Thesis. 1978. M.S.--Massachusetts Institute of Technology. Dept. of Materials Science and Engineering. / MICROFICHE COPY AVAILABLE IN ARCHIVES AND SCIENCE. / Includes bibliographical references. / by Richard Lister Bye, Jr. / M.S.

Metal dusting is a kind of catastrophic corrosion phenomenon that can be observed in several of petrochemical processes. It occurs on iron-, nickel- and cobalt-base metals in carbonaceous atmospheres at high temperature when gaseous carbon activity is higher than one. The process is particularly rapid for ferritic alloys The aim of this project was to compare the dusting kinetics of pure iron and a 2.25Cr-1Mo alloy steel under CO-H2-H2O atmosphere at 650??C. Polished (3??m) samples of iron and the steel were exposed to flowing CO-H2-H2O gas atmospheres at 650??C, when the gases were supersaturated with respect to graphite. The partial pressure of CO was varied between 0.25 and 0.9 atm, and the carbon activity was varied from 2.35 to 16, in order to obtain a series of experimental conditions. In most experiments, pO2 was less than 7.37E-24 atm, and no iron oxide could form. However, Cr2O3 would always have been stable. When exposed to these gases, both iron and steel developed a surface scale of Fe3C which was buried beneath a deposit of carbon, containing iron-rich nanoparticles (the dust). Examination by Scanning Electron Microscopy allowed the observation of fine and coarse carbon nanotubes, and also spiral filaments. However, the morphology of the graphitic carbon was not sensitive to pCO and aC. Moreover, the carbon deposit was gas permeable, allowing continuing gas access to the underlying metal. At a fixed=4.5, the carburizing rate clearly increased with CO content from 0.25 to 0.68 atm. However, increasing the CO content to higher value led to decreased rates, indicating that carburizing rate reaches a maximum value at pCO=0.68 atm. When pCO was fixed at 0.25 atm and 0.68 atm, and carbon activity was varied. The induction period was extended by the formation of protective oxide layers at low values of carbon activity (aC= 2.35 and 2.55) where pO2 exceed the iron oxide formation value. For other reaction conditions, the carbon uptake rate for iron and steel did not increase with aC. The present work showed that the carbon deposition rates were not proportional to pCO or pCOpH2. Instead, the rate was affected by the partial pressure of all three reaction gases, and the carbon uptake rate for both materials could be expressed at r=k1pCOpH2+k2pCO2+k3pH22 and the rate constant k3 has a negative value, corresponding to coke gasification. From XRD analyses, it was found that cementite was the only iron-containing phase in the dusting product. The cementite particles acted as catalysts for carbon deposition from the gas. The same deposition process at the surface of the cementite layer led to its disintegration, thereby producing the particles. This disintegration process was faster on the steel than on pure iron. Consequently, the rates of both metal wastage and coke accumulation were faster for the steel. It is concluded that chromium and molybdenum do not stabilize the carbide but accelerate its disintegration process. It is suggested that Cr2O3 fine particles in the cementite layers provide more nucleation sites in the cementite layer on steel, explaining its more rapid dusting kinetics. However, appropriate methods of proving this assumption, such as TEM and FIB, are required.

The research work in this thesis involves an experimental and theoretical investigation for high speed machining of AISI 4140 medium carbon steels and AISI D2 tool steels which are classified as being difficult to machine materials. An experimental program was carried out to determine the cutting forces, chip formation, the secondary deformation zone thickness and surface roughness at different cutting speeds using a 0.4mm and 0.8mm nose radii ceramic tools and -7?? rake angle for annealed (virgin) AISI 4140 and heat treated AISI 4140 steel. Another series of experiments was carried out on the annealed (virgin) and heat treated AISI D2 with 0.4mm, 0.8mm and 1.2mm nose radii CBN (Cubic Boron Nitride) tools under various cutting conditions. A theoretical model is developed by taking into account the flow stress properties of the AISI 4140 (0.44% carbon content) to use with the Oxley Machining approach. To find the flow stress data for AISI D2 tool steel, the Johnson and Cook empirical constitutive equation is used as the constitutive model. In addition, the magnitude of tool radius should be also considered to determine the prediction of cutting performances. To account for the effect of nose radius edge in hard machining, a simplified geometrical method is used to model the parameters for application in the Oxley Model and works for the cutting conditions considered here. These extensions to the Oxley machining theory were verified by experimental results. These results show a good agreement between the Oxley machining theory and hard machining experiment at data. The research work described in this thesis provides useful data for hard machining conditions.

"May 2002" / Includes bibliographical references (leaves 210-229) / xxvi, 368 leaves : ill. ; 30 cm. / Title page, contents and abstract only. The complete thesis in print form is available from the University Library. / Thesis (Ph.D.)--University of Adelaide, Dept. of Mechanical Engineering, 2003

Thesis (Ph.D.)--McMaster University, 2005. / Supervisor: C.L.E. Swartz Includes bibliographical references (leaves 144-154).

Thesis (Ph. D.)--Oregon Graduate Center, 1988.

Thesis (Ph. D.)--University of Hong Kong, 2006. / Title proper from title frame. Also available in printed format.

Thesis (Ph. D.)--Lehigh University, 2006. / Includes bibliographical references and vita.

Originally published as first author's thesis. / "May 2004." "John A. Blume Earthquake Engineering Center, Dept. of Civil & Environmental Engineering, Stanford University." Includes bibliographical references.

Thesis (M.S.)--California Polytechnic State University, 2010. / Mode of access: Internet. Title from PDF title page; viewed on March 19, 2010. Major professor: Graham Archer, Ph.D., P.E. "Presented to the faculty of California Polytechnic State University, San Luis Obispo." "In partial fulfillment of the requirements for the degree [of] Master of Science in Architecture with a specialization in Architectural Engineering." "February 2010." Includes bibliographical references (p. 73).