CoordenaÃÃo de AperfeiÃoamento de Pessoal de NÃvel Superior / Este trabalho teve como objetivo avaliar as caracterÃsticas operacionais (geometria da solda e diluiÃÃo) e metalÃrgicas (microestrutura, composiÃÃo quÃmica, microdureza e resistÃncia à corrosÃo) de revestimentos compostos pela mistura das ligas de nÃquel Inconel 625 e Hastelloy C-276 depositadas simultaneamente pelo processo MIG/MAG duplo arame sobre chapas de aÃo ASTM 516 Gr 60. Inicialmente foi realizado um estudo preliminar para conhecer os parÃmetros iniciais de soldagem e os limites operacionais do processo. Em seguida, foram realizados ensaios em simples deposiÃÃo atravÃs da aplicaÃÃo do MÃtodo Taguchi com intuito de selecionar os melhores parÃmetros de cada fator de controle avaliado em um nÃmero reduzido de experimentos. Posteriormente, foram realizados revestimentos iniciais a partir dos parÃmetros selecionados. Em seguida foram realizados revestimentos definitivos nos quais foram feitas anÃlises das caracterÃsticas geomÃtricas e diluiÃÃo, alÃm de uma caracterizaÃÃo metalÃrgica com uso de microscopia Ãtica, microscopia eletrÃnica de varredura e anÃlise de composiÃÃo quÃmica. Ainda foram realizadas anÃlises do perfil de microdureza dos revestimentos, bem como anÃlise de resistÃncia à corrosÃo. Os resultados mostraram que os nÃveis de diluiÃÃo global mÃnimos alcanÃados nos ensaios definitivos foram de aproximadamente 22%. A microestrutura dos revestimentos soldados com a mistura das ligas Inconel 625 e Hastelloy C-276 foi constituÃda de uma maneira geral por uma matriz gama com precipitaÃÃo de fases secundÃrias ricas em niÃbio, molibdÃnio e titÃnio. A anÃlise de composiÃÃo quÃmica revelou que o percentual de Fe na solda à crescente com o aumento da diluiÃÃo. O aumento de Mo, W e reduÃÃo do Fe no metal de solda contribuiu para a formaÃÃo de fases secundÃrias. Em relaÃÃo à microdureza, nÃo houve diferenÃas significativas entre o primeiro e o Ãltimo cordÃo de solda e os valores obtidos foram adequados para revestimento. Jà para a resistÃncia à corrosÃo, algumas amostras atingiram temperatura crÃtica de pite (TCP) de 80ÂC e houve uma relaÃÃo entre os fatores de controle os principais elementos de liga presentes nos revestimentos. / The aim of this work was to evaluate the operational (weld geometry and dilution) and metallurgical characteristcs (microstructure, chemical composition, microhardness and corrosion resistance) of Inconel 625 and Hastelloy C-276 nickel-based alloys weld overlay deposited simultaneously by GMAW Double Wire process on steel plate ASTM 516 Gr 60. Initially a previous study was carried out in order to know the early welding parameters and the operational limits of process. Next, single passes welding trials was conducted by applying Taguchi method aiming to select the best parameters of each control factor studied in a reduced numbers of experiments. After, weld overlays were made based on selected parameters. Next, the definitive weld overlays were deposited on steel plates and thus were analysed the geometric features, dilution and metallurgical characterization using optical microscopy and scanning electron microscopy, also a chemical composition analysis was carried out. The profile of microhardness were also performed, as well as analysis of corrosion resistance. The results showed that the minimal global dilution levels measured on definitive weld overlays were 22% approximately. The microstructure of the weld overlays deposited by mixing Inconel 625 and Hastelloy C-276 was constituted generally by a gamma matrix and secondaries phases enriched in niobium, molybdenum and titanium. The chemical composition analysis revealed that the the percentage of Fe on weld increases when dilution levels rises. The increase in Mo, W and reduction in Fe content on the weld metal contributed to the formation of secondaries phases. Regarding the microhardness, no significative differences between first and last weld bead and the microhardness values obtained were appropriate for weld overlays. For corrosion resistance, some of the samples supported Critical Pitting Temperature (CPT) of 80 ÂC and there were a relation between the controled factors and principals alloy elements presents in the weld overlays.

AgÃncia Nacional do PetrÃleo / CoordenaÃÃo de AperfeiÃoamento de Pessoal de NÃvel Superior / A soldagem de revestimento com ligas à base de nÃquel constitui uma interessante opÃÃo para a construÃÃo e o reparo de equipamentos para aplicaÃÃes em ambiente de corrosÃo severa, permitindo alcanÃar as caracterÃsticas desejadas (resistÃncia à corrosÃo) com uma significativa reduÃÃo de custos. Neste contexto, alguns estudos indicam que o processo de soldagem TIG com alimentaÃÃo de arame pode ser uma boa opÃÃo, desde que os parÃmetros de soldagem sejam corretamente ajustados. O objetivo do presente trabalho foi avaliar e otimizar os principais parÃmetros de soldagem, bem como avaliar o comportamento metalÃrgico de revestimentos de ligas de nÃquel depositados pelo processo TIG com alimentaÃÃo de arame frio sobre chapas de aÃo C-Mn. TrÃs ligas à base de nÃquel foram avaliadas no presente estudo: AWS ER Ni-Cr-Mo 3; AWS ER Ni-Cr-Mo 4 e AWS ER Ni-Cr-Mo 14. As soldagens foram realizadas numa primeira anÃlise em simples deposiÃÃo e, posteriormente, na formaÃÃo de camadas de revestimento, variando diversos parÃmetros operacionais. A caracterizaÃÃo microestrutural consistiu de anÃlises de microscopia Ãtica, microscopia eletrÃnica de varredura (MEV) e de transmissÃo (MET), espectroscopia de raio-X dispersivo em energia (EDS), difraÃÃo de elÃtrons retroespalhados (EBSD) e difraÃÃo de raios-X (DRX). Ensaios de polarizaÃÃo eletroquÃmica e desgaste com roda de borracha foram realizados para avaliar a resistÃncia à corrosÃo e ao desgaste, respectivamente. Os resultados mostraram que o processo TIG com alimentaÃÃo automÃtica de arame frio demonstrou ser uma opÃÃo interessante para a soldagem de revestimentos de ligas de nÃquel, podendo depositar em apenas uma camada, revestimentos que alcanÃam nÃveis de diluiÃÃo inferiores ou muito prÃximos de 5%, caracterÃstica favorÃvel para garantir boas propriedades aos revestimentos. A microestrutura dos revestimentos depositados com a liga AWS ER Ni-Cr-Mo 3 foi constituÃda por uma matriz γ com fases secundÃrias ricas em Nb (fase Laves e carboneto/nitreto de Ti e Nb). Estruturas complexas constituÃdas por um nÃcleo de nitreto de titÃnio-niÃbio (TiNbN) e uma casca de carboneto de niÃbio (NbC) ou niÃbio-titÃnio (NbTiC) foram observadas. A microestrutura dos revestimentos depositados com as ligas AWS ER Ni-Cr-Mo 4 e AWS ER Ni-Cr-Mo 14 foi constituÃda por uma matriz γ e fases secundÃrias ricas em Mo (fases σ, P e μ). Foi identificado um empobrecimento de Mo ao redor dos precipitados ricos em Mo, tornando esta regiÃo susceptÃvel à corrosÃo. O ensaio de polarizaÃÃo eletroquÃmica nÃo se mostrou capaz de avaliar o comportamento dos revestimentos quanto à corrosÃo por pites. O baixo nÃvel de dureza da matriz associada com uma pequena fraÃÃo volumÃtrica e dimensÃo dos precipitados resultou numa baixa resistÃncia ao desgaste abrasivo. / The weld overlay with nickel-based alloys is an interesting alternative for the construction and repair of equipments for applications in severe corrosive medium, allowing reach the desirable characteristics (corrosion resistance) with a significant reduction of cost. In this context, the GTAW cold wire feed process can be a good option for overlay deposition, since the welding parameters are correctly adjusted. The main objective of the present work was to evaluate and to optimize the operational and metallurgical characteristics of nickel-based alloys weld overlays deposited by the GTAW cold wire feed on C-Mn steel plates. The nickelbased alloys AWS ER Ni-Cr-Mo 3; AWS ER Ni-Cr-Mo 4 and AWS ER Ni-Cr-Mo 14 were studied in the this work. The welds were performed initially in single weld bead and later in multipass to produce the coating, changing several operational parameters. The microstructure was investigated using light microscopy, scanning electron microscopy (SEM), transmission electron microscopy (TEM), energy dispersive of X-ray spectroscopy (EDS), electron backscattering diffraction (EBSD) and X-ray diffraction (XRD). Potentiodynamics polarization analysis and wheel rubber wear test were used to evaluate the corrosion and abrasive wear resistance, respectively. The results showed that the GTAW cold wire feed process demonstrated to be an interesting option for the weld overlay with nickel-base alloys, could deposit in just one layer, coatings with dilution levels inferior or very close to 5%, important characteristics to assure a good performance of the coatings. The microstructure of the coatings deposited with AWS ER NiCrMo-3 alloy was constituted by the γ-matrix and secondary phases Nb-rich (Laves phase and Nb-Ti carbide/nitrides). It was observed that the precipitates with cuboidal and cruciform morphologies are formed by a complex structure constituted by titanium-niobium nitride (TiNbN) as nucleus and niobium carbide (NbC) or niobium-titanium (NbTiC) carbide as shell. The microstructure of the coatings deposited with the AWS ER NiCrMo-4 and AWS ER NiCrMo-13 alloys were constituted by the γ-matrix and secondary phases Mo-rich (σ, P and μ phases). It was identified a Mo depletion around the precipitates rich in Mo, causing a drop in the corrosion resistance. The potentiodynamic polarization was not shown capable to evaluate the behavior of the coatings for the pitting corrosion. The low level of hardness of the matrix associated with a small volumetric fraction of secondary phases (hard precipitates) resulted in a low abrasive wear resistance.

Arbetet som utförts är en material studie som inriktar sig på nickel-krom-molybdenbaserade legeringar som används i dagens våt skrubber. Eftersom kraven på mängden utsläpp av svaveldioxid är en viktig miljöfråga, skapar detta ett behov för användandet av en våt skrubber. Den här produkten befinner sig i anläggningar där förbränningsmotorer finns och förekommer i princip i alla större fartyg. Rökgasen som motorerna släpper ifrån sig är skadlig för miljön och därför absorberas flödet in till en våt skrubber där en förbränning sker. Rökgasen separeras med hjälp av ett antal sprinklers som är placerade ovanpå gas ingången i en skrubber. Med hjälp av havsvatten som samlas upp och sluts till skrubbern injiceras detta genom sprinklers sen vidare nedåt på rökgasen som separerar föroreningar ifrån den gasen som är tänkt ska kondensera genom och ut i atmosfären. Havsvatten tillsammans med föroreningarna samlas på botten av skrubbern och samlas i tankar. Denna miljö är väldigt skadlig för materialet som produkten består av, framför allt på botten där materialet riskerar att korrodera som mest. Arbetet beskriver ett antal typer av korrosion och förklarar innebörden av de olika typerna så att det enklare går att förstå sammanhanget med miljön och omständigheternas påverkan på legeringarna. Syftet i arbetet är att studera de olika legeringarna och beskriva de med hjälp av den litteraturstudie som gjorts. Med hjälp av insamlad data av tester som tidigare utförts enligt standard, har detta tolkats och bidragit till evalueringen av de olika legeringarna. De grundläggande tester som används vid evaluering av legeringarnas karaktär är tester där en bit av materialet doppas ned i en specifik lösning med olika omständigheter och villkor. Detta räcker inte för att säkerställa en hållbar livscykel för en våt skrubber och därför evalueras legeringarna även med hjälp av olika fälttester. Teoretiska studier på tester i aggressiva miljöer används för att resultera rangordningen av de olika materialen och även ett nytt material undersöks vid namnet alloy 2120. / This thesis work is a study of materials which focus on nickel-chromium-molybdenum-based alloys used in today’s wet scrubbers. Since the requirements for emissions of sulfur dioxide is a major environmental issue, this creates a need for the use of a wet scrubber. This product is in installations where combustion engines are available and are basically in all larger vessels. The flue gas that engines emit are harmful to the environment and for that reason, the flow is absorbed into a wet scrubber where combustion takes place. The flue gas is separated by a number of sprinklers placed above of the gas in a scrubber. Collected seawater is used to separate the gas through the sprinklers that injects the water on top of the flue gas where impurities is separated from the gas that will condense out to the atmosphere. The water fluid together with the contaminants is collected on the bottom of the scrubber and into the tanks. This environment is very harmful to the material that the product is made of, in particular on the bottom where the material is more susceptible for corrosion. The work describes several types of corrosion and the meaning of the different types so that the reader easily can understand the impact of the environment on the alloys. The type of corrosion that occurs primarily in scrubbers is pitting corrosion and is considerate to be a highly local type of corrosion, and the most dangerous type. Pitting occurs when the protective oxide layer does not have time to repassivate and can also lead to other types of corrosion. Due to the dangerous work environment, the risk for corrosion to occur is high and therefore, focus is put on this specific material group. The purpose of this work was to study the alloys and describe them with the help of a literature study. Using data collected from tests previously performed in accordance with standards, the collected data has been interpreted and contributing to the evaluation of the various alloys. The basic tests used in the evaluation of the nature of the alloy are tests in which a piece of material immersed in a specific solution with different circumstances and conditions. This is not enough to ensure a sustainable life cycle for a wet scrubber and therefore, alloys is evaluated using various field tests as well. Theoretical studies on tests in aggressive environments is used to result the ranking of the various materials and also a new material is examined by the name alloy 2120.