No description available.

This study describes the mechanical response of thermoset polymers under high compressive loads. The study is divided into two parts. The first part focuses on the behaviour of a powder coating when used in a clamping force joint and how the properties vary when the chemical and physical structure of the coating is changed. The second part discusses the fundamental understanding of the behaviour of thermoset polymers with small thickness-to-width ratio subjected to compressive stresses, the aim being to develop mathematical material models for viscoelastic materials under high compressive loads. In the first part polyester powder coatings were used with variations in molecular weight, number of functional groups of the resin, amount and type of filler and thickness of the coating. The coatings were subjected to conventional tests for coatings and polymers and also to specially designed tests developed to study the behaviour of powder coatings in clamping force joints. The high compressive loads in a clamping force joint put high demands on the relaxation and creep resistance of the coating and the study shows the importance of crosslink density, filler content, and also coating thickness in order to achieve the desired mechanical properties of a coating. A high reactivity of the resin, facilitating a high crosslink density and hence a high Tg, is the most important property of the coating. A film with high crosslink density shows increase in relaxation time and in apparent yield strength under compression, and also an increase in relaxation modulus and storage modulus in tension at temperatures above Tg. Addition of fillers reduces the deformation during compression and tension, but also induces a lower strain at break and hence a more brittle coating. The reinforcing effect of the fillers is pronounced when increasing the crosslink density of the coating, especially in the compression tests. The effect is evident in compression even at low amounts of fillers, where the relaxation time and resistance to deformation are strongly increased. The combination of high crosslink density and addition of fillers is therefore desirable since fillers then can be used moderately in order to achieve a reinforcing effect in compression while minimising embrittlement. The study also showed that increased coating thickness will give rise to defects in the coating, especially voids and blisters due to evaporation of water formed during the curing of the polyester powder coating. These defects will give rise to stress concentrations and increased plastic deformations in the coating, impairing the properties of the clamping force joint. The results from relaxation tests in tension were used to create a micromechanical model. This model was used in finite element modelling to estimate the loss of clamping force in a screw joint and to correlate with the experimental results of the powder coatings. In the second part of the study a well-defined free radically cured vinyl ester resin was used and studied in six different geometries in order to determine the dependence of apparent mechanical properties on the particular size and shape of a sample when it is subjected to high compressive loads. Variation of the specimen thickness, boundary conditions and loading conditions reveals that the geometry of the sample has a significant effect on the mechanical performance of the polymer. The apparent modulus and the yield strength increase dramatically when the thickness-to-width ratio of the sample is reduced, whereas they decrease when the friction between the sample and the compression plate is reduced. The creep strain rate decreases when the thickness of the material is reduced and it decreases even more when the amount of material surrounding the compressed part of the sample is increased. Creep and strain recovery tests on large specimens were used to develop a mathematical model including non-linear viscoelastic and viscoplastic response of a thermoset vinyl ester. The model was used in FEM calculations where the experimental results were compared with the calculated results in order to model the trends of the material response when varying the sample geometry. / QC 20100921

No description available.

Organic coatings are frequently applied to metals, often in circumstances where there is a need to protect the substrate from corrosion or to improve the aesthetic quality of a product. Increasingly, coatings are also expected to provide additional functionality, such as anti-bacterial properties. Concurrent with the need to satisfy ever more demanding specifications, coating formulators are being obliged to comply with stringent environmental legislation. A research area which may benefit the development of coating formulations is that of nanocomposite synthesis, in which the composite additives have at least one dimension in the nanometre size range. The current research has sought to modify a waterborne organic coating primer with two types of nano-sized additives: layered clays and titanium dioxide nanoparticles. Dispersion of the particles at loadings up to 5% w/w was achieved by ball milling and the modified coatings were subjected to numerous tests to ascertain the effect of the additives. Titanium dioxide was found to improve the tribological properties and corrosion resistance of the coatings, while the addition of magnesium aluminium hydroxycarbonate (hydrotalcite) layered clay had a deleterious effect. Some coatings exhibited a cracked morphology, although no correlation between particle loading and the presence of cracks could be determined. A preliminary investigation into substrate preparation was also conducted. This ensured that the degree of cleanliness of the hot-dip galvanized substrates was both satisfactory and consistent.

This work investigated the protection of mechanism of organic coatings on steel exposed to 3% sodium chloride solution at 50°C, coupled with the use of electrochemical impedance spectroscopy (EIS) to monitor progress of corrosion and degradation of coating. Unlike Walter, EIS measurement was conducted at 50°C as well as after cooling, and measurements at intermediate temperatures have been used to characterize the dependence of the process involved. The proposition that corrosion rate is controlled by the ionic resistance of an organic coating has been tested. EIS results were fitted to a model circuit and changes in the film resistance and charge-transfer resistance with temperature were analyzed to deduce activation energies for the processes involved. Surprisingly, the calculated activation energy for coating resistance is significantly lower than the activation energy for the charge transfer resistance. This suggests that ion conduction in the coating, as apparent in an AC measurement, cannot be controlling the corrosion rate. Potentiostatic pulse tests on coated metal enable iR-corrected polarization curves to be plotted at different temperatures. From this, the activation energy determined from the corrosion currents also higher matches the higher activation energy value calculated from the charge transfer resistance. However, measurements of coating resistance on free films of the same coating also generate higher activation energy values, leaving two possible models that can account for the results.

Motivada pelos inúmeros desafios relacionados à exploração de petróleo na região do pré-sal, onde o ambiente agressivo aliado com a grande profundidade são fatores sempre presentes, a busca por materiais alternativos para aplicações em válvulas ganhou destaque. As válvulas subsea, essenciais para projetos de exploração nestas áreas são consideradas um desafio ainda maior. Dessa maneira, estudos e ensaios de desempenho em revestimentos anticorrosivos orgânicos nesse ambiente tornam-se necessários. O objetivo deste trabalho é avaliar a resistência à corrosão e ao desgaste do revestimento anticorrosivo orgânico ECTFE (Halar®) para a aplicação em válvulas industriais do tipo esfera para operações subsea, através da realização de ensaios em corpos de prova e em protótipos, perante as condições simuladas do ambiente agressivo na qual deverão operar em conformidade com o programa de qualificação do revestimento D-SMA/ING/SPF/TCNA-14-00047. Para a realização dos ensaios, foram projetados sistemas de tubulações fechadas (loopings), nos quais os protótipos foram instalados. Os parâmetros de testes estabelecidos, assim como os dados monitorados pelos sensores instalados, foram coletados durante todo o período de teste. Os ensaios definidos para a avaliação do revestimento orgânico em protótipos foram: ciclos de pressão, circulação sob vazão, circulação com água arenosa e ensaios de corrosão com e sem defeito imposto no revestimento. Complementarmente, corpos de prova em escala reduzida foram submetidos a ensaio de adesão e de fadiga. Os resultados obtidos foram conclusivos e o revestimento mostrou-se resistente às condições impostas aos protótipos, uma vez que não foram detectadas descontinuidades consideradas relevantes segundo os critérios de aceitação pré-estabelecidos em procedimento. / The search for alternative materials for applications in valves has been highlighted motivated by the numerous challenges related to oil and gas in the pre-salt region, where the aggressive environment combined with great depth are always present factors. The subsea valves, essential for exploration projects in these areas, are considered an even bigger challenge, thus, studies and performance tests on organic anti-corrosion coatings in this environment become necessary. The purpose of this study is to evaluate resistance to corrosion and wear of organic anti-corrosion coating ECTFE (Halar®) for application of industrial ball valves for subsea operations, by conducting tests on specimens and prototypes, under simulated harsh environment conditions in which they should operate in accordance with the coating qualification program D-SMA / ING / SPF / TCNA-14-00047. Closed pipes systems are designed (loops) for the carrying out of the tests, in which the prototypes were installed. The set of test parameters as well as the monitored data by installed sensors were collected during the entire test period. The defined tests for the evaluation of the organic coating in prototypes were: pressure cycles, flow rate circulation, circulation in soapy water and corrosion tests with and without defects imposed in the coating. In addition, reduced specimens were submitted to adhesion and fatigue tests. The results were conclusive and the coating was resistant to the imposed conditions on prototypes, since relevant discontinuities were not detected according to pre-established acceptance criteria for the procedure.

Em função das novas fronteiras exploratórias de petróleo, principalmente proveniente das reservas do pré-sal, as situações operacionais e condições de serviços estão se tornando cada vez mais severas (pressão, temperatura, composição dos fluidos, etc), exigindo o desenvolvimento de novos materiais e de novas tecnologias para a adequação de materiais tradicionais existentes, como o aço carbono, agregando-lhes novas propriedades e características, por exemplo, com o uso de revestimentos poliméricos. Este trabalho tem por objetivo desenvolver e avaliar um projeto de uma válvula esfera industrial com todas suas partes internas revestidas, incluindo componentes internos, e realizar uma análise do processo de revestimento e validação do projeto final com os testes de desempenho realizados baseados na norma ABNT NBR 15827, com vistas a possibilitar a substituição de ligas metálicas nobres de alto custo (inconel, duplex, superduplex etc.), por aço carbono revestido. Inicialmente, foram realizadas alterações no projeto original da válvula esfera industrial de diâmetro 4‖ CL300 montagem tipo flutuante para tornar o projeto convencional em um projeto com revestimento interno. Na sequência, foram revestidas duas válvulas com o polímero etileno clorotrifluoroetileno (ECTFE), e realizados ensaios de controle de qualidade durante as etapas do revestimento e ao final do processo. Após a montagem e testes iniciais funcionais e de vedação das válvulas, estas foram submetidas a teste de ciclagem e desempenho, com 1000 ciclos de abertura e fechamento com a pressão máxima de trabalho, sendo realizado monitoramento contínuo do torque de acionamento e pressão aplicada. Foram realizadas sete avaliações de integridade das vedações e do revestimento durante a ciclagem. Gráficos de ciclagem, pressão e testes de vedação foram gerados na etapa de avaliação de desempenho dos protótipos. Ao final dos ensaios os protótipos foram desmontados e uma avaliação dos componentes foi realizada, sendo observado apenas desgaste uniforme nas vedações e superfície de vedação da esfera e haste devido ao atrito gerado pela abertura e fechamento da válvula. Este desgaste não comprometeu a vedação das válvulas. Os resultados satisfatórios validaram o projeto e o processo de revestimento desenvolvido. / Due to new exploratory frontiers of oil, mainly from pre-salt reserves, the operational situations and service conditions are becoming increasingly severe (pressure, temperature, composition of fluids, among others), demanding the development of new materials and technologies to the suitability of the traditional materials, as the carbon steel, by adding them new properties and characteristics, for example, with the use of polymeric coatings. This paper has the objective of to develop and evaluate the project of an industrial ball valve, with all the inner parts coated, including internal components, perform an analysis of the coating and validate the final design process with performance tests conducted based on standard ABNT NBR 15827, with the objective of enabling the replacement of noble metal alloys of high cost (inconel, duplex, super duplex, etc.) by coated carbon steel. Initially, there were changes in the original design of industrial ball valve of a diameter 4‖ CL300 floating mounting type to turn the conventional project in a project with internal coating. Following, two valves were coated with the polymer ethylene chlorotrifluoroethylene (ECTFE) and control quality tests performed during the stages of the coating and the end of the process. After the assembly and the initial functional tests and sealing of the valves, they were subjected to cycling and performance tests with 1000 cycles of opening and closing at maximum working pressure, being carried out continuous monitoring of the drive torque and pressure applied. Seven evaluations of the integrity of the sealing and coating were performed during cycling. Charts of cycle number, pressure and sealing tests were generated during the stage of evaluation of the prototype's performance. At the end of the testing, the prototypes were disassembled and a review of the components was conducted, being observed only the uniform wear on the seals and sealing surfaces of the sphere and the stem due to the friction generated by the opening and closing of the valve. This wear did not commit the seal of the valves. Satisfactory results have validated the project and the coating process developed.

Motivada pelos inúmeros desafios relacionados à exploração de petróleo na região do pré-sal, onde o ambiente agressivo aliado com a grande profundidade são fatores sempre presentes, a busca por materiais alternativos para aplicações em válvulas ganhou destaque. As válvulas subsea, essenciais para projetos de exploração nestas áreas são consideradas um desafio ainda maior. Dessa maneira, estudos e ensaios de desempenho em revestimentos anticorrosivos orgânicos nesse ambiente tornam-se necessários. O objetivo deste trabalho é avaliar a resistência à corrosão e ao desgaste do revestimento anticorrosivo orgânico ECTFE (Halar®) para a aplicação em válvulas industriais do tipo esfera para operações subsea, através da realização de ensaios em corpos de prova e em protótipos, perante as condições simuladas do ambiente agressivo na qual deverão operar em conformidade com o programa de qualificação do revestimento D-SMA/ING/SPF/TCNA-14-00047. Para a realização dos ensaios, foram projetados sistemas de tubulações fechadas (loopings), nos quais os protótipos foram instalados. Os parâmetros de testes estabelecidos, assim como os dados monitorados pelos sensores instalados, foram coletados durante todo o período de teste. Os ensaios definidos para a avaliação do revestimento orgânico em protótipos foram: ciclos de pressão, circulação sob vazão, circulação com água arenosa e ensaios de corrosão com e sem defeito imposto no revestimento. Complementarmente, corpos de prova em escala reduzida foram submetidos a ensaio de adesão e de fadiga. Os resultados obtidos foram conclusivos e o revestimento mostrou-se resistente às condições impostas aos protótipos, uma vez que não foram detectadas descontinuidades consideradas relevantes segundo os critérios de aceitação pré-estabelecidos em procedimento. / The search for alternative materials for applications in valves has been highlighted motivated by the numerous challenges related to oil and gas in the pre-salt region, where the aggressive environment combined with great depth are always present factors. The subsea valves, essential for exploration projects in these areas, are considered an even bigger challenge, thus, studies and performance tests on organic anti-corrosion coatings in this environment become necessary. The purpose of this study is to evaluate resistance to corrosion and wear of organic anti-corrosion coating ECTFE (Halar®) for application of industrial ball valves for subsea operations, by conducting tests on specimens and prototypes, under simulated harsh environment conditions in which they should operate in accordance with the coating qualification program D-SMA / ING / SPF / TCNA-14-00047. Closed pipes systems are designed (loops) for the carrying out of the tests, in which the prototypes were installed. The set of test parameters as well as the monitored data by installed sensors were collected during the entire test period. The defined tests for the evaluation of the organic coating in prototypes were: pressure cycles, flow rate circulation, circulation in soapy water and corrosion tests with and without defects imposed in the coating. In addition, reduced specimens were submitted to adhesion and fatigue tests. The results were conclusive and the coating was resistant to the imposed conditions on prototypes, since relevant discontinuities were not detected according to pre-established acceptance criteria for the procedure.

Em função das novas fronteiras exploratórias de petróleo, principalmente proveniente das reservas do pré-sal, as situações operacionais e condições de serviços estão se tornando cada vez mais severas (pressão, temperatura, composição dos fluidos, etc), exigindo o desenvolvimento de novos materiais e de novas tecnologias para a adequação de materiais tradicionais existentes, como o aço carbono, agregando-lhes novas propriedades e características, por exemplo, com o uso de revestimentos poliméricos. Este trabalho tem por objetivo desenvolver e avaliar um projeto de uma válvula esfera industrial com todas suas partes internas revestidas, incluindo componentes internos, e realizar uma análise do processo de revestimento e validação do projeto final com os testes de desempenho realizados baseados na norma ABNT NBR 15827, com vistas a possibilitar a substituição de ligas metálicas nobres de alto custo (inconel, duplex, superduplex etc.), por aço carbono revestido. Inicialmente, foram realizadas alterações no projeto original da válvula esfera industrial de diâmetro 4‖ CL300 montagem tipo flutuante para tornar o projeto convencional em um projeto com revestimento interno. Na sequência, foram revestidas duas válvulas com o polímero etileno clorotrifluoroetileno (ECTFE), e realizados ensaios de controle de qualidade durante as etapas do revestimento e ao final do processo. Após a montagem e testes iniciais funcionais e de vedação das válvulas, estas foram submetidas a teste de ciclagem e desempenho, com 1000 ciclos de abertura e fechamento com a pressão máxima de trabalho, sendo realizado monitoramento contínuo do torque de acionamento e pressão aplicada. Foram realizadas sete avaliações de integridade das vedações e do revestimento durante a ciclagem. Gráficos de ciclagem, pressão e testes de vedação foram gerados na etapa de avaliação de desempenho dos protótipos. Ao final dos ensaios os protótipos foram desmontados e uma avaliação dos componentes foi realizada, sendo observado apenas desgaste uniforme nas vedações e superfície de vedação da esfera e haste devido ao atrito gerado pela abertura e fechamento da válvula. Este desgaste não comprometeu a vedação das válvulas. Os resultados satisfatórios validaram o projeto e o processo de revestimento desenvolvido. / Due to new exploratory frontiers of oil, mainly from pre-salt reserves, the operational situations and service conditions are becoming increasingly severe (pressure, temperature, composition of fluids, among others), demanding the development of new materials and technologies to the suitability of the traditional materials, as the carbon steel, by adding them new properties and characteristics, for example, with the use of polymeric coatings. This paper has the objective of to develop and evaluate the project of an industrial ball valve, with all the inner parts coated, including internal components, perform an analysis of the coating and validate the final design process with performance tests conducted based on standard ABNT NBR 15827, with the objective of enabling the replacement of noble metal alloys of high cost (inconel, duplex, super duplex, etc.) by coated carbon steel. Initially, there were changes in the original design of industrial ball valve of a diameter 4‖ CL300 floating mounting type to turn the conventional project in a project with internal coating. Following, two valves were coated with the polymer ethylene chlorotrifluoroethylene (ECTFE) and control quality tests performed during the stages of the coating and the end of the process. After the assembly and the initial functional tests and sealing of the valves, they were subjected to cycling and performance tests with 1000 cycles of opening and closing at maximum working pressure, being carried out continuous monitoring of the drive torque and pressure applied. Seven evaluations of the integrity of the sealing and coating were performed during cycling. Charts of cycle number, pressure and sealing tests were generated during the stage of evaluation of the prototype's performance. At the end of the testing, the prototypes were disassembled and a review of the components was conducted, being observed only the uniform wear on the seals and sealing surfaces of the sphere and the stem due to the friction generated by the opening and closing of the valve. This wear did not commit the seal of the valves. Satisfactory results have validated the project and the coating process developed.

Motivada pelos inúmeros desafios relacionados à exploração de petróleo na região do pré-sal, onde o ambiente agressivo aliado com a grande profundidade são fatores sempre presentes, a busca por materiais alternativos para aplicações em válvulas ganhou destaque. As válvulas subsea, essenciais para projetos de exploração nestas áreas são consideradas um desafio ainda maior. Dessa maneira, estudos e ensaios de desempenho em revestimentos anticorrosivos orgânicos nesse ambiente tornam-se necessários. O objetivo deste trabalho é avaliar a resistência à corrosão e ao desgaste do revestimento anticorrosivo orgânico ECTFE (Halar®) para a aplicação em válvulas industriais do tipo esfera para operações subsea, através da realização de ensaios em corpos de prova e em protótipos, perante as condições simuladas do ambiente agressivo na qual deverão operar em conformidade com o programa de qualificação do revestimento D-SMA/ING/SPF/TCNA-14-00047. Para a realização dos ensaios, foram projetados sistemas de tubulações fechadas (loopings), nos quais os protótipos foram instalados. Os parâmetros de testes estabelecidos, assim como os dados monitorados pelos sensores instalados, foram coletados durante todo o período de teste. Os ensaios definidos para a avaliação do revestimento orgânico em protótipos foram: ciclos de pressão, circulação sob vazão, circulação com água arenosa e ensaios de corrosão com e sem defeito imposto no revestimento. Complementarmente, corpos de prova em escala reduzida foram submetidos a ensaio de adesão e de fadiga. Os resultados obtidos foram conclusivos e o revestimento mostrou-se resistente às condições impostas aos protótipos, uma vez que não foram detectadas descontinuidades consideradas relevantes segundo os critérios de aceitação pré-estabelecidos em procedimento. / The search for alternative materials for applications in valves has been highlighted motivated by the numerous challenges related to oil and gas in the pre-salt region, where the aggressive environment combined with great depth are always present factors. The subsea valves, essential for exploration projects in these areas, are considered an even bigger challenge, thus, studies and performance tests on organic anti-corrosion coatings in this environment become necessary. The purpose of this study is to evaluate resistance to corrosion and wear of organic anti-corrosion coating ECTFE (Halar®) for application of industrial ball valves for subsea operations, by conducting tests on specimens and prototypes, under simulated harsh environment conditions in which they should operate in accordance with the coating qualification program D-SMA / ING / SPF / TCNA-14-00047. Closed pipes systems are designed (loops) for the carrying out of the tests, in which the prototypes were installed. The set of test parameters as well as the monitored data by installed sensors were collected during the entire test period. The defined tests for the evaluation of the organic coating in prototypes were: pressure cycles, flow rate circulation, circulation in soapy water and corrosion tests with and without defects imposed in the coating. In addition, reduced specimens were submitted to adhesion and fatigue tests. The results were conclusive and the coating was resistant to the imposed conditions on prototypes, since relevant discontinuities were not detected according to pre-established acceptance criteria for the procedure.