Equipamentos utilizados na produção offshore de petróleo estão sujeitos a danos severos devido à exposição a compostos corrosivos presentes no fluido produzido. Por isso, materiais resistentes à corrosão, como a superliga à base de níquel UNS N06625 (Inconel® 625), são usados em áreas de passagem de fluido de produção. Entretanto, o elevado custo desta liga restringe sua utilização em todo o equipamento. Como solução para este problema são produzidos equipamentos com materiais de menor custo e revestidos com a liga mais nobre. Para esses revestimentos o processo de soldagem TIG alimentado duplo arame quente é tido opção por produzir soldas com qualidade e produtividade. O objetivo desse trabalho foi determinar a influência da corrente média (Im), velocidade de soldagem (Vs), velocidade de alimentação (Va), corrente do material de adição (Ia) e composição do gás de proteção (Gs) sobre a diluição (D), penetração (P), largura (L) e reforço (R) dos cordões de solda depositados pelo processo de soldagem TIG alimentado duplo arame quente sobre um aço AISI/SAE 4130. Para essa análise foi utilizado um planejamento DOE (Design of Experiments) composto central com cinco fatores totalizando trinta e duas (32) condições de aplicação dos cordões. Medições de áreas e dimensões de largura, penetração e reforço foram realizadas nas seções transversais dos cordões depositados utilizando-se um estereoscópio e software de análise de imagens. Além disso, análises dos elementos químicos, nessas seções, foram realizadas utilizando-se espectrometria de energia dispersiva, para determinar o teor do elemento Fe e, por consequência, a diluição. Para a análise do comportamento das variáveis e determinação de um modelo empírico utilizou-se a metodologia de superfície de resposta (RSM – Response Surface Methodology). Verificou-se que todas as variáveis influenciaram na diluição, e com o modelo adotado foi possível obter valores de diluição mínima de 6,37%. Adicionalmente, foram determinadas penetração na faixa 0,37 a 2,16 mm, largura na faixa de 8,09 a 10,04 mm e reforço entre 1,93 a 3,16 mm. / Equipment used in offshore oil production are subject to severe damage due toexposure to corrosive compounds present in the produced fluid. Therefore, corrosion resistant materials such as nickel base super alloy UNS N06625 (Inconel® 625), are used in the production fluid passage areas. However, the high cost of this alloy limits its use in all equipment. As a solution to this problem equipment with lower cost materials, overlaid with the noblest alloy, are manufactured. For these overlays the TIG twin hot wire welding process is seen as an option for generate quality weld with productivity. So the aim of this study is to determine the influence of the average current (Im), welding speed (Vs), feed rate (Va), filler material current (Ia) and shielding gas composition (Gs) on the dilution (D), penetration (P), width (W) and reinforcement (R) of the weld beads deposited by TIG twin hot wire welding process on steel AISI / SAE 4130. For this analysis it was used a DOE (Design of) central composite five factors planning totalling thirty-two (32) deposition conditions of weld beads. Using a stereoscopic and image analysis software, measurements of areas and dimensions of width, penetration and reinforcement were made in cross sections of the deposited beads. Furthermore, analysis of the chemical elements in these sections were performed using energy dispersive spectrometry to determine the content of Fe element and hence the dilution. To analyse the behaviour of variables and determine an empirical model, the response surface methodology (RSM - Response Surface Methodology) was used. It was found that all variables influence the dilution, and for the adopted model the minimal dilution obtained was 6.37%. In addition, It was obtained penetration between 0.37 and 2.16 mm, width ranging from 8.09 to 10.04 mm and reinforcement between 1.93 to 3.16 mm.

Made available in DSpace on 2014-10-09T12:42:49Z (GMT). No. of bitstreams: 0 / Made available in DSpace on 2014-10-09T14:08:07Z (GMT). No. of bitstreams: 0 / O NbAl3 e algumas ligas intermetálicas do sistema Nb-Ni-AI foram sintetizadas por combustão a partir dos pós de seus elementos constituintes. O efeito de variáveis de processo, como o tamanho de partícula dos pós, a composição química, a pressão de compactação, o tratamento de desgaseificação e a taxa de aquecimento, foram investigados na síntese do NbAl3 na forma de pastilhas cilíndricas. A síntese de ligas do sistema Nb-Ni-AI foi realizada a partir de misturas com as composições Nb10Ni70AI, Nb20Ni65AI e Nb30Ni60AI. A microestrutura das amostras reagidas foi caracterizada por microscopia óptica, microscopia eletrônica de varredura, EDS e difração de raios-X (método de Rietveld). Foram obtidas pastilhas de NbAl3 com 98,5 % da densidade teórica, superior ao valor encontrado na literatura (95%), mediante o controle de variáveis de processo. Nas pastilhas contendo níquel, a combustão ocorreu nas pastilhas de todas as composições. Fases metaestáveis, presentes na microestrutura das pastilhas baitas de reação, foram transformadas após tratamento térmico, originando ligas trifásicas com diferentes concentrações de fases (NbAl3, NiAI e NbNiAI), conforme a composição inicial do compactado. Algumas propriedades mecânicas de amostras brutas de reação e tratadas termicamente foram determinadas pela técnica da impressão (microdureza e tenacidade). Os resultados obtidos são comparáveis aos da literatura, salvo algumas discrepâncias atribuídas a processos de fabricação distintos. As etapas de reação da síntese do NbAl3 e de ligas Nb-Ni-AI foram posteriormente investigadas mediante interrupção da reação durante sua propagação ao longo de barras paralelepipédicas compactadas. Verificou-se que a síntese do NbAl3 ocorre pela dissolução de nióbio no alumínio fundido, seguida da precipitação do NbAl3. Nas amostras contendo níquel, a síntese ocorre em dois estágios: no primeiro estágio formam-se o Ni2Al3 ou o NiAl3, em quantidades relativas dependentes da composição geral. As reações deste primeiro estágio podem disparar as reações do segundo estágio, referentes à síntese do NbAl3. / Tese(Doutoramento) / IPEN/T / Instituto de Pesquisas Energeticas e Nucleares - IPEN/CNEN-SP

AgÃncia Nacional do PetrÃleo / Este trabalho teve como objetivo determinar os parÃmetros de soldagem que proporcionem condiÃÃes adequadas para revestimentos com ligas de nÃquel atravÃs do processo MIG/MAG com transferÃncia metÃlica por curto-circuito indicadas para aplicaÃÃes no setor de petrÃleo e gÃs natural. A primeira etapa consistiu na realizaÃÃo de ensaios exploratÃrios para determinar os fatores de controle e seus nÃveis a serem utilizados na etapa posterior denominada de âensaios definitivosâ. Nos ensaios definitivos, para determinar o nÃmero de ensaios a serem realizados, optou-se pelo uso do mÃtodo Taguchi (planejamento robusto de experimentos), de forma a cumprir, com um reduzido nÃmero de ensaios, dois objetivos: o primeiro foi obter a influÃncia dos fatores de controle (parÃmetros de soldagem) sobre as variÃveis respostas (caracterÃsticas geomÃtricas dos cordÃes de solda); e segundo foi determinar as condiÃÃes ideais para aplicaÃÃo das ligas de nÃquel nas soldagens de revestimentos. Foram escolhidos seis fatores de controle com trÃs nÃveis cada: tensÃo de referÃncia (Ur = 20, 22, 24 V), velocidade soldagem (Vs = 0,2, 0,3 e 0,4 m/min), tipo de tecimento (sem tecimento, duplo oito e tecimento triangular), tÃcnica da tocha (normal, empurrando e puxando), gÃs de proteÃÃo (100%Ar, 70%Ar+30%He e 99,97%Ar+0,03%NO) e o material de adiÃÃo (AWS ERNiCrMo-3, AWS ERNiCrMo-14 e AWS ERNiCrMo-4). Tais fatores foram divididos pelo mÃtodo Taguchi em duas matrizes L9, resultando num total de 18 ensaios. JÃ as variÃveis respostas escolhidas foram: a diluiÃÃo (D), a razÃo entre o reforÃo e a largura (R/L) e produto da diluiÃÃo pela razÃo R/L (DxR/L). As soldagens foram realizadas na posiÃÃo plana por simples deposiÃÃo sobre chapas de aÃo ASTM 516 Gr60 com dimensÃes de 200 x 50 x 12,7 mm. Foram mantidas constantes a vazÃo do gÃs de proteÃÃo em 20 L/min, a velocidade de alimentaÃÃo em 6,0 m/min e a DBCP em 20 mm. Assim com base nos ensaios definitivos e nos custos de soldagem, foi realizada a soldagem de um revestimento. Os resultados mostraram que os menores nÃveis da tensÃo de referÃncia e da velocidade de soldagem proporcionaram as menores diluiÃÃes. O uso do tecimento proporcionou cordÃes com baixos valores da razÃo R/L. O material de adiÃÃo e o gÃs de proteÃÃo foram capazes de alterar significativamente a geometria do cordÃo de solda. A tÃcnica da tocha na posiÃÃo empurrando obteve os menores valores para a diluiÃÃo e para a razÃo R/L. E por fim os parÃmetros de soldagem selecionados pelo mÃtodo Taguchi e as caracterÃsticas econÃmicas demonstram ser capazes de obter um revestimento com um bom acabamento superficial e isento de defeitos / This work aims to determine the welding process parameters that provide appropriate conditions for weld overlay with nickel alloy through the GMAW process in a short circuiting transfer mode indicated for applications in petroleum and natural gas Industry. Exploratory tests were conducted initially to determine the control factors and their levels to be used in the subsequent stage called the definitive tests. In the definitive tests to determine the number of tests to be accomplished, was chosen by the Taguchi method (Robust design of experiments) and thus with a limited number of tests achieve two objectives: the first was to obtain the influence of the control factors (welding parameters) on quality characteristics (weld bead geometry) and the second was to determine optimal conditions for weld overlay with nickel alloy. Six control factors were employed with three levels each: reference voltage (Ur = 20, 22, 24 V), welding speed (Vs = 0,2, 0,3 and 0,4 m/min), arc oscillation (linear, double 8 and triangular weaving) , welding gun orientation (perpendicular, forehand and backhand), shielding gas (100%Ar, 70%Ar+30%He and 99,97% Ar+0,03% NO) and filler metal (AWS ERNiCrMo-3, AWS ERNiCrMo-14 and AWS ERNiCrMo-4). These factors were divided into two L9 orthogonal array resulting in a total of 18 experiments. The employed quality characteristics were: Percent of dilution (D), the ration between reinforcement and bead width (R/L) and product of the dilution for the ratio R/L (DxR/L). The weldings were accomplished using a bead on plate (BOP) technique, flat position, in steel ASTM 516 Gr60 with dimensions of 200 x 50 x 12,7 mm. The other parameters which were kept constant were gas flow rate at 20 L/min, wire feed rate at 6,0 m/min and stick out was at 20 mm. Based in the definitive tests and in the weld costs weld overlay was accomplished. The results showed that the smallest levels of the reference voltage and of the welding speed provided the smallest dilutions. The use of arc oscillation promote weld bead with low values of the ratio R/L. The filler metal and the shielding gas were capable to alter the weld bead geometry significantly. The welding gun orientation forehand obtained the smallest values for the dilution and for the ratio R/L. Finally the welding parameters selected by the Taguchi method and the weld costs demonstrated to be capable for obtaining an overlay with a good superficial aspect and without welding defects.

O NbAl3 e algumas ligas intermetálicas do sistema Nb-Ni-AI foram sintetizadas por combustão a partir dos pós de seus elementos constituintes. O efeito de variáveis de processo, como o tamanho de partícula dos pós, a composição química, a pressão de compactação, o tratamento de desgaseificação e a taxa de aquecimento, foram investigados na síntese do NbAl3 na forma de pastilhas cilíndricas. A síntese de ligas do sistema Nb-Ni-AI foi realizada a partir de misturas com as composições Nb10Ni70AI, Nb20Ni65AI e Nb30Ni60AI. A microestrutura das amostras reagidas foi caracterizada por microscopia óptica, microscopia eletrônica de varredura, EDS e difração de raios-X (método de Rietveld). Foram obtidas pastilhas de NbAl3 com 98,5 % da densidade teórica, superior ao valor encontrado na literatura (95%), mediante o controle de variáveis de processo. Nas pastilhas contendo níquel, a combustão ocorreu nas pastilhas de todas as composições. Fases metaestáveis, presentes na microestrutura das pastilhas baitas de reação, foram transformadas após tratamento térmico, originando ligas trifásicas com diferentes concentrações de fases (NbAl3, NiAI e NbNiAI), conforme a composição inicial do compactado. Algumas propriedades mecânicas de amostras brutas de reação e tratadas termicamente foram determinadas pela técnica da impressão (microdureza e tenacidade). Os resultados obtidos são comparáveis aos da literatura, salvo algumas discrepâncias atribuídas a processos de fabricação distintos. As etapas de reação da síntese do NbAl3 e de ligas Nb-Ni-AI foram posteriormente investigadas mediante interrupção da reação durante sua propagação ao longo de barras paralelepipédicas compactadas. Verificou-se que a síntese do NbAl3 ocorre pela dissolução de nióbio no alumínio fundido, seguida da precipitação do NbAl3. Nas amostras contendo níquel, a síntese ocorre em dois estágios: no primeiro estágio formam-se o Ni2Al3 ou o NiAl3, em quantidades relativas dependentes da composição geral. As reações deste primeiro estágio podem disparar as reações do segundo estágio, referentes à síntese do NbAl3. / NbAl3 and Nb-Ni-AI intermetallic alloys have been obtained by pressureless combustion synthesis from elemental powders. The effects of process variables as powder particle size, composition, compaction pressure (green density), degassing treatment and heating rate on the combustion (thermal explosion mode) of NbAl3 cylindrical pellets were studied. Combustion synthesis of Nb-Ni-AI alloys was performed on powder mixtures with nominal compositions Nb10Ni70AI, Nb20Ni65AI and Nb30NI60AI. The microstructure of reacted samples was characterized by optical microscopy, scanning electron microscopy, EDS and X-ray diffraction (Rietveld method). It was shown that careful control of the processing conditions allowed near full (98,5%) dense pellets of NbAl3. In the nickel containing pellets, reaction occurred for all the compositions investigated. Metastable phases were seen to be present in the as reacted pellets, which were transformed after a heat treatment, producing a three phase alloy (NbAl3, NiAI and NbNiAI) with different phase concentrations, depending on the initial compact composition. Some mechanical properties, like microhardness and tenacity were measured by microidentation technique on the as reacted and heat-treated samples. The results are comparable with the literature, excepted for some discrepancies caused by different fabrication processes. The reaction sequence for both cases (NbAl3 and Nb-Ni-AI alloys) was further investigated by DSC analysis and also by interrupting the reaction during its propagation along compacted parallelopipedal bars. It was found that the NbAl3 synthesis occurs through niobium dissolution in molten aluminum and precipitation of NbAl3. In the nickel containing samples, synthesis occurs as two-stage reaction: Ni2Al3 or NiAl3 are formed in the first stage, with relative amounts depending on the general composition. This first stage reaction can trigger the second one, related to the formation of NbAl3.

Orientador: Alex Antonelli / Dissertação (mestrado) - Universidade Estadual de Campinas, Instituto de Fisica Gleb Wataghin / Made available in DSpace on 2018-08-04T02:41:04Z (GMT). No. of bitstreams: 1 Meirelles_BernardoRadefeld_M.pdf: 1827063 bytes, checksum: c7056762ebe8e49320a7987daa28a57a (MD5) Previous issue date: 2005 / Resumo: O objetivo desta dissertação foi estudar o efeito da ordem local sobre o volume, a energia livre vibracional e a entropia vibracional da liga N i3Al. Esse estudo foi realizado através de cálculos de dinâmica molecular clássica utilizando o potencial empírico de Cleri-Rosato, e as equações de movimento de Martyna, Klein e Tuckerman associadas ao método de Andersen que permitem simular o ensemble isobárico. O volume foi obtido por simulações de relaxação. E a energia livre da liga Ni3Al foi obtida através do método computacional chamado reversible scaling, que inclui todos os efeitos anarmônicos. Nos cálculos foram utilizadas diversas células computacionais possuindo diferentes graus de ordem local, mas com desordem total de longo alcance. A partir da determinação da energia livre obteve-se a diferença de entropia vibracional entre a liga ordenada e as várias fases possuindo apenas ordenamento local. Os resultados obtidos sugerem que a ordem local exerce um papel fundamental sobre o volume e a entropia vibracional, mostrando que existe uma estreita ligação entre a diferença de entropia vibracional e a variação do volume. Além das simulações de dinâmica molecular clássica, realizaram-se cálculos de primeiros princípios dentro da aproximação da teoria do funcional da densidade (DFT), que permitiram obter o volume da liga em função da ordem local, assim como a entalpia e entropia de formação de vacâncias de Ni na liga Ni3Al. Para realizar esses cálculos utilizou-se o código computacional VASP (Vienna Ab-Initio Simulation Package), que permite realizar cálculos eficientes com metais de transição através da utilização de pseudopotenciais ultrasoft ou do método PAW (Projector Augmented Wave). Em nossos cálculos utilizamos a GGA (Gener-alized Gradient Approximation) para o termo de troca-correlação, e nossos resultados sugerem que o potencial emp'ýrico de Cleri-Rosato descreve com boa concordancia as propriedades estruturais do Ni3Al previstas pelos cálculos ab initio / Abstract: The aim of this work was to study how properties such as volume, vibrational free energy and vibrational entropy are affected by the presence of local order in the Ni3Al alloy. We performed molecular dynamics calculations using the empirical potential of Cleri-Rosato and for the dynamics we used Martyna, Klein and Tuckerman equations of motion associated with the Andersen method, which allowed us to simulate the isobaric ensemble. We obtained the volume by simulations of relaxation and the free energy was calculated through a method called reversible scaling, which includes all anharmonic effects. The computational cells, used in our calculations, had only local order with zero long range order. Vibrational entropy differences could be obtained from the free energy results of an ordered cell and several others exhibiting only local order. Our results suggest that local order plays a central role in the volume and in the vibrational entropy, indicating that there is an important connection between vibrational entropy differences and volume. We also carried out first principles calculations at the density funcional theory (DFT) level of the Ni3Al alloy from which were obtained the volume as a function of local order and the formation enthalpy and entropy of Ni vacancies. These calculations were done using a computational code called VASP (Vienna Ab-Initio Simulation Package), which describes with good accuracy systems containing transition metals by using ultrasoft pseudopotentials or the PAW (Projector Augmented Wave) method. In these calculations, the electron exchange correlation effects were described using the approximation called GGA (Generalized Gradient Approximation). Our results suggest that the Cleri-Rosato empirical potential describes with good accuracy the ab initio results obtained for Ni3Al / Mestrado / Física / Mestre em Física

No description available.

Thesis (Sc.D.)--Massachusetts Institute of Technology, Dept. of Nuclear Engineering, 1982. / MICROFICHE COPY AVAILABLE IN ARCHIVES AND SCIENCE. / Includes bibliographical references. / by Ronald George Ballinger. / Sc.D.

Mechanical properties of structural materials are highly correlated to their microstructure. The relationship between microstructure and mechanical properties can be established experimentally. The growing need for structural materials in industry promotes the study of microstructural evolution of materials by design using computational approaches. This thesis presents the microstructural evolution of two different structural materials. The first uses a genetic algorithm approach to study the microstructural evolution of a high-temperature nickel-based oxide-dispersion-strengthened (ODS) alloy. The chosen Ni-20Cr ODS system has nano Y2O3 particles for dispersion strengthening and submicron Al2O3 for composite strengthening. Synergistic effects through the interaction of small dispersoids and large reinforcements improved high-temperature strength. Optimization considered different weight factors on low temperature strength, ductility, and high temperature strength. Simulation revealed optimal size and volume fraction of dispersoids and reinforced particles. Ni-20Cr-based alloys were developed via mechanical alloying for computational optimization and validation. The Ni-20Cr-1.2Y2O3-5Al2O3 alloy exhibited significant reduction in the minimum creep rate (on the order of 10-9 s-1) at 800oC and 100 MPa. The second considers the microstructural evolution of AA 7050 alloy during friction stir welding (FSW). Modeling the FSW process includes thermal, material flow, microstructural and strength modeling. Three-dimensional material flow and heat transfer model was developed for friction stir welding process of AA 7050 alloy to predict thermal histories and extent of deformation. Peak temperature decreases with the decrease in traverse speed at constant advance per revolution, while the increase in tool rotation rate enhances peak temperature. Shear strain is higher than the longitudinal and transverse strain for lower traverse speed and tool rotation rate; whereas for higher traverse speed and tool rotation rate, shear and normal strain acquire similar values. Precipitation distribution simulation using TC-PRISMA predicts the presence of η' and η in the as-received AA 7050-T7451 alloy and mostly η in the friction stir welded AA7050 alloy, which results in the lower predicted strength of friction stir welded alloy. Further, development of modeling assists in process optimization and innovation, and enhances the progression rate. Accelerating the development process requires coupling experimental methods with predictive modeling. The overall purpose of this work was to develop an integrated computational model with predictive capabilities. In the present work, an application tool to predict thermal histories during FSW of AA7050 was developed using COMSOL software.

Plastic deformation of metals and alloys are invariably accompanied by the development of texture. The origin of texture is attributed to the deformation micro-mechanisms associated with processing. The face-centered cubic (FCC) metals and alloys are known to exhibit two distinct types of textures when subjected to large strain rolling deformation, namely, (i) Cu-type texture, commonly seen in high/medium stacking fault energy (SFE) materials, (ii) Bs-type texture in low SFE materials. The circumstances that could result in the formation of Bs-type texture in low SFE materials still remains an open question and no definite mechanism has been uniquely agreed upon. Apart from the SFE, grain size could also influence the deformation mechanism and hence the deformation texture. It is well known that in materials with grain sizes less than 100 nm (referred to as nano-crystalline materials), the microstructures contain large fraction of grain boundaries. This subsequently introduces a variety of deformation mechanisms in the microstructure involving grain boundary-mediated processes such as grain boundary sliding and grain rotation, in addition to slip and twinning. A clear understanding of texture evolution in nano-crystalline materials, particularly at large strains, is a topic that remains largely unexplored. The present work is an attempt to address the aforementioned issues pertaining to the evolution of deformation texture, namely, (i) the effect of SFE and (ii) the effect of grain size, in FCC metals and alloys. Nickel-cobalt alloys are chosen as the model system for the present investigation. The addition of cobalt to nickel leads to a systematic reduction of SFE as a function of cobalt content. In this thesis, three alloys of Ni-Co system have been considered, namely, nickel – 20 wt.% cobalt, nickel – 40 wt.% cobalt and nickel – 60 wt.% cobalt. For a comparison, pure nickel has also been subjected to similar study. Chapter 1 of the thesis presents a detailed survey of literature pertaining to the evolution of rolling textures in FCC metals and alloys, and chapter 2 includes the details of the experimental techniques and characterization procedures, which are commonly employed for the entire work. Chapter 3 addresses the effect of stacking fault energy on the evolution of rolling texture. The materials subjected to study in this chapter are microcrystalline Ni-Co alloys. The texture evolution in Ni-20Co is very similar to pure Ni, and a characteristic Cu-type rolling texture is observed. The evolution of texture in these materials is primarily attributed to the intense dislocation activity throughout the deformation stages. In Ni-40Co, a medium SFE material, the rolling texture was predominantly Cu-type up to a strain of ε = 3 (95% thickness reduction). However, beyond this strain level, namely at ε = 4 (98%), the texture gets transformed to Bs-type with orientations maxima predominantly close to Goss ({110} <001>) position. Simultaneously, the Cu component which was dominant until 95% reduction has completely disappeared. The analysis of microstructures indicate that deformation is mostly accommodated by dislocation slip up to 95%, however, at ε > 3, Cu-type shear bands get initiated, preferably in the Cu-oriented ({112} <111>) grains. The sub-grains within the shear bands show preferred orientation towards Goss, which indicates that the Cu component should have undergone transformation and resulted in high fraction of Goss component. In Ni-60Co alloy, Bs-type texture forms in the early stages of deformation (ε ~ 0.5) itself and further deformation results in strengthening of the texture with an important difference that the maximum in orientation distribution has been observed at a location close to Goss component, rather than at exact Bs-location. The development of Bs-type texture is accompanied by the complete absence of Cu and S components. Extensive EBSD analyses show that the deformation twinning gets initiated beyond 10% reduction and was found extensively in most of the grains up to 50% reduction. At higher strains, tendency for twinning ceases and extensive shear banding is observed. A non-random distribution of orientations close to Goss orientation was found within the shear bands. The near-Goss component in the Ni-60Co alloy can be explained on the basis of deformation twinning and shear banding. Thus, a reasonable understanding of the deformation texture transition in the extreme SFE range has been developed. In chapter 4, the effect of fine grain size on the evolution of rolling texture has been addressed. Nanocrystalline (nc) nickel-cobalt alloys with a mean grain size of ~20 nm have been prepared by pulse electro-deposition method. For a comparison, nc Nickel (without cobalt) with similar grain size has also been deposited. For all the materials, a weakening of the initial fiber texture is observed in the early stage of room temperature rolling (ε ~ 0.22). A combination of equiaxed grain microstructure and texture weakening suggests grain boundary sliding as an operative mechanism in the early stage of rolling. At large strain (ε = 1.2), Ni-20Co develops a Cu-type texture with high fractions of S and Cu components, similar to pure Ni. The texture evolution in Ni-40Co and Ni-60Co alloys is more towards Bs-type. However, the texture maximum occurs at a location 10° away from the Goss. The evolution of Cu and S components in nc Ni-60Co alloy takes place simultaneously along with the α-fiber components during rolling. Microstructural investigation by TEM indicates deformation twinning to be more active in all the materials up to 40% reduction. However, no correlation could be drawn between the texture evolution and the density of twins. The deformation of nc Ni-20Co alloy, is also accompanied by significant grain growth at all the stages of rolling. The increase in grain size, subsequently, renders the texture to be of Cu-type. However, Ni-40Co and Ni-60Co alloys show high grain stability. The absence of strain heterogeneities such as shear bands, and the lack of significant fraction of deformation twins indicate that the observed Bs-type texture could be due to planar slip. The increase in deformation beyond 70% reduction caused a modest reduction in the intensity of deformation texture. The microstructural observation indicates the occurrence of restoration mechanisms such as recovery/ recrystallization at large strains. The overall findings of the investigation have been summarized in chapter 5. The deformation mechanism maps relating stacking fault energy with amount of strain and with grain size are proposed for micro- and nano- crystalline materials respectively.

Scanning Laser Epitaxy (SLE) is a new layer-by-layer additive manufacturing process being developed in the Direct Digital Manufacturing Laboratory at Georgia Tech. SLE allows for the fabrication of three-dimensional objects with specified microstructure through the controlled melting and re-solidification of a metal powder placed atop a base substrate. This dissertation discusses the work done to date on assessing the feasibility of using SLE to both repair single crystal (SX) turbine airfoils and manufacture functionally graded turbine components. Current processes such as selective laser melting (SLM) are not able to create structures with defined microstructure and often have issues with warping of underlying layers due to the high temperature gradients present when scanning a high power laser beam. Additionally, other methods of repair and buildup have typically been plagued by crack formation, equiaxed grains, stray grains, and grain multiplication that can occur when dendrite arms are separated from their main dendrites due to remelting. In this work, it is shown that the SLE process is capable of creating fully dense, crack-free equiaxed, directionally-solidified, and SX structures. The SLE process, though, is found to be currently constrained by the cumbersome method of choosing proper parameters and a relative lack of repeatability. Therefore, it is hypothesized that a real-time feedback control scheme based upon a robust offline model will be necessary both to create specified defect-free microstructures and to improve the repeatability of the process enough to allow for multi-layer growth. The proposed control schemes are based upon temperature data feedback provided at high frame rate by a thermal imaging camera. This data is used in both PID and model reference adaptive control (MRAC) schemes and drives the melt pool temperature during processing towards a reference melt pool temperature that has been found to give a desired microstructure in the robust offline model of the process. The real-time control schemes will enable the ground breaking capabilities of the SLE process to create engine-ready net shape turbine components from raw powder material.