The primary intention with this Doctoral thesis is to fillin the knowledge gaps and raise the level of understandingregarding the different metal dusting mechanisms in general andexplain the process in detail for high alloyed materials.Considerable effort is put into identifying the driving forcesand elucidating the diffusional processes in metal dusting. The results are based on a series of long-term laboratory exposures of stainless steels and high-performance commercial alumina-forming Fe- and Ni-base alloys in synthesis gasmixtures, plus a separate shorter study on ultra pure iron. ANi-base alloy was also investigated after a two years field exposure in a methanol plant. Post exposure metallographic examinations and analysis aswell as thermodynamic calculations were made in order toidentify and describe the operating metal dusting mechanisms.Two main mechanisms were previously used to explain metaldusting, one on the basis of decomposition of metastable carbides (Type I) the other on graphite formation (TypeII). A new metal dusting mechanism has been identified in this Thesis which appears on high alloyed steels and Ni-base alloys,an active corrosion induced by carbon and oxygen, denoted TypeIII. Both the mechanisms and the type of corrosion products were consistent with the thermodynamic conditions of the material under the influence of a carbon and oxygen gradient.It was shown that this mechanism not only accelerates the metaldusting process, in fact, it determines the overall metaldusting kinetics on stainless steels and Ni-base alloys. Another feature, which may occur at temperatures where metalbulk and even static grain boundary diffusion is too slow forexplaining the metal dusting corrosion process, was identifiedon a Ni-base alloy. It involves a fast growing cellular structure with discontinuous precipitated carbides whichprovides fast metal dusting kinetics by the Type IIImechanism. A Type IV metal dusting mechanism, continued fragmentationby graphitization until nano-sized particles are formed andcatalyse carbon nanotube formation is also described. Thesteady state process and the driving force for metal dusting onpure iron was identified and described. With these additional processes it is now possible to extendour understanding of the metal dusting processes to a widerange of engineering alloys. / QC 20100825

Orientadores: Antonio Jose Ramirez, Rubens Caram Junior / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-11T13:06:54Z (GMT). No. of bitstreams: 1 TorresLopez_EdwarAndres_M.pdf: 39783627 bytes, checksum: 03310e12f2969671a1edcad6da907e3b (MD5) Previous issue date: 2008 / Resumo: Foi desenvolvido um experimento para estudo in-situ dos processos de deformação a alta temperatura no interior do microscópio eletrônico de varredura, permitindo assim o estudo do fenômeno de trincamento a alta temperatura, denominado fratura por queda de ductilidade. Este experimento teve como finalidade o estudo específico das ligas de níquel AWS A5.14 ERNiCrFe-7 e ERNiCr-3AWS empregadas como metal de aporte para a soldagem de ligas de Ni. Instrumentação cientifica dedicada foi desenvolvida e modificada de modo a superar os desafios impostos pelas condições experimentais adversas associadas as elevadas temperaturas necessárias, à compatibilização do experimento com o nível de vácuo necessário na câmera do microscópio e finalmente, à estabilidade mecânica necessária para o acompanhamento do processo de deformação em escala micrométrica juntamente com os processos de aquecimento e de aplicação de forças elevadas. Utilizando esta instrumentação foram definidas as condições e procedimentos adequados para o acompanhamento do processo de deformação das ligas de Ni AWS A5.14 ERNiCrFe-7 e ERNiCr-3 em temperaturas entre 700 e 1000 °C, de forma a estudar as condições de inicio da fratura por queda de ductilidade nestes materiais. Porém, a instrumentação desenvolvida permite não apenas estudar o fenômeno de fratura por queda de ductilidade e avaliar o desempenho de ligas experimentais, mas também o estudo tanto qualitativo como quantitativo de diversos outros fenômenos de fratura e transformação de fase / Abstract: An in-situ high temperature deformation experiment was developed and adapted be performed within the vacuum chamber of a scanning electron microscope in order to study the high temperature cracking phenomenon known as ductility-dip cracking. This experiment was specifically applied to the study of Ni-base alloys AWS A5.14 ERNiCrFe-7 e ERNiCr-3, which are commonly used as filler metal to weld Ni- and Fe- based alloys. Dedicated scientific instrumentation was developed and modified to overcome the challenges imposed by the severe experimental conditions as elevated temperatures and forces, the compatibleness with the microscope vacuum chamber, and the required mechanical stability to track deformation processes at the micro scale. Using this instrumentation were defined and optimized the conditions to study the deformation of Ni-base alloys AWS A5.14 ERNiCrFe-7 e ERNiCr-3 alloys between 700 and 1000 °C and therefore, helps to elucidate the causes of ductility-dip cracking phenomenon . However, the developed instrumentation is a powerful tool to perform several other qualitative and quantitative studies of deformation, cracking phenomena and phase transformations in different materials / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica

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