperatures. The molecular dynamics simulations did not show considerable difference in formation energies of ½<111> and <100> loops for NFA and Cr3C2@SiC-NFA composites. The additional Si element in the SiC-NFA sample could have been an important factor in determining the dominant loop types. SiC-C@NFA composites showed heavy dislocation damage during irradiation at 300oC. At 450oC, SiC-C@NFA showed high dislocation damage in thicker regions. Thinner regions near the edge of TEM samples were largely free from dislocation loops. The precipitation and growth of new (Ti,W)C carbides were observed at 450oC with increasing irradiation dose. (Fe,Cr)7C3 precipitates were largely free from any dislocation damage. Some Kr bubbles were observed inside (Fe,Cr)7C3 precipitates and at the interface between α-ferrite matrix and carbides ((Fe,Cr)7C3, (Ti,W)C). The results were discussed using the fundamental understanding of irradiation and ThermoCalc simulations. / Doctor of Philosophy / With the United Nations describing climate change as 'the most systematic threat to humankind', there is a serious need to control the world's carbon emissions. The ever increasing global energy needs can be fulfilled by the development of clean energy technologies. Nuclear power is an attractive option as it can produce low cost electricity on a large scale with greenhouse gas emissions per kilowatt-hour equivalent to wind, hydropower and solar. The problem with nuclear power is its vulnerability to potentially disastrous accidents. Traditionally, fuel claddings, rods which encase nuclear fuel (e.g. UO2), are made using zirconium based alloys. Under 'loss of coolant accident (LOCA) scenarios' zirconium reacts with high temperature steam to produce large amounts of hydrogen which can explode. The risks associated with accidents can be greatly reduced by the development of new accident tolerant materials. Nanostructured ferritic alloys (NFA) and silicon carbide (SiC) are long considered are leading candidates for replacing zirconium alloys for fuel cladding applications. In this dissertation, a novel composite of SiC and NFA was fabricated using spark plasma sintering (SPS) technology. Chromium carbide (Cr3C2) and carbon (C) coatings were employed on SiC and NFA powder particles respectively to act as reaction barrier between SiC and NFA. Microstructural evolution after spark plasma sintering was studied using advanced characterization tools such as scanning electron microscopy (SEM), electron backscattered diffraction (EBSD), transmission electron microscopy (TEM) and energy dispersive spectroscopy (EDS) techniques. The results revealed that the Cr3C2 and C coatings successfully suppressed the formation of detrimental reaction products such as iron silicide. However, some reaction products such as (Fe,Cr)7C3 and (Ti,W)C carbides and graphite retained in the microstructure. This novel composite material was subjected to high temperature oxidation under a water vapor environment to study its performance under the simulated reactor environment. The degradation of the material due to high temperature irradiation was studied using state-of-the-art TEM equipped with in-situ ion irradiation capabilities. The results revealed excellent oxidation and irradiation resistance in SiC-NFA composites as compared to NFA. The results were discussed based on fundamental theories and thermodynamic simulations using ThermoCalc software. The findings of this dissertation imply a great potential for SiC-NFA based composites for future reactor material designs.

En raison de leur propriétés spécifiques élevées, par rapports aux alliages légers, les Composites à matrice métallique (CMM) représentent des matériaux d'intérêt pour des applications de haute technologie dans les domaines aéronautique et aérospatiale. Les CMM les plus couramment utilisés sont à renfort particulaire, ou PRMMC, et à matrice Al en raison de leur faible densité. Cette thèse porte sur la mise au point de PRMMC à renfort nanométrique par une voie de synthèse réactive globale. En raison des normes encadrant l’usage des nanomatériaux et visant à limiter l’exposition des usagers et de l’environnement, la manipulation de poudres de taille nanométrique est coûteuse et problématique dans le cadre d’un usage industriel. La nouvelle voie de synthèse qui a été développée dans le cadre de cette thèse a permis de démontrer la faisabilité de composites à matrice métallique et à renfort particulaire nanométrique, dimension moyenne de 30 nm, sans avoir recourt initialement à des poudres de taille nanométrique. Le procédé étudié consiste en une réaction chimique à haute température entre deux matériaux précurseurs qui conduit à la formation in-situ non seulement du renfort mais aussi de la matrice. Par rapport aux techniques de synthèse classiques, cette technique permet de synthétiser des nanoparticules in situ et d’en contrôler la taille. De plus, la matrice et le renfort étant co produits par la réaction à haute température, l’interface entre les deux phases est exempte de couches d’oxydes, ce qui lui assure une très bonne adhésion. Dans le cadre du projet ANR NanoTiCAl, la faisabilité de cette nouvelle méthode a été étudiée à travers le cas d'un composite à matrice aluminium renforcé par des particules de carbure de titane (TiC). Les synthèses ont été réalisées entre 900°C et 1000°C à partir d’un couple de précurseurs incluant le graphite et un aluminiure de titane (Al3Ti). Le composite obtenu, caractérisé par un taux de renfort élevé de 34wt.%, possède un module de Young de 106 GPa, un allongement maximal à la rupture de 6% ainsi qu’une énergie à rupture de l’ordre de 28 J.cm-3. Ces valeurs démontrent un compromis entre résistance et capacité d’endommagement original et particulièrement intéressant, jamais observé dans la littérature pour des composites d’une teneur en renfort aussi importante. La caractérisation fine de la microstructure du composite ainsi que du renfort TiC après extraction du composite massif, ont permis de mieux comprendre les mécanismes à l’oeuvre dans cette voie de synthèse réactive. Enfin, sur la base de la compréhension obtenue dans le cas du composite Al/TiC, des critères ont été identifiés permettant d’aller vers une généralisation de ce procédé de synthèse. La pertinence de cette généralisation a finalement pu être démontrée par quelques mises en application à d’autres systèmes / Metal Matrix Composites (MMCs) have attracted research and industrial attentions as materials for high technological applications in the aeronautic and aerospace industry. The MMCs differ by their high specific mechanical properties compared to light weight alloys. The most commonly used are the Particulate Reinforcement Metal Matrix Composites (PRMMCs), especially the Al based matrices because of their low density.This thesis deals with the reactive synthesis of PRMMCs reinforced by nanoparticles. Because of the standards governing the use of nanomaterials to limit the exposure of users and environment, handling nanoscaled powders is very problematic and expensive in industry. Furthermore, the cost of this kind of processes is very high. This new synthesis route, developed during this thesis, shows the feasibility of PRMMCs reinforced by nanosized particles, with a mean size of 30 nm, without using any starting nanoparticles.The process consists in a chemical reaction at high temperature between precursor materials which leads to form both of the matrix and the reinforcement phase. Compared to conventional synthesis techniques as stir casting, this route allows to synthesis nanoparticles in-situ and to control their size. In addition, the matrix and the reinforcement, which are formed by a reaction at high temperature, have an interface free of oxide layers which assures a good adhesion.In the NanoTiCAl project, the feasibility of this new method is illustrated in the case of an aluminium based composite reinforced by titanium carbide (TiC). The synthesis were realized between 900°C and 1000°C from a couple of precursors including graphite and titanium aluminide (Al3Ti). The resulting composite, characterized by a high reinforcement ratio (34 wt.%), presents a Young’s modulus of 106 GPa, a maximum elongation of 6 % and a high toughness, about 28 J.cm-3. These values represent an uncommon compromise between strength and toughness never seen in the literature regarding to the high content of reinforcement.The characterization of the composite microstructure and of the reinforcement phase, after extraction of the solid composite, allowed a better understanding of the reaction mechanism during the reactive synthesis. Finally, based on our understanding of the Al-TiC composite, criteria have been identified to generalize this synthesis process. This generalization was demonstrated with success in other systems

Este trabalho versa sobre a caracterização de uma junta soldada em cheio (bead-onplate) de liga AA356 reforçada com partículas de SiC, soldada por um Laser de fibra de alta potência. A soldagem foi realizada em duas amostras com diferentes condições térmicas, tratadas termicamente T6 (solubilização e envelhecimento) antes da soldagem (amostra A) e após a soldagem (amostra B). Nas amostras A e B foram realizadas as análises de materialográfia via Microscopia Óptica de luz reflexiva (M.O) e Microscopia Eletrônica de Varredura (MEV), também foram realizadas análises microquímica por Energia Dispersiva de Raios-X (EDX), ensaio mecânico de microdureza e difração de Raios-X. Os corpos de prova submetidos ao ensaio de tenacidade em Flexão três pontos tinham condições térmicas iguais a da amostra A, pois essa condição térmica é a condição que normalmente o Compósito de Matriz Metálica (CMM) exibe em serviço. A inspeção materialográfica por M.O identificou a interferência do tratamento térmico T6 realizado na amostra A, fazendo que fosse possível identificar a baixa proporção das partículas de Si na matriz, conforme análise se aproximava da zona fundida (ZF), e a presença de uma estrutura metaestável com a presença dendritas na ZF, aos quais foram diretamente correlacionados com os resultados da microdureza. A amostra B exibiu uma microestrutura bem homogênea em relação à amostra A, em termos de dispersão das partículas de Si e presença de dendritas na ZF. A fratográfia por MEV em modo de imageamento por elétrons secundários, permitiu analisar as superfícies de fratura do compósito em estudo (AA356+SiC), fraturado após o ensaio de tenacidade em Flexão três pontos, identificando a presença de muitos dimples que formavam uma estrutura alveolar, conhecida como uma estrutura típica de um regime dúctil. Por meio desta técnica, também foi possível detectar os principais mecanismos de tenacificação nos CMM, tais como: trincamento, descolamento ou destacamento das partículas de SiC, e o crescimento e coalescência de dimples na estrutura da matriz, os quais foram identificados e correlacionados com o desempenho mecânico dos corpos de prova analisados. A microanálise química por EDS permitiu o mapeamento dos elementos químicos presentes nas regiões do Metal Base (MB) e na Zona Termicamente Afetada (ZTA) do CMM. Por meio desta técnica, foi possível identificar a presença das partículas de Si e SiC, os elementos químicos presentes nas regiões dendriticas, os elementos fragilizantes presentes na microestrutura do CMM, tais: como Fe, Cr e Mn, e a presença de carbeto de Aluminio-Silício (Al4SiC4) presentes nas ZF, em forma de agulhas. A microanálise química foi realizada tanto nas regiões das juntas soldadas quanto nas superfícies de fraturas provenientes do ensaio de tenacidade em Flexão três pontos. / This work focuses on the characterization of a joint welded bead-on-plate of SiC particulate-reinforced A356-alloy welded by high power fiber laser. The welding was achieved in two samples with different conditions, both with T6 applied, before (sample A) and after (sample B) the welding process respectively. Samples A and B were performed materialographic analysis by Optic Microscopy of light reflected (O.M) and scanning electron microscopy (SEM), were also performed chemical microanalysis by energy dispersive X-ray , mechanical testing microhardness and X-ray diffraction. Specimens submitted to the three point bending toughness test present a thermal condition similar to sample A, because this thermal condition is the condition that normally the Metal Matrix Composite (MMC) exhibits in service. The inspection metallographic by (O.M) identified heat treatment T6 interference in the sample A, and though this is it was possible to identify low proportion of Si particles in the matrix, while the analysis was approaching fused zone, and the presence of a metastable structure with formation of dendrites in the fused zone, were which promptly correlated with results of microhardness. The sample B exhibited more homogenous a microstructure in terms of dispersion of Si particles. SEM fractography in secondary electron imaging mode allowed to analyze fracture surface of MMC, identifying the presence of more microvoids creating an alveolar structure typical of an ductile regime. Through this technique, it also was possible to detect main toughening mechanisms for MMC, such as, cracking, debonding and growth and coalescence dimples in the structure the of matrix which were identified and correlated with performance of specimens analyzed. EDS micro-chemical analysis allowed to map chemistry elements present in various regions of CMM, such as, Base Metal (BM), heat affected zone (HAZ) and Fused Zone (FZ). Through this technique, it was possible to identify and quantify the presence of Si and SiC particles, the elements present in the dendrites and presence of embrittlement elements in the microsctructure of MMC, such as, Fe,Cr and Mn and presence of needle-shapped Aluminium-Silicon carbides (Al4SiC4) in the FZ of sample A. Chemical microanalyses were performed both in regions of welded joints and in surface of fracture from the three points bending toughness test.

Compósitos de matriz metálica (CMM) reforçados com dois tipos de particulado cerâmico foram produzidos por meio do processo ARB (Accumulative Roll Bonding) a fim de estudar os efeitos destes no que diz respeito às propriedades mecânicas e microestruturais. ARB é um processo de deformação plástica severa aplicada originalmente a uma pilha de lâminas metálicas, a qual é laminada, seccionada em duas metades, as quais são empilhadas e novamente laminadas, e assim por diante, desenvolvido com o propósito de reduzir o tamanho de grão e aumentar a resistência mecânica do produto final. O processo é econômico e capaz de produzir de folhas ultrafinas a placas espessas, sem que haja restrição de quantidade. Confeccionou-se CMM de alumínio reforçados com partículas de carbeto de silício (Al+SiCp) e alumina (e Al+Al2O3p) com granulometria média de 40µm, as quais foram caracterizadas microestruturalmente e ensaiadas em tração até a falha, cuja análise foi conduzida via microscopia eletrônica de varredura. Ambas as amostras obtiveram ganho em sua resistência mecânica, comparadas ao alumínio monolítico (sem adição de partículas de reforço) e alumínio recozido. Foram ensaiados em tração corpos de prova com e sem presença de entalhe, sendo que as peças entalhadas apresentaram comportamento esperado de aumento de resistência mecânica e baixo alongamento e fratura de aspecto frágil. De acordo com análise feita por fratografia houve boa ancoragem e dispersão das partículas de reforço na matriz. / Metal matrix composite (CMM) reinforced with two types of ceramic particles have been produced through the process ARB (Accumulative Roll Bonding) in order to study their effect as regards the mechanical and microstructural properties. ARB is a severe plastic deformation process originally applied to a stack of metal sheets, which is laminated, sectioned into two halves, which are stacked and rolled again, and so on, developed with the purpose of reducing the grain size and increase the mechanical strength of the final product. The process is economical and capable of producing ultrafine sheets to thicker plates without much restriction. Were fabricated CMM of the aluminum reinforced with particles of silicon carbide (Al + SiCp) and alumina (and Al + Al2O3p) with an average particle size of 40&#956;m, which are characterized microstructurally and tested in tension until failure, whose analysis was conducted via scanning electron microscopy. Both samples were successful in its mechanical strength compared to the monolithic aluminum (without addition of reinforcing particles) and annealed aluminum. They were tested for tensile specimens with and without the presence of notch, and the carved pieces showed strength-enhancing behavior and low elongation and frail fracture. According to analysis by fractography was good anchoring and reinforcement particles dispersed in the matrix.

The material development cycle is becoming too slow if compared with other technologies sectors like IT and electronics. The materials scientists’ community needs to bring materials science back to the core of human development. ICME (Integrated Computational Materials Engineer) is a new discipline that uses advanced computational tools to simulate material microstructures, processes and their links with the final properties. There is the need for a new way to design tailor-made materials with a faster and cheaper development cycle while creating products that meet “real-world” functionalities rather than vague set of specifications. Using the ICME approach, cutting edge computational thermodynamics models were employed in order to assist the microstructure characterization and refinement during the TIG welding of a functionally graded composite material with outstanding wear and corrosion resistance. The DICTRA diffusion model accurately predicted the carbon diffusion during sintering, Thermo-Calc and TC-PRISMA models described the thermodynamic and kinetics of harmful carbide precipitation, while COMSOL Multhiphysic furnished the temperature distribution profile at every timestep during TIG welding of the material. Bainite transformation and the influence of chromium and molybdenum was studied and modelled with MAP_STEEL software. The simulations were then compared with experimental observations and a very good agreement between computational works and experiments was found for both thermodynamic and kinetics predictions. The use of this new system proved to be a robust assistance to the classic development method and the material microstructures and processes were carefully adjusted in order to increase corrosion resistance and weldability. This new approach to material development can radically change the way we think and we make materials. The results suggest that the use of computational tools is a reality that can dramatically increase the efficiency of the material development.

Silver is a precious metal that has traditionally been used for jewellery and money. It also possesses desirable properties such as being corrosion resistant and having good electrical conductivity, resulting in its use for industrial applications. Furthermore, it is also recognised for its tribological properties in non-cost prohibitive applications. Silver can be used as a surface coating and can be deposited using an electroplating process. The utilisation of silver as a surface coating is advantageous and sustainable, as the substrate material properties are enhanced while usage of silver is kept to a minimum. On the other hand, electroplating has been used for over a century. It is a process which is able to produce a layer of uniform and dense coating that adheres well to the substrate metal, thus modifying the properties of the substrate. It benefits from being relatively low cost and is scalable. Silver is electroplated onto stainless steel threaded compression fittings to prevent galling. Traditional silver electroplating, which contains the use of cyanide as a complexing agent in the electroplating bath, is still in use within industry, even to this day. Cyanide, in its various forms can be poisonous, toxic and even lethal, which presents a risk during the silver electroplating process. Furthermore, the toxic wastes created during the cyanide silver electroplating process are detrimental to the environment. The aim of this work is to develop a self-lubricating non-cyanide silver PTFE composite coating suitable for use in threaded compression fittings of the ferruled type. The composite can be considered self-lubricating when a concentration of 8% or more by volume of the self-lubricating PTFE substance is incorporated. My original contribution to knowledge is firstly the successful development and characterisation of a self-lubricating non-cynanide Ag-PTFE coating on stainless steel without a strike resulting in improved CoF of 0.06 from the CoF of 0.6 based on an unlubricated surface. Secondly is the application of a non-cyanide Ag-PTFE MMC for threaded compression fittings. Thirdly is the characterisation of the make-up process of threaded compression fittings through the proposed use of the torque-angle slope in assessing coating performance for threaded compression fittings during make-up. Conclusions that can be drawn for the work are that the performance non-cyanide Ag-PTFE coating exceeded the performance of the pure Ag coating made using the same non-cyanide process. Moreover, the performance of the Ag-PTFE coating shows promising results when compared to the performance of the commercial silver cyanide coating. As a viable replacement to the current silver cyanide process, the self-lubricating non-cyanide Ag-PTFE coating, will improve the working conditions and have a positive contribution to the environment. Moreover, a thinner coating with has the potential to reduce raw material usage and electroplating waste disposal costs.

Made available in DSpace on 2014-06-11T19:32:50Z (GMT). No. of bitstreams: 0 Previous issue date: 2009-04-24Bitstream added on 2014-06-13T20:08:31Z : No. of bitstreams: 1 ranieri_k_dr_guara.pdf: 3032038 bytes, checksum: 78d562848610f76e621250d9538e5ad3 (MD5) / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / O estudo do processamento de compósitos de matriz metálica pelo método de fundição com agitação é de grande interesse em engenharia pelo seu baixo custo e possibilidade de utilizar equipamentos convencionais de fundição. Nesse trabalho é feito o estudo do processo de síntese de compósitos da matriz da liga A356 reforçada com partículas de alumina, focalizando a influência dos fatores de processo na fração de partícula incorporada. Foram sintetizados lingotes de compósitos variando as condições de processo. Foram desenvolvidos métodos específicos de amostragem estatística associados à análise e processamento de imagens e utilizados na obtenção de estimativas confiáveis da fração volumétrica. Para investigar a influência dos fatores e suas interações foi projetado um experimento fatorial com 4 fatores, definidos em ensaios preliminares. Os resultados confirmam achados teóricos e experimentais anteriores e indicam novos caminhos para se obter uma melhor incorporação de partículas, além de um entendimento do mecanismo da molhabilidade da liga no estado semissólido. Compósitos com maior grau de partículas incorporadas foram examinados por microscópio eletrônico de varredura e microscópio óptico, mostrando que a partícula se aloja preferencialmente na região interdendrítica da matriz. / The study of metal matrix composite processing through stir casting method is of great interest for engineering because of its low cost and possibility of using conventional casting equipment as well. The synthesis of hypoeutectic A356 matrix alloy reinforced with alumina particle was done in this work focusing the influence of the processing factors on the incorporated particle fraction. Ingots of composites were synthesized by varying the process conditions. Methods of statistic sampling connected to the analysis and processing images were developed and used for reliable estimate of volumetric fraction. To investigate the influence of the factors and their interactions, a factorial experiment was planned with four factors defined in a preliminary test. The results confirm theorical and experimental findings and points to a new way of getting better particle incorporation and an insight of the wettability mechanism. Composites with high level of particle incorporation were checked through electronic and optical microscopes showing that the particle stays mainly in interdendritic regions.

Este trabalho versa sobre a caracterização de uma junta soldada em cheio (bead-onplate) de liga AA356 reforçada com partículas de SiC, soldada por um Laser de fibra de alta potência. A soldagem foi realizada em duas amostras com diferentes condições térmicas, tratadas termicamente T6 (solubilização e envelhecimento) antes da soldagem (amostra A) e após a soldagem (amostra B). Nas amostras A e B foram realizadas as análises de materialográfia via Microscopia Óptica de luz reflexiva (M.O) e Microscopia Eletrônica de Varredura (MEV), também foram realizadas análises microquímica por Energia Dispersiva de Raios-X (EDX), ensaio mecânico de microdureza e difração de Raios-X. Os corpos de prova submetidos ao ensaio de tenacidade em Flexão três pontos tinham condições térmicas iguais a da amostra A, pois essa condição térmica é a condição que normalmente o Compósito de Matriz Metálica (CMM) exibe em serviço. A inspeção materialográfica por M.O identificou a interferência do tratamento térmico T6 realizado na amostra A, fazendo que fosse possível identificar a baixa proporção das partículas de Si na matriz, conforme análise se aproximava da zona fundida (ZF), e a presença de uma estrutura metaestável com a presença dendritas na ZF, aos quais foram diretamente correlacionados com os resultados da microdureza. A amostra B exibiu uma microestrutura bem homogênea em relação à amostra A, em termos de dispersão das partículas de Si e presença de dendritas na ZF. A fratográfia por MEV em modo de imageamento por elétrons secundários, permitiu analisar as superfícies de fratura do compósito em estudo (AA356+SiC), fraturado após o ensaio de tenacidade em Flexão três pontos, identificando a presença de muitos dimples que formavam uma estrutura alveolar, conhecida como uma estrutura típica de um regime dúctil. Por meio desta técnica, também foi possível detectar os principais mecanismos de tenacificação nos CMM, tais como: trincamento, descolamento ou destacamento das partículas de SiC, e o crescimento e coalescência de dimples na estrutura da matriz, os quais foram identificados e correlacionados com o desempenho mecânico dos corpos de prova analisados. A microanálise química por EDS permitiu o mapeamento dos elementos químicos presentes nas regiões do Metal Base (MB) e na Zona Termicamente Afetada (ZTA) do CMM. Por meio desta técnica, foi possível identificar a presença das partículas de Si e SiC, os elementos químicos presentes nas regiões dendriticas, os elementos fragilizantes presentes na microestrutura do CMM, tais: como Fe, Cr e Mn, e a presença de carbeto de Aluminio-Silício (Al4SiC4) presentes nas ZF, em forma de agulhas. A microanálise química foi realizada tanto nas regiões das juntas soldadas quanto nas superfícies de fraturas provenientes do ensaio de tenacidade em Flexão três pontos. / This work focuses on the characterization of a joint welded bead-on-plate of SiC particulate-reinforced A356-alloy welded by high power fiber laser. The welding was achieved in two samples with different conditions, both with T6 applied, before (sample A) and after (sample B) the welding process respectively. Samples A and B were performed materialographic analysis by Optic Microscopy of light reflected (O.M) and scanning electron microscopy (SEM), were also performed chemical microanalysis by energy dispersive X-ray , mechanical testing microhardness and X-ray diffraction. Specimens submitted to the three point bending toughness test present a thermal condition similar to sample A, because this thermal condition is the condition that normally the Metal Matrix Composite (MMC) exhibits in service. The inspection metallographic by (O.M) identified heat treatment T6 interference in the sample A, and though this is it was possible to identify low proportion of Si particles in the matrix, while the analysis was approaching fused zone, and the presence of a metastable structure with formation of dendrites in the fused zone, were which promptly correlated with results of microhardness. The sample B exhibited more homogenous a microstructure in terms of dispersion of Si particles. SEM fractography in secondary electron imaging mode allowed to analyze fracture surface of MMC, identifying the presence of more microvoids creating an alveolar structure typical of an ductile regime. Through this technique, it also was possible to detect main toughening mechanisms for MMC, such as, cracking, debonding and growth and coalescence dimples in the structure the of matrix which were identified and correlated with performance of specimens analyzed. EDS micro-chemical analysis allowed to map chemistry elements present in various regions of CMM, such as, Base Metal (BM), heat affected zone (HAZ) and Fused Zone (FZ). Through this technique, it was possible to identify and quantify the presence of Si and SiC particles, the elements present in the dendrites and presence of embrittlement elements in the microsctructure of MMC, such as, Fe,Cr and Mn and presence of needle-shapped Aluminium-Silicon carbides (Al4SiC4) in the FZ of sample A. Chemical microanalyses were performed both in regions of welded joints and in surface of fracture from the three points bending toughness test.