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This work is a preliminary attempt to study the effect between thermal shock and abrasive wear in WC-Co alloys. This was done by evaluating the thermal shock resistance of a WC-12wt%Co mining grade as a function of temperature, number of thermal shock cycles and making comparisons between the abrasive wear responses of samples subjected to thermal shock and samples not subjected to thermal shock. A furnace was designed for the thermal shock treatments. Abrasive wear tests were performed on a 2-body sliding wear apparatus using 80-grit SiC abrasive paper as a counter-face. Stereo and electron microscopy as well as microprobe techniques were used to analyse the effects of thermal shock. It is confirmed that thermal shock has a negative effect on the wear rate of WC-12wt%Co. The results showed an initial high mass loss rate during abrasive wear testing, which increased with increasing temperature and a decrease in wear rate with time until the wear rates converged for all samples. The surface analysis after thermal shock indicated voids on and below the surface, stained surfaces, a thin oxide layer and the possibility of WC decarburization which accelerated the wear response.

<p>Wear of hardmetals is a complicated topic because the wear resistance and the wear mechanisms are influenced by microstructural factors. Although edge wear resistance has a vital importance, most of the researches made in laboratories are related to flat wear resistance using coarse abrasive paper. This situation produces problems with the prediction of abrasive wear behaviour and with the estimation of the lifetime of cutting edges of different kinds of tooling.</p><p>Several studies have been done in order to clarify edge wear behaviour. It has been published correlations of the edge toughness to the load and to the bulk fracture toughness. In those publications coarse abrasive or Vickers indenter were used.</p><p>In the present research, edge shaped specimens of WC-6wt%Co grades were investigated. In order to compare the obtained results for flat sliding and edge wear behaviour two test arrangements, pin on flat disc and edge on flat disc were employed. The specimens were tested using 120, 320, 800 and 2400 mesh SiC abrasive paper and the worn surfaces were investigated using SEM instrument to evaluate wear mechanisms. The edge wear was observed was discussed in relation to wear mechanisms investigated and correlated to the flat wear behaviour.</p><p>The obtained results showed limited applicability of the results obtained with the pin on the flat disc test arrangement for prediction of the edge wear resistance, especially in the case when size of the abrasive particles is close to the WC grain size. However, both edge and flat wear results were similar in; 1) large WC grain sized hard metals wore more than fine grain sized against coarse abrasive paper whereas the reverse occurred against fine abrasives, and 2) wear mechanisms were mainly ploughing (or grooving) for fine grain sized hardmetals in all cases, whereas wear mechanisms changed from ploughing to binder removal and carbide pull-out going from coarse to fine abrasive paper.</p>

Wear of hardmetals is a complicated topic because the wear resistance and the wear mechanisms are influenced by microstructural factors. Although edge wear resistance has a vital importance, most of the researches made in laboratories are related to flat wear resistance using coarse abrasive paper. This situation produces problems with the prediction of abrasive wear behaviour and with the estimation of the lifetime of cutting edges of different kinds of tooling. Several studies have been done in order to clarify edge wear behaviour. It has been published correlations of the edge toughness to the load and to the bulk fracture toughness. In those publications coarse abrasive or Vickers indenter were used. In the present research, edge shaped specimens of WC-6wt%Co grades were investigated. In order to compare the obtained results for flat sliding and edge wear behaviour two test arrangements, pin on flat disc and edge on flat disc were employed. The specimens were tested using 120, 320, 800 and 2400 mesh SiC abrasive paper and the worn surfaces were investigated using SEM instrument to evaluate wear mechanisms. The edge wear was observed was discussed in relation to wear mechanisms investigated and correlated to the flat wear behaviour. The obtained results showed limited applicability of the results obtained with the pin on the flat disc test arrangement for prediction of the edge wear resistance, especially in the case when size of the abrasive particles is close to the WC grain size. However, both edge and flat wear results were similar in; 1) large WC grain sized hard metals wore more than fine grain sized against coarse abrasive paper whereas the reverse occurred against fine abrasives, and 2) wear mechanisms were mainly ploughing (or grooving) for fine grain sized hardmetals in all cases, whereas wear mechanisms changed from ploughing to binder removal and carbide pull-out going from coarse to fine abrasive paper.

The present work was conducted in Sandvik Coromant to enhance the knowledge and understanding of general flank wear growth and specifically in this case flank wear growth on the cutting edge of the coated (Ti(C, N)/ Al2O3/ TiN) tool inserts.   Reliable modeling of tool life is always a concern for machining processes. Numbers of wear models studies predicting the tool life length have been created throughout the metal-cutting history to better predict and thereby control the tool life span, which is a major portion of the total cost of machining.   A geometrical contact model defining the geometry of the flank wear growth on the cutting tool inserts was proposed and then compared with four suggested models, which estimates flank wear. The focus of this work is on the initial growth of flank wear process and thereby short cutting-time intervals are measured.   Wear tests on cutting tool inserts were performed after orthogonal turning of Ovako 825 B steel and were analysed by optical instrument, 3D optical imaging in Alicona InfiniteFocus and EDS in SEM. Force measurements for cutting speeds, Vc, 150, 200, and 250 m/min and feed rate, fn, 0.15 mm/rev were recorded as well.   Results show that initial flank wear land, VB, growth is dominated by sliding distance per cutting length for different cutting speeds. A good correlation between the geometrical contact model and estimation models is indentified. The cutting force measurements compared with the flank wear land show proportionality between two parameters. For the machining data in the present study the flank wear rate per sliding distance, dW/dL, is estimated to 2x103 (μ3/m).

Abrasive wear occurs when a contact associated with stress between a metal surface and a herd particle (frequently of mineral origin) leads to friction between the two. In a very wide range of industrial applications, abrasive wear is the main reason for component and equipment repair or replacement. In most of these applications, especially those of earth moving, construction and mining equipment, digger teeth are used to improve equipment performance. Digger teeth can be produced in different shapes and sizes (mainly by casting) and a wide range of materials are used. This project is concerned with both a field trial of the wear of digger teeth fixed to the front of a bucket used in a gravel pit, and also a laboratory investigation of abrasive wear mechanisms. It was found that the wear of digger teeth increased with increasing working hours, but the wear rate eventually decreased. The dimensions and shape of the front of the tooth changed and gravel removal became more inefficient. Plastic deformation and phase transformation were observed in the worn surfaces of the teeth. In the laboratory study, many parameters were investigated utilising a pin-on disc technique. Wear rate increases linearly with load and decreases with sliding distance. The effect of attack angle on abrasive wear showed that wear volume increases with increasing attack angle up to a certain value (90°) and then decreases. Corrosion increases the initial wear rate, and the amount of material removed in the wet corrosive test was higher than the corresponding dry test. It was difficult to reproduce the same results from the field trial in the laboratory because of the difference in the conditions in the two cases. Optical and scanning electron microscopy were used to study the worn surfaces, abrasive papers and wear debris. Different abrasive wear mechanisms were observed throughout this investigation. A cutting mechanism associated with spiral debris was observed during short pin-on disc tests and with higher attack angles. A ploughing action associated with plate-like debris was observed during longer tests and at lower attack angles. Fragmentation was observed in brittle materials.

Made available in DSpace on 2014-06-11T19:32:51Z (GMT). No. of bitstreams: 0 Previous issue date: 2009-11-10Bitstream added on 2014-06-13T19:22:34Z : No. of bitstreams: 1 souza_cn_dr_guara.pdf: 5417862 bytes, checksum: 45f7392a335fde8b9a67ef7d60be0ce9 (MD5) / Este trabalho tem como objetivo avaliar a influência dos tempos de fotopolimerização nas resinas odontológicas, onde quatro resinas compostas foram utilizadas, sendo três micro híbridas e uma nanoparticulada. Esses compósitos foram submetidos ao desgaste abrasivo de esfera rotativa pelo método de ball cratering. Para tal ação foi projetado e construído um dispositivo de desgaste por micro abrasão de esfera rotativa livre de três corpos. Os corpos de prova foram confeccionados e embutidos em uma matriz de alumínio, com uma profundidade de 2mm. Usam-se o aparelho LED RADII, com os tempos de exposição de 20, 30 e 40 segundos e uma esfera com 15 mm de diâmetro de aço temperada, retificada e revenida. A lama abrasiva utilizada nesse estudo foi uma solução composta por 20% de talco (USP/200) e 80% de soro fisiológico, na quantidade de 3 gotas por segundo. Para comprovação dos resultados obtidos, utilizaram-se os testes de: Espectroscopia por Dispersão de Energia (EDS), Infravermelho por Transformada de Fourier (FT-IR), Análise Termogravimétrica (TGA), micro dureza Vickers, ensaio de desgaste de micro abrasão por esfera rotativa pelo método de ball cratering e a análise da superfície desgastada por Microscopia Eletrônica de Varredura (MEV). Esta análise foi realizada para verificar o real mecanismo de desgaste ocorrido. Os resultados obtidos comprovam que o tempo recomendado pelos fabricantes, tem a capacidade suficiente de fotopolimerizar toda a matriz orgânica, comprovaram também que a resina nanoparticulada obteve em todos os ensaios os melhores resultados em relação às resinas híbridas, e que a cultura do acréscimo de até 20s além do recomendado não tem influência direta em relação ao desgaste abrasivo. / This work has as an objective to evaluate the influence of photopolymerization in odontological resins, where composed four resins were used, being three of them micro hybrid and one nanoparticulated. These composites were submitted to abrasive wear and tear of rotative sphere by the method ball cratering. For such action a device of micro abrasion of rotative sphere was designed and built free of three bodies. The bodies of proof were produced and put in a matrix of aluminum with a depth of 2mm. The device used was a LED RADII, with exposition time of 20, 30 and 40 seconds and a sphere of 15mm diameter made of tempered steel, rectified and soften, the abrasive lama used in this study was a solution composed by 20% of powder (USP/200) and 80% of physiological serum released at 3 drops per second. For verification of the results obtained the tests of Energy Dispersion Spectrograph (EDS) was used, transformed Infra red of Fourier (FT-IR), Thermogravimetric Analysis (TGA) Vickers micro hardness, wear and tear of micro abrasion by rotative sphere by the method ball cratering and the analysis of worn superficies by Sweeping Electronic Microscopy (SEM). This analysis was carried out to verify the real mechanism of the worn occurred. The results obtained prove that the time recommended by the manufacturer has enough capacity to photopolymerized all the organic matrix, it also proved that the resin nanoparticulated obtained in all the essays the best results in what concerns to the hybrid resins. And the culture of the addition of 20 seconds besides what is recommended has no direct influence in relation to the abrasive wear and tear.

<p>The objective of this research was to work with industrial partners to develop and apply innovative and intelligent improvement to their production processes in order to achieve a higher level of productivity and quality while lowering cost.</p> <p>Two projects were completed and are discussed in this work. The first project was focused on improving tooling in a milling process of high value parts by varying coatings and geometries of the tooling. The second project involved implementing statistical process control (SPC) using control charts and process capability metrics through customized software.</p> <p>In the first project, the industrial partner was experiencing rapid wear of tools when milling NiCrMoV steel. A detailed material characterisation study revealed the likely cause was the presence of un-tempered martensite having high hardness. Cutting tools were then chosen to compare the performance of tools with varying rake angle and coating; where all other geometry/features were identical. It was found that the best performing tooling had a relatively more aggressive rake angle at 16º, and a PVD coating consisting of TiAlN + Al₂O₃+ ZrN; showing a tool life 300% greater than the baseline tooling. Inspection of the worn tools by SEM, EDX, and Raman spectroscopy revealed that the Al₂O₃ and ZrN coating layers detached long before the failure.</p> <p>In the second project, software was developed collaboratively with an industrial partner for a CNC turning process. The process was semi-automated, and used 100% inspection of parts. Part measurement data was recorded by the software, allowing for SPC to be applied to identify common-cause sources of variation. The software was then able to make offset recommendations in real-time to correct for variation. Providing process history for quality assurance (QA) also allowed for identifying of several areas for improvement in the process which were corrected, considerably reducing variability.</p> / Master of Applied Science (MASc)

No / This study investigates the effect of heat treatment on changes in microstructure and wear behaviour of WC-NiCr coatings. Two feedstock powders with a similar chemical composition and different particle sizes (near nano-structured WC-17NiCr and microstructured WC-15NiCr) were used. High-velocity oxyfuel spraying technique was used to deposit coatings on to a mild steel substrate using identical spraying parameters. Coated samples were then heat treated in a nitrogen atmosphere at 500 and 700°C. The effect of heat treatment on changes in hardness and wear performance of the coatings was studied using microstructural analysis, micro-hardness indentation and abrasive wear tests. The results showed that the heat treatment increased the hardness of both coatings and a corresponding increase in wear resistance was recorded. The formation of a brittle CrWO4 phase in the microstructured coating resulted in brittle fracture of the coating and this gave lower wear resistance compared to the nanostructured coatings.