Vacuum arc remelting is a secondary melting process used to produce a variety of segregation sensitive and reactive metal alloys. The present day VAR practice for superalloys involves, typically, melting electrodes of 17'' into ingots of 20'' in diameter. Even larger diameter forging stock is desirable. However, beyond 20'' ingots of superalloys are increasingly prone to segregation defects if solidification is not adequately controlled. In the past years a new generation of model-based controllers was developed to prevent segregation in VAR by controlling melt rate, or the total amount of power flowing into the liquid pool. These controllers were seen as significant improvements in the industry of remelting processes, but these controllers were still focusing on the melting sub-process and ignoring ingot solidification. Accurate control of the liquid pool profile is expected to result in segregation-free ingots, but unfortunately a controller capable of stabilizing the solidification front in VAR is currently not available. The goal of the proposed research is to develop a cyber-enabled controller for VAR pool depth control that will enhance the capabilities of current technologies. More specifically, the objectives of this research are threefold. Firstly, a control-friendly model is proposed based on a high-fidelity ingot solidification model and is coupled to a thermal model of electrode melting. Secondly, sequential Monte Carlo estimators are proposed to replace the traditional Kalman filter, used in the previous VAR controllers. And finally, a model predictive controller (MPC) is designed based on the proposed reduced-order model. The time-critical characteristics of these methods are studied, and the feasibility of their real-time implementation is reported. / text

Vacuum Arc Remelting (VAR) is a secondary process used for homogenization of high-melting-point and oxygen-sensitive materials such as superalloys and titanium alloys. The VAR process is carried out with the aim of melting a large consumable electrode in such a way that the resulting ingot has improved homogeneity. The Specialty Metals Processing Consortium (SMPC) has spent the past 20 years developing technology to improve control over the final ingot remelting and solidification processes to alleviate conditions that lead to the formation of inclusions and segregation. Channel segregates are concentration defects arising during the solidification of large-diameter solute-rich alloys. As manufacturers for turbine engines and generators call for larger ingots, it becomes more difficult to produce them without these defects. If, however, liquid pool depth can be controlled precisely to stabilize the solidification zone in the ingot, we could, in principle, produce larger ingots that are defect free. A problem arises because measurements obtained from the VAR furnace do not give enough information to accurately estimate the liquid pool shape in dynamic melting situations. Also, the solidification process in VAR is extremely complex due to the multiple physical domains present and a high-fidelity model is required to give an accurate description of the dynamic process. The Basic Axisymmetric Remelting (BAR) code was initially developed by Lee Bertram at Sandia National Laboratories as a high-fidelity multi-energy model to describe ingot casting in this system. In this work we present a new strategy to improve the accuracy of the estimates used in the control system. This strategy consists of implementing BAR as a new set of measurements to be used by the estimator. This new strategy was used in tests jointly sponsored by SMPC and Los Alamos National Laboratory (LANL) in February 2011 using a laboratory-scale furnace and alloy 718 electrodes. / text

This diploma thesis is focused on description of the properties of a layer of Inconel 718 applied on austenitic steel AISI 304 by the Cold Spray and subsequently remelted by electron beam. The first part presents the Cold Spray with its properties, advantages and disadvantages, and also describes the principle of electron beam remelting and other possible uses of electron beam, for example welding, drilling, heat treatment etc. The second part describes the material and the methods used for the preparation and evaluation of the samples. There are evaluated the porosity, microstructure and microhardness of the layers applied by the Cold Spray and these properties are further compared with the properties of the same layers remelted by electron beam. In conclusion, the results of the porosity of the layers applied by the Cold Spray are discussed with the literature and the results of electron beam remelting are only partially described here, because it was not possible to find literature about this topic. There are also suggestions for further research of the properties of this layers, which is necessary to know before implementing this method of producing layers for commercial production.

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Low alloy steel electrodes have been electroslag remelted using alternating and direct current power sources. Changes in electrical contact between the furnace mould wall and mould base provided an improved understanding of the thermal ,and chemical processes characteristic of the remelting technique. 1m ion regeneration process has been postulated to account for current flow within the slag phase. Observed changes in furnace heating effects, electrode droplet sizes and in slag and metal compositions have be,en related to overtensions impressed on the slag/electrode and slag/ingot boundaries. The desulfurization reaction has been studied in detail. / Thesis / Doctor of Philosophy (PhD)

Cyber-Physical Systems theory is a new concept that is about to revolutionize the way computers interact with the physical world by integrating physical knowledge into the computing systems and tailoring such computing systems in a way that is more compatible with the way processes happen in the physical world. In this master’s thesis, Field Programmable Gate Arrays (FPGA) are studied as a potential technological asset that may contribute to the enablement of the Cyber-Physical paradigm. As an example application that may benefit from cyber-physical system support, the Electro-Slag Remelting process - a process for remelting metals into better alloys - has been chosen due to the maturity of its related physical models and controller designs. In particular, the Particle Filter that estimates the state of the process is studied as a candidate for FPGA-based computing enhancements. In comparison with CPUs, through the designs and experiments carried in relationship with this study, the FPGA reveals itself as a serious contender in the arsenal of v computing means for Cyber-Physical Systems, due to its capacity to mimic the ubiquitous parallelism of physical processes. / text

A soldagem tem grande importância no setor metroferroviário, pois é empregada na fabricação de componentes estruturais e no acabamento de vagões de passageiros, que em sua maior parte são de aço inoxidável. As juntas soldadas podem apresentar descontinuidades que são interrupções que afetam as propriedades mecânicas e metalúrgicas da junta soldada. A presença destas descontinuidades, dependendo do seu tamanho, natureza ou efeito combinado, pode ocasionar a reprovação da junta soldada, quer pela redução de propriedades mecânicas ou pela não aceitação, segundo critérios estabelecidos em normas. Uma estrutura que tenha uma solda reprovada durante sua qualificação ou inspeção, pela presença de descontinuidades pode ser recuperada, por meio de um retrabalho a ser realizado nesta junta. A refusão do cordão de solda por meio do processo TIG (Tungsten Inert Gas), sem a utilização do material de adição, é uma técnica de retrabalho que pode ser empregada, em especial pela viabilidade técnica e econômica do processo. Neste estudo analisou-se a influência que o processo de reparo por soldagem TIG exerceu no comportamento mecânico e microestrutural das juntas soldadas pelo processo MIG, por meio de: ensaios mecânicos (tração, fadiga e microdureza Vickers), ensaios não destrutivos (inspeção visual e líquidos penetrantes) e caracterização microestrutural do cordão de solda. Resultados das amostras de ensaio de tração e fadiga indicaram que o reparo dos cordões de solda não alterou o comportamento mecânico das juntas. As juntas submetidas ao reparo nas quais foram retirados os reforços dos cordões apresentaram modificações nas propriedades mecânicas, mas também apresentaram resultados satisfatórios. / The welding has great importance in manufacture of subway cars because it is used in the manufacture of structural components and finishing in passenger cars which are mostly stainless steel. Joints may show the presence of discontinuities. The discontinuities are interruptions that affect the mechanical and metallurgical properties of the weld. The presence of these discontinuities, depending on their size, nature or the combined effect may lead to failure of the weld either by reduction of mechanical properties or non-acceptance criteria established in standards. A structure that has a weld failed during its qualification or inspection by the presence of discontinuities can be retrieved through a rework to be done in this joint. The remelting of the weld using the TIG process without the use of additional material, rework is a technique that can be employed in particular the technical and economic feasibility of the process. This study analyzes the influence that the process of TIG welding rework has on mechanical behavior and microstructure of welded joints by means of: mechanical tests (tensile and Vickers hardness), non-destructive testing (visual inspection and liquid penetrant) and characterization microstructure of the weld. Results of tensile test specimens and fatigue indicated that the repair of the weld beads did not change the mechanical behavior of joints. The joints subjected to repair in which they were removed the ribs of the beads showed changes in the mechanical properties, but also had satisfactory results.

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Non-isothermal crystallization of the PET/PTT copolyesters was studied at five different cooling rates over 1-20oC/min by means of differential scanning calorimetry (DSC). Both the Ozawa equation and the modified Avrami equation have been used to analyze the crystallization kinetics. The non-isothermal kinetics of most copolymers cannot be described by the Ozawa analysis, except the copolyester with a composition of 66.3% trimethylene- (TT) and 33.7 %ethylene- terephthalates (ET). It may be due to the inaccuracy of the Ozawa assumptions, such as the secondary crystallization is neglected. From the kinetic analysis using the modified Avrami equation, the Avrami exponents, n, were found to be in the range of 2.43-4.67 that are dependent on the composition of the copolyesters. The results indicated that the primary crystallization of the PET/PTT copolymers followed a heterogeneous nucleation and a spherulitic growth mechanism during the non-isothermal crystallization. In the cases of the copolyesters with either TT or ET less than 10%, we found the molten temperature is a key factor to decide whether the Ozawa equation can be succeeded in analyzing the dynamic crystallization. For the non-isothermal crystallization, a single exothermic peak was detected in each DSC curve regardless of the composition and the cooling rate. It indicated that a single-mode distribution of the crystallite sizes was formed during the cooling process. After the non-isothermal crystallization, the melting behavior of the specimens was monitored by temperature modulated DSC (TMDSC) in the conventional mode and the modulated mode. Multiple endothermic peaks were observed in both modes. The wide-angle X-ray diffraction (WAXD) patterns of these copolymers showed that the peak height became sharper and sharper as the crystallization temperature increased, but the position of the diffraction peaks did not change apparently. It indicated that the multiple melting behaviors did not originate from the melting of the crystals with different structures. The melting behavior of these PET/PTT copolyesters can be explained logically by using the melt-recrystallization model. From the reversing and non-reversing signals of TMDSC, the melting-recrystallization-remelting phenomena were further verified. In addition, a small endothermic peak was found at the highest melting temperature in the reversing thermogram for TT-enriched copolyesters. It is reasonably to believe that this endotherm is attributed to the melting of the crystals that are formed in regime I during the heating scan. The cocrystallization of the PET/PTT copolyesters was studied using DSC and WAXD. A clear endothermic peak in the DSC thermogram was detected over the entire range of copolymer composition. A minimum melting temperature was found for the copolyester with 50% ET. The WAXD patterns of these copolymers can be divided into two groups with sharp diffraction peaks, i.e., PET type and PTT type crystals. The transition of crystal structure between PET type and PTT type occurred around the eutectic composition (50 % ET and TT), determined from the variation of the melting temperature with the composition. In addition, the fiber diagram and the WAXD pattern of the copolyester with the eutectic composition showed a different crystalline structure. These results indicated that the cocrystallization behavior of the PET/PTT copolyesters was isodimorphic.

No description available.