This thesis deals with the heat evolution duringsolidification and its relation to the formation of porosity.It intends to improve the current understanding of theformation of porosity in cast materials with special interestin nodular cast iron and the spray forming process. Twodifferent systems, a Fe-based alloy, Cast iron, and a Ni-basedalloy, Inconel 625, are examined. The effect on the heatevolution of the morphology and the processing parameters inspray forming are treated. An evaluation of the microstructural features, segregationbehavior and physical properties such as latent heat of fusionis performed byusing thermal analysis under cooling ratesranging from 0.1 to 104 K/s. In order to achieve this amodified differential thermal analysis (DTA) equipment, amirror furnace and levitation casting are used. Results arepresented in terms of the fraction of solidified, the coolingrate and the microstructure observed. The measured latent heatof fusion is not constant throughout the solidificationprocess. Variations in morphology and cooling rate affect therelease of the latent heat. A thermodynamic model is used to describe the experimentalobservations and to explain the formation of pores in nodularcast iron by taking into consideration the formation of latticedefects during the liquid/solid transformation. In this casethe formation of porosity is regarded as a consequence ofchanges in the volume fraction ratio graphite/ during thesolidification process. A numerical model of the spray forming process is developedby means of CFD modelling and compared with experimentalmeasurements performed in an industrial facility. Stagnationpressure measurements provided information about the gas flowvelocity and an analysis of the overspray powder providedinformation about the particle thermal history. Evaluation ofthe deposit was also performed. It is observed that the processconditions in spray forming promote non-equilibriumsolidification even though solidification at the deposit occursat a lower rate. In this case the porosity formed near theinterface substrate/deposit depends largely on the substratetemperature. The presence of certain reactive elements, such astitanium, affects the porosity levels in the rest of thedeposit. <b>Keywords:</b>Thermal Analysis, Nodular Cast Iron, Inconel625, CFD, Flow Assesment, Multiphase Flow, Spray Deposition,Microporosity, Superalloys

This study focuses on joining pearlitic ductile cast iron with low carbon steel by welding and investigation of this joint in microstructural and mechanical viewpoints. For this purpose E355 steel and GJS600-3 cast iron were joined using metal active gas (MAG) welding process by G3Si1 filler wire. The joining process is shaped mainly by the problems related to the low weldability of cast. Preheating was applied to prevent formation of cooling cracks and effects of post weld heat treatments (PWHT) were surveyed. Micro examination and micro hardness tests were applied to characterize the general microstructure. Grain size measurements were done for E355. Hardness profiles, tension and impact toughness properties were designated via mechanical tests. Fatigue behavior was surveyed and general fracture characteristics were determined via scanning electron microscopy (SEM) examinations. According to study it was concluded that successful weld joint could be formed between the materials by suitable preheating. Formation of ledeburitic white cast iron and martensite in heat affected zone of cast piece was witnessed. It was possible to lower high hardness values of these phases gradually by increasing post weld heat treatment temperatures. The weld joint behaved superior to the base metals under tension and fatigue tests. In tension tests failure occurred at E355 base metal whereas fatigue loading resulted failure at GJS600-3. A great impact toughness variation was determined between two pieces. It is seen that heat treatments had minor effect on mechanical test results except hardness. The study was concluded that a useful fusion weld joint between these materials can be built.

<p>This thesis deals with the heat evolution duringsolidification and its relation to the formation of porosity.It intends to improve the current understanding of theformation of porosity in cast materials with special interestin nodular cast iron and the spray forming process. Twodifferent systems, a Fe-based alloy, Cast iron, and a Ni-basedalloy, Inconel 625, are examined. The effect on the heatevolution of the morphology and the processing parameters inspray forming are treated.</p><p>An evaluation of the microstructural features, segregationbehavior and physical properties such as latent heat of fusionis performed byusing thermal analysis under cooling ratesranging from 0.1 to 104 K/s. In order to achieve this amodified differential thermal analysis (DTA) equipment, amirror furnace and levitation casting are used. Results arepresented in terms of the fraction of solidified, the coolingrate and the microstructure observed. The measured latent heatof fusion is not constant throughout the solidificationprocess. Variations in morphology and cooling rate affect therelease of the latent heat.</p><p>A thermodynamic model is used to describe the experimentalobservations and to explain the formation of pores in nodularcast iron by taking into consideration the formation of latticedefects during the liquid/solid transformation. In this casethe formation of porosity is regarded as a consequence ofchanges in the volume fraction ratio graphite/ during thesolidification process.</p><p>A numerical model of the spray forming process is developedby means of CFD modelling and compared with experimentalmeasurements performed in an industrial facility. Stagnationpressure measurements provided information about the gas flowvelocity and an analysis of the overspray powder providedinformation about the particle thermal history. Evaluation ofthe deposit was also performed. It is observed that the processconditions in spray forming promote non-equilibriumsolidification even though solidification at the deposit occursat a lower rate. In this case the porosity formed near theinterface substrate/deposit depends largely on the substratetemperature. The presence of certain reactive elements, such astitanium, affects the porosity levels in the rest of thedeposit.</p><p><b>Keywords:</b>Thermal Analysis, Nodular Cast Iron, Inconel625, CFD, Flow Assesment, Multiphase Flow, Spray Deposition,Microporosity, Superalloys</p>

[pt] Esta pesquisa teve como objetivo avaliar a vida-fadiga de dois ferros fundidos nodulares modificados metalurgicamente, sendo uma classe predominantemente ferrítica e outra.perlítica. Inicialmente, amostra dos dois ferros fundidos nodulares ferrítico e perlítico foram fundidas adotando-se moldação em areia na geometria padrão Y-block. Em seqüência, corpos de prova para ensaios mecânicos e de fadiga foram usinados das amostras ferríticas e perlíticas. Após os ensaios de tração e dureza, realizaram-se análises metalográficas qualitativas e quantitativas em ambos os materiais, com o intuito de se determinar suas características metalúrgicas, tais como contagem, distribuição e classe dos nódulos de grafita, bem como quantidade da matriz ferrítica e perlítica. Dando continuidade a etapa experimental, as curvas tensão versus número de ciclos para a falha do ferro fundido nodular ferrítico e do ferro fundido nodular perlítico foram levantadas por meio de ensaios de flexão rotativa. A vida útil em fadiga dos dois materiais foi relacionada com as suas características metalúrgicas. Quanto a resistência à fadiga, as amostras do ferro fundido nodular perlítico tiveram um melhor comportamento sob carregamento cíclico do que as amostras do ferro fundido nodular ferrítico. Tal comportamento superior foi atribuído a maior microdureza da matriz e a presença da estrutura olho-de-boi. Finalmente, as curvas experimentais tensão versus número de ciclos para a falha dos ferros fundidos nodulares ferrítico e perlítico foram modeladas pela equação de Coffin-Manson, que se mostrou eficiente no tratamento de dados experimentais da vida em fadiga de ambos os materiais. / [en] The objective of the present work was to evaluate the fatigue life of two nodular cast irons with metallurgical modifications and resulting in ferritic and perlitic different classes of material. Initially, samples of both materials were cast in sand moulds adopting the standard Y-block geometry. In the sequence, tensile and fatigue specimens were machined from the ferritic and perlitic samples. After the tensile and hardness tests, the microstructure of the both materials were analyzed by qualitative and quantitative metallography, aiming to characterize their metallurgical aspects as content, distribution and class of graphite nodules, as well as the contents of the ferritic and perlitic matrix. Following the metallurgical characterization, rolating bend fatigue tests were performed in order to estabilish the stress-life curves of the ferritic and perlitic nodular cast irons. Regarding the fatigue resistance, the specimens machined from the perlitic nodular sample showed a longer fatigue life than that related to the ferritic nodular specimens. The longer fatigue life of the perlitic nodular specimens was associated with a higher microhardness of the perlitic matrix and the preserve of the bull`s-eye structure. Finally, the experimental stress-life curves of the ferritic and perlitic nodular cast irons were modeled adopting the Coffin-Manson law, which was considered efficient in fitting experimental fatigue life data of both materials.

Latent heat during recalesence and nucleation and post-recalesence temperature was analysed for refractory metals. An effect on latent heat was found by alloying the pure elements with other refractories. Latent heat was found to be 15-65% of tabulated values. Interface energy was evaluated from undercooling experiments. It was found that the dimensionless numbers β (σLs/ σLv) and α can be used to classify elements into distinctive groups and crystallographic structure. The phase diagrams for Al-Ti, Al-Ti-B and Al-Ti-C as well as inoculation were analysed. It was found that Al nucleates on Al3Ti which nucleates on TiB2. TiC was found to decompose into Al4C3 and Al3Ti. The inoculation of nodular cast iron with Mg, Ce; Ca and the formation of sulphides and oxides was analysed. The formation of new inclusions during the solidification as well as the formation of graphite is discussed. / QC 20100602

[pt] A utilização de compósitos de matriz ferrosa com pré-forma cerâmica oferece a possibilidade de redução do desgaste abrasivo em aplicações onde as ligas usuais não são efetivas. Nesta tese, foi desenvolvido um estudo voltado para a obtenção de um compósito de matriz metálica com ênfase na caracterização e previsão da infiltração espontânea de um ferro fundido nodular através de uma préforma granulada porosa de óxido de alumínio. O processo de infiltração de pré-forma porosa constituída de óxido de alumínio, em três granulometrias distintas (12#, 16# e 42#), por um ferro fundido nodular de composição eutética (3,9 graus Celsius) foi realizado em três temperaturas de vazamento diferentes (1403 graus Celsius, 1299 graus Celsius e 1250 graus Celsius), desde a elaboração das pré-formas passando pela infiltração do metal, até a caracterização microestrutural. Os resultados dos ensaios de compressão com as pré-formas foram processados por análise fatorial e mostraram que, dentro dos níveis estudados, o percentual utilizado de ligante (silicato de sódio) e o tempo de cura influenciam positivamente e de forma mais significativa do que a granulometria do óxido de alumínio. A microestrutura da matriz foi afetada pelos grãos cerâmicos da préforma, fato este caracterizado pela presença de veios de grafita no lugar de nódulos em uma extensão variável entre 10 micrômetros e 60 micrômetros a partir da superfície do grão. Após a permeabilidade da pré-forma cerâmica ter sido estimada por processamento digital de imagens em 3D, foi desenvolvido um modelo matemático voltado para a identificação da penetração máxima da fase metálica levando em consideração as temperaturas de vazamento e de solidificação do ferro fundido. As curvas do modelo mostraram boa correlação quando comparados com os resultados experimentais. / [en] Iron metal matrix composites in aluminium oxide offers an outstanding possibility to reduce abrasive wear where usual alloys are not working well. For the present study the composite was obtained by carrying out an spontaneous infiltration of an eutectic (3,9 degrees Celsius) nodular iron in a preform made with three aluminiun oxide granulometries (#12, #16 and #42), in three different pouring temperatures (1403 degrees Celsius, 1299 degrees Celsius e 1250 degrees Celsius). The preforms compression tests results were processed by factorial analysis and showed a greater influence of the sodium silicate amount and the curing time over the aluminium oxide granulometry. After the estimation of the ceramic phase permeability by 3D image digital processing it was developed a mathematical model to predict the maximum infiltration of the ferrous melt through the ceramic phase. It was based on the pouring and alloy solidification temperatures and produced a good agreement with the experimental results. The matrix microstructure was affected by the ceramic grains. This was characterized by the presence of lamellar graphite instead of the expected nodules in an extension between 10 micrometers and 60 micrometers from the border of the composite.

The object of the diploma thesis was to solve and to describe the influence of cement sands moulds on the structure of castings with cast iron LKG. The work was intent on watching the tendency of cement sands to the metal penetration of castings, rising of the compounds on the metal mould interface and liquid metal and accompanies elements on the shape of the graphite in the surface of casting. The study of this processes has a big theoretical and a practical meaning, for prevent and prediction of rising of the defects that are attached with unsuitable choice of sand.

Företaget Svensk Kärnbränslehantering AB (SKB) håller på att utveckla en slutförvaringskapsel som kommer innehålla avfall från den svenska kärnkraften. Det är dock fortfarande en process under utveckling och därför undersöks olika typer av metoder och kapselmaterial för att kunna tillverka en hållbar och säker kapsel. Kapseln består av ett hölje av kopparrör med svetsad botten och lock och en insats med stållock. Insatsen är en cylindrisk konstruktion  av segjärn och innehåller en svetsad stålkassett för att skapa utrymmen till det använda kärnbränslet. Insatsen innehåller bland annat stålrör som under tillverkning får utstå en gjutprocess med segjärn och erhåller efter det icke homogena egenskaper. Målet med undersökningen är hur stor påverkan gjutningen har på stålets kemiska sammansättning samt mikrostrukturer. Det som orsakar de inhomogena egenskaperna är främst värmebehandlingen som driver diffusionen av kol från gjutjärnet till stålet, som då ger ett hårdare men sprödare material. Med hjälp av experiment och simuleringar upptäcks hur mycket kol som diffunderar in i stålet samt ändringar i den kemiska sammansättningen i de påverkade zonerna. Identifiering av fasomvandlingar, diffusion och ändringar i mikrostrukturer är stora faktorer som i sin tur ändrar de mekaniska egenskaperna i stålet. / The Swedish Nuclear Fuel and Waste Management Company (SKB) have developed a final storage canister that will contain waste from the Swedish nuclear power plants. However, it is still in a development phase and therefore different types of methods and canister materials are investigated to produce the most durable and safe canister. The canister is made of a copper tube with a welded bottom and lid with an insert. The insert is a cylindrical construction of nodular cast iron that contains a welded steel cassette, to make space for the spent fuel, and a steel lid. The steel tubes showed inhomogeneous properties after being exposed to a casting around them. The aim of this investigation is to clarify the impact of casting on the chemical composition of the steel as well as the microstructure. The cause to the inhomogeneous properties were the diffusion of carbon from the cast iron to the steel, which then produced a harder and more brittle material. Experiments and simulations were used to see the carbon diffusion into the steel as well as what happens with the chemical composition in the affected zones. Identification of phase changes, diffusion and microstructures contributed to changes of mechanical properties in the steel.

In the present thesis, fatigue behavior of nodular cast iron (NCI) is investigated using micromechanical simulations. An elastic-plastic porous material experiences an increase in a void volume fraction with each cycle of loading. This is called void ratchetting. The hypothesis of this thesis is to explain the fatigue failure of NCI using void ratchetting mechanism. The strain-life, stress-life, notch support effect, and fatigue crack growth are studied using the micromechanical simulations. In all these studies, matrix material is defined as an elastic-plastic with isotropic/kinematic hardening. No damage law is used to define material degradation. The axisymmetric cell model is developed to study strain-life and stress-life approaches for fatigue. The cell model is subjected to cyclic loading and cycle by cycle simulations are carried out until failure. The failure of the cell model is defined based on the drop in the macroscopic response of the cell model. The notch support effect is investigated using a 2D plane strain model within stress-life concept. From the simulation results, strain-life and stress-life curves are extracted, and they are in qualitative and quantitative agreement with experimental data collected from literature. The fatigue crack growth is studied using a micromechanical cell model under small scale yielding conditions. The graphite particles are considered as voids, and they are resolved discretely in fracture process zone. The region outside of the fracture process zone is considered as a homogenized medium. When positive alternating loads are applied, ligaments in the fracture process zone show ratchetting behavior, which is responsible for an effective fatigue crack growth. This mechanism is relevant for the fatigue crack growth in NCI. The 2D plane strain boundary layer model is able to predict the effect of load ratio on threshold for the fatigue crack growth and the fatigue crack growth rate. The fatigue crack growth rate curves obtained from the simulations are compared with experimental data. It is essential to note that the void ratchetting (plastic collapse of the intervoid ligaments) is a crucial mechanism in NCI and more focus should be given to this mechanism as it is simple to implement and gives satisfying simulation results.

Ce mémoire présente une méthode mise au point pour caractériser et analyser des fissures de fatigue présentant un fort caractère tridimensionnel dans des matériaux métalliques opaques. L'analyse consiste à déterminer avec précision la position du front de la fissure étudiée et à mesurer des valeurs de facteurs d'intensité des contraintes le long du front par projection sur les séries de Williams du champ de déplacement issu de la corrélation numérique d'images 3D obtenues par tomographie aux rayons X. La corrélation d'images 3D numériques est utilisée afin de mesurer le champ de déplacement en volume lors de la mise sous chargement d'une éprouvette fissurée fatiguée. La corrélation d'images nécessitant un mouchetis, le matériau retenu pour les expériences est la fonte à graphite sphéroïdal car il présente un mouchetis 3D naturel (les nodules de graphites) parfaitement imagé par tomographie aux rayons X. Le cyclage est appliqué à l'aide d'une machine de fatigue in situ permettant d'alterner des phases de propagation de la fissure avec des acquisitions tomographiques sous différentes charges. L'introduction d'un défaut artificiel (une entaille obtenue par usinage laser) permet de maîtriser l'amorçage et la propagation de la fissure in situ. La méthode de corrélation d'images 3D numériques employée dans ces travaux étant basée sur des éléments finis, nous avons cherché à tirer profit de différents outils développés dans le cadre de cette méthode. Les surfaces libres sont spécifiées afin de bien conditionner le maillage et un enrichissement dans l'esprit des X-FEM permet de renseigner la fissure dont la position est repérée grâce à la trace laissée dans le résidu de corrélation entre l'image avant cyclage et la dernière image acquise. Une régularisation mécanique est également introduite dans le calcul sous forme d'un filtre de longueur d'onde choisie. Le champ de déplacement mesuré avec précision est ensuite projeté sur les séries de Williams augmentées des termes correctifs de Leblond et Torlai qui prennent en compte la courbure du front de la fissure. L'annulation du terme super-singulier d'ordre -1 des séries de Williams est utilisée pour détecter la position du front de la fissure. Une procédure itérative a été mise en place afin de concilier l'enrichissement et la courbure du front avec la projection sur les séries de Williams. Une fois la position du front 3D de la fissure déterminée et les valeurs des facteurs d'intensité des contraintes associées calculées, les résultats obtenus sont confrontés à la littérature. / This manuscript describes a methodology used to compute Stress Intensity Factor values along the curved front of a fatigue crack inside a nodular cast iron. An artificial defect is introduced at the surface of a small sample. The initiation and growth of a fatigue crack from this defect during constant amplitude cycling is monitored in situ by laboratory x-ray tomography. The method for processing the 3D images in order to compute SIF values is described in detail. The results obtained show variations of the stress intensity factor values along the crack front.