<p>Shape rolling is a common manufacturing process used to produce long products i.e. bars and wire. One of the problems that might occur during rolling is defect formation leading to rejection of the finished product. This work is a step towards a better understanding of the evolution of some of these defects. </p><p>The evolution and reduction of cracks during shape rolling is studied in this thesis. To accomplish this, artificial longitudinal cracks are machined along bars of high speed steel. The cracks are positioned at different sites evenly distributed along the periphery in intervals of 45°. Some of the cracks are left open and some are filled with carbon or stainless steel welds. FE simulations are performed using the commercial code MSC.Marc and the results from the simulations are compared with experimental ones. Generally, simulations predict less reduction than observed experimentally. For most positions, the cracks tend to reduce most effectively followed by carbon steel welds and stainless steel welds. </p><p>To evaluate the inner deformation of a cross section during shape rolling in an oval-round-oval-round series, sample bars of M2 high speed steel are prepared with grids made up by stainless steel wires. After collecting samples after each pass, they are X-rayed to create an image of the grid. The deformation of the wires can favorably be described by FE simulations of a bar originally rotated 10° when entering the first pass. The results suggest that the simulations describe the deformation during shape rolling well. </p>

<p>The topic of this thesis is estimation of the dynamic changes of the surface temperatureand heat flux during heating processes by using an inverse method. The local transient surface temperature and heat flux of a steel slab are calculated based on measurements in the interior of the slab.</p><p>The motivations for using an inverse method may be manifold. Sometimes, especially in the field of thermal engineering, one wants to calculate the transient temperature or heat flux on the surface of a body. This body may be a slab, or billet in metallurgical applications. However, it may be the case that the surface for some reason is inaccessible to exterior measurements with the aid of some measurement device. Such a device could be a thermocouple if contact with the surface in question is possible or a pyrometer if an invasive method is preferred. Sometimes though, these kinds of devices may be an inappropriate choice. It could be the case that the installation of any such device may disturb the experiment in some way or that the environment is chemically destructive or just that the instruments might give incorrect results. In these situations one is directed to using an inverse method based on interior measurements in the body, and in which the desired temperature is calculated by a numerical procedure.</p><p>The mathematical model used was applied to experimental data from a small scale laboratory furnace as well as from a full scale industrial reheating furnace and the results verified that the method can be successfully applied to high temperature thermal applications.</p>

Current water-cooling technology used in the metallurgical industry poses a major safety concern. In addition, these systems are expensive to operate and result in significant energy losses. / The purpose of the research presented in this thesis was to develop a viable cooling system based on novel heat pipe technology which addresses these problems. This technology employs boiling as the means to store and transfer heat energy. The large heat extraction capacity of the device is owed to two design features: firstly, a separate return line that generates a column of liquid working fluid which drains into the evaporator by gravity, and secondly, a helical flow modifier in the evaporator that stabilizes annular two-phase flow. / A full-scale copper tapblock and launder were designed with water-based heat pipe cooling systems. These systems were successfully tested under industrial heat loading conditions, using a gas burner to simulate the heat loads. / The tapblock cooling system was able to dissipate 142 kW per heat pipe, at heat fluxes as high as 2.4 MW/m2. These values are the largest to date using the novel water-based heat pipe technology. The launder system was the first to incorporate horizontal heat pipes, as well as have multiple evaporators feeding a single condenser. / The cooling systems used in both experiments were fundamentally safer than watercooling systems, being operated at low pressures and with only several kilograms of water exposed to the heat source. The cooling water requirements of these systems represent a reduction of 80-95% compared to conventional water-cooling, with increased potential for energy recovery. / During the testing, dry-out and film boiling were identified as the main limitations. It was found that film boiling occurs when the flow in the evaporator is not great enough to generate a helical motion. The dry-out limitation was achieved when the velocity of the flow within the evaporator was too great, causing a large pressure gradient that opposes the gravity head of the return line. / Both of these limitations are related to the configuration of the evaporator, i.e. the return line and the flow modifier. A methodology was developed to model the evaporator numerically using computational fluid dynamics. This methodology can be used to understand how the design parameters of the evaporator affect the flow patterns during operation.

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Bibliography: pages 129-137. / This investigation was undertaken as part of an endeavour to design an ideal wear resistant material for particular applications. The research was aimed at the alleviation of wear in the gold mining industry. In order to achieve this objective it was necessary to examine the surfaces of worn materials in order to gain a better understanding of the different wear mechanisms and also to examine the extent and depth of deformation induced by abrasive wear. Numerous proprietary wear resistant materials and stainless steels presently used in the gold mining industry together with other materials were included in this investigation. The abrasion and corrosion- abrasion wear resistance of two particular proprietary wear resisting materials was determined to be superior to mild steel and attempts were made to explain the good performance of these materials in terms of micro- structural and mechanical properties. Various techniques were used to study the effects of low and high stress wear of materials which had been tested in both the laboratory and in-situ in the mines. These techniques include scanning and transmission electron microscopy, optical metallography and microhardness studies. It was found that as the nominal load on the abrasive increased, the mode of material became more severe, the depth of deformation increased and the surface hardness increased. Attempts were made to explain these phenomena in terms of microstructural considerations, work hardening capacity, phase transformations and recovery and recrys- tallization. This work has assisted in the specification of the composition and microstructure of steels which should provide improved performance in severe working conditions.

Please read the abstract in the section 00front of this document / Dissertation (MEng (Metallurgical Engineering))--University of Pretoria, 2001. / Materials Science and Metallurgical Engineering / unrestricted

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Properties of cast aluminum components can be improved by strategically placing ferrous inserts to locally improve properties such as wear resistance and stiffness. A cost-effective production method is to cast-in the insert using the solidification of the molten aluminum as a joining method. Metallurgically bonding between the metals could potentially improve both load and heat transfer across the interface. The metallurgical bond between the steel and the aluminum has to be strong enough to withstand stresses related to solidification, residual stresses, thermal expansion stresses, and all other stresses coupled with the use of the component. Formation of a continuous defect free bond is inhibited by the wetting behavior of aluminum and is governed by a diffusion process which requires both energy and time. Due to the diffusional nature of the bond growth in combination with post manufacturing heat treatments defects such as Kirkendall voids can form. The effect of aluminum alloying elements during liquid-solid bond formation in regards to microstructural changes and growth kinetics has been described. A timeframe for defect formation during heat treatments as well as microstructural changes has been established. The effect of low melting point coatings (zinc and tin) on the nucleation of the metallurgical bond has been studied as well the use of a titanium coating for microstructural modification. A set of guidelines for successful metallurgical bonding during multi- material metal casting has also been constructed.

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