MAX-phase ceramics are a class of ductile ceramic material group with the general molecular formula Mn+1AXn (n = 1, 2, 3….), where M is an early transition element, A is an element from the ‘A’ group of the periodic table and X is either nitride or carbide. One advantage of these materials is that they maintain their strength at high temperatures. In addition these ceramic materials possess the best properties of both ceramics and metals. Some of their important characteristics are low density, high stiffness, machinability, excellent thermal and electrical conductivity and they even exhibit some plasticity at elevated temperature. These amazing combinations of properties have made researchers foresee the technological importance of these materials as a structural ceramic for high temperature application. Since this ceramic is relatively new to the market, only a handful of work has been undertaken on this material and its applications are limited to heating elements. In addition, analysis of the thermodynamic data on this material is incomplete. This PhD work addresses this issue and conducts a complete thermodynamic analysis involved in the formation mechanism of the ternary titanium carbide MAX-phase Ti2AlC ceramic, using Self-propagating High temperature Synthesis (SHS) form of combustion synthesis process, based on the following exothermic reaction: (2+x) Ti + (y) Al + C → Ti2AlC + (x) Ti + (y) Al (i) Where x and y = 0.1. 0.2, 0.3… A thermodynamic model has been formulated to predict the temperature evolution during the reaction (i), for the formation of Ti2AlC using SHS process. In addition the effect of particle size in the elemental reaction has been studied on the formation mechanism of Ti2AlC and methods to control the porosity by fine tuning the particle size has been recognized. Manufacturing processes such as Self-propagating High temperature Synthesis (SHS), foam replication and freeze casting have been developed in this thesis to produce micro and macro porous Ti2AlC ceramic mainly for electrode applications. A systematic material development technique to produce macro porous Ti2AlC ceramic, using a foam replication technique has been established in this research work. The material fabricated by this technique has a uniform pore size (up to 5mm), with open interconnected pores and is ideal for a flow battery application which requires a multifunctional electrode material which is highly porous to allow the flow of electrolyte through it, is corrosion resistant and at the same time being electrically conductive. The mechanical properties of the ceramic produced by this method has been characterised and steps to mitigate the cracks and defects formed during the fabrication process to obtain structurally stable macro porous Ti2AlC ceramic has been reported in this work. This research demonstrates that one of the applications of macro porous Ti2AlC ceramic formed using foam replication technique is as an electrode material in a photo-Microbial Fuel Cell (p-MFC). Graded porosity micro porous Ti2AlC ceramics have also been fabricated using a freeze casting technique, with camphene as the freezing vehicle. A systematic material development process has been tailored for this particular material. A ceramic material with gradient pore size ranging from 27-305µm has been fabricated using this technique. This type of ceramic is a good candidate as an electrode material in micro-redox battery and for sensing applications. A variety of processing parameters such as solid loading (amount of ceramic content in the material), freezing temperature and mould material which affect the pore formation and pore size have been studied in this PhD and the range of porosities achieved by controlling these parameters have been reported.

The enactement of the Energy Policy and conservation Act of 1975, led to a paradigm shift in material selection and design in the automotive industry. The net effect was an increased focus by the automotive industry toward the use of light metals leading for the reduction of weight and hence, the dependence of imported oil. Increasing use of aluminum was a transition in that direction. However, raw aluminum on an average is 1.5 - 2 times as expensive as steel. Near net shape manufacturing processes (Die casting, Thixo-forging, etc) provided the much needed competitive advantage vis-à-vis steel / iron parts by permitting the manufacturing of Al components. Semi solid processing involves the net shape manufacturing of alloys in a two phase region (liquid + solid). The reduced turbulence (during casting), less entrapped gases and lower operating temperatures (processes below the liquidus) make semi solid processing ideal for the manufacturing of high integrity Al parts. Traditionally, semi solid processing involved the heating of billets to a two phase region (called Thixcasting). Rheocasting is a new semi solid processing technique wherein the alloy is cooled from a liquid state (a combination of controlled heat / nucleation and growth phenomena) to yield structures similar to the Thixocasting process. Rheocasting or Slurry-On-Demand is in its early stages of development (the first industrial prototype of rheocasting was invented in the late 1990's) and forms the central point of interest in this work. Much research is underway around the globe to understand the controlling mechanism as well as the structure - property relationships in rheocast parts, primarily limited to the hypoeutectic Al-Si alloys (less than 12.6% Si). This work is dedicated in the development of novel methods for the rheocasting of hypereutectic Al-Si alloys (greater than 12.6% Si) and Al based wrought alloys (alloys with Cu, Zn, Mg and Si as alloying elements). The thesis presents the problems associated with microstructure control of hypereutectic Al-Si (primary Si coarsening and accelerated growth) and Al based wrought alloys (dendritic structures and hot tearing) with currently available technologies. Novel processing techniques are presented for the casting of hypereutectic Al-Si alloys and Al based wrought alloys with a combination of industrial trials and a through analysis of the underlying mechanisms.

"Aluminum-Silicon and Aluminum-Copper alloys are important non-ferrous casting alloys. Different methods have been applied to improve their casting characteristics, their microstructure and consequently, their mechanical properties. Application of mechanical vibrations to the mold during solidification of the alloy is one of these methods. In this study, the effect of controlled mechanical vibrations on the dendrite coherency point, the hot tearing tendency, and the microstructure of B206, B390, and binary Al-7%Si alloys was evaluated. The dendrite coherency point was determined using the two-thermocouple method. The hot tearing tendency was evaluated using the crack susceptibility criterion (CSCb) and by means of measurements using a specially designed ring mold. Microstructure characterization was performed using optical and scanning electron microscopy coupled with image analysis. It was found that mechanical vibrations refine the microstructure of the alloys; and, in the case of B390 alloy, it resulted in significant improvement in the distribution of the primary silicon particles. In the case of B206 and Al-7%Si alloys, where aluminum is the primary phase, mechanical vibrations caused the dendrite coherency point to shift towards lower temperature, i.e., towards higher fraction solid. This shift, together with the refinement of the grain structure, manifested itself in significant reduction in the incidence of hot tearing in B206 castings. "

As peças fundidas sob pressão com Zamac Z5 no formato de peças técnicas com galvanoplastia em Cromo, rejeitadas durante o processo são encaminhadas para beneficiamento, como sucata, na empresa fornecedora de Zamac. No entanto, durante o beneficiamento, somente 35% do material enviado retorna para empresa, assim 65% do peso deste material é perdido. A matéria-prima é um dos principais custos da empresa, apresentando assim uma grande oportunidade de economia no processo de fabricação. O objetivo desse trabalho é verificar a viabilidade de fundição das peças técnicas rejeitadas, como matéria-prima para a fabricação de peças de moda. As sucatas foram analisadas quanto a sua composição química, microestrutura e análise térmica. Com esta sucata foram fundidas sob pressão peças de moda usadas em calçados e acessórios, fivelas e enfeites, com estes foram realizadas análises de microestrutura e ensaios de corrosão, propriedades mecânicas e ainda testes de desempenho pertinentes as suas aplicações. As amostras fundidas com 100% de sucata responderam de forma satisfatória a todos os ensaios, em alguns casos de maneira superior às peças de controle fundidas com matéria-prima virgem. Evidenciou-se que a sucata, oriunda de peças técnicas com galvanoplastia em Cromo, pode ser usada como matéria-prima para confecção de peças de moda, fivelas e enfeites, apresentando assim uma redução de 30% no custo de fabricação das mesmas. / In the production of Zamac Z5 metal parts by ppressure casting, which are normally chrome electroplated, some of those end up being rejected and, as a consequence, returned as scrap to the Zamac supplier companies. However, from the supplier after reprocessing, only 35% of the material returns to be used in the manufacturing. So, 65% of this material weight is lost. The raw material is one of the main costs of the company, presenting a great opportunity for savings in the manufacturing process. The objective of this research is to check the viability of feeding the casting process with rejected parts, reusing them as raw material for fashionable accessories manufacturing. The scraps have been analyzed for verification of the chemical composition, microstructure and submmited to thermal analysis. These scraps were used as basis to die casted parts which were used in the manufacturing process of footwear, accessories, buckles and frills. Microstructure, mechanical testing, relevant performance and corrosion tests were carried out according with the parts applications. The samples manufactured with 100% scrap have had satisfactory results to all the tests, in some cases in a superior manner in comparison to controled parts manufactured with Virgin raw material. There are evidences which prove that the scraps, when coming from technical parts with chrome electroplating, can be used as raw material for production of parts of sets, buckles and frills, showing a 30% reduction in the costs of their manufacturing .

Thesis. 1975. Sc.D.--Massachusetts Institute of Technology. Dept. of Materials Science and Engineering. / Vita. / Includes bibliographical references. / Sc.D.

Ao longo da última década, vários trabalhos têm destacado as vantagens do titânio e suas ligas e estudado a possibilidade de utilização para a confecção de estruturas metálicas de prótese parcial removível. Apesar das vantagens, o processo de fundição ainda apresenta problemas, limitando o uso do titânio. O objetivo deste estudo foi avaliar a influência de dois métodos de fundição, sobre microestrutura, microdureza, porosidade e força de retenção de grampos de PPR, fundidos em Co-Cr (controle) e titânio comercialmente puro (Ti cp). Foram utilizados os seguintes métodos: 1- arco voltaico (plasma) sob vácuo e pressão de argônio, com injeção do metal fundido por vácuo-pressão, e 2- indução sob vácuo e atmosfera de argônio, com injeção do metal fundido por centrifugação. Para análise da força de retenção foram confeccionadas estruturas metálicas com grampos circunferenciais sob retenção de 0,25; 0,50 e 0,75 mm, submetidas a ciclos de inserção/remoção simulando o uso por um período de 5 anos. Previamente ao ensaio de simulação, os corpos-de-prova foram radiografados em unidade laboratorial de raios X. Para o ensaio de microdureza Vickers e microestrutura foram confeccionados discos, com 5 mm de diâmetro e 2 mm de espessura, polidos metalograficamente. Os resultados mostraram que os métodos de fundição interferem nas características dos materiais estudados. As peças em titânio cp fundidas por plasma/vácuo-pressão apresentaram maior número de porosidades (50%) do que as fundidas por indução/centrifugação (16,66%). Para as peças fundidas em liga de Co-Cr, segundo a metodologia empregada, não foi possível observar a ocorrência de porosidades. As peças fundidas por plasma/vácuo-pressão apresentaram maior flexibilidade e as fundidas por indução/centrifugação apresentaram maior rigidez. Conseqüentemente, as forças de retenção foram, em geral, maiores para os corpos-de-prova obtidos por indução/centrifugação do que para aqueles obtidos por plasma/vácuo-pressão, com exceção da condição experimental de retenção 0,75 mm. Os corpos-de-prova fundidos por indução/centrifugação apresentaram, tanto para o Ti cp quanto para a liga de Co-Cr, maiores valores de microdureza Vickers do que os fundidos por plasma/vácuo-pressão. O Ti cp fundido pelo método de indução/centrifugação resultou em microestrutura de aspecto Widmanstätten, enquanto quando fundido pelo método de plasma/vácuo-pressão tem aspecto metalográfico tipo feather-like. Para a liga de Co-Cr, ambos os métodos resultaram em microestrutura dendrítica, mais fina para o método de plasma/vácuo-pressão. O Ti cp e a liga de Co-Cr, parecem ser afetados pela velocidade de resfriamento associada ao equipamento utilizado. Na análise química não foram detectadas alterações de composição dos materiais que indicassem contaminação resultante dos métodos de fundição utilizados. Assim, embora ainda apresentem problemas técnicos a serem resolvidos, ambos os métodos de fundição, indução/centrifugação e plasma/vácuo-pressão, permitem a obtenção de resultados satisfatórios na produção de estruturas metálicas de PPR em Ti cp. / Along the last decade, several jobs have been highlighting the advantages of titanium and titanium alloys and studied the possible utilization for removable partial dentures (RPD) metal frameworks confection. Although advantages, the cast process still presents problems, limiting the titanium use. The objective of this study was to evaluate the influence of two casting methods, on microstructure, microhardness, porosity and retention force of RPD clasps, casted in Co-Cr alloy (control) and commercially pure titanium (cp Ti). The cast methods used were: 1- voltaic arc (plasma) under vacuum and argon pressure, with molten metal injection by vacuum-pressure, and 2- induction under vacuum and argon atmosphere, with molten metal injection by centrifugation. For retention force analysis were made metal frameworks with circumferential clasps under retention of 0.25; 0.50 and 0.75 mm, submitted to insertion/removal cycles, simulating a 5 years use of a metal framework. Previously to the simulation test, the samples were radiographed in a laboratorial unit to verify the porosities occurrence. For Vickers microhardness test and microstructure analysis, disks with 5mm diameter and 2 mm thickness were made. The results showed that the casting methods interfere in the characteristics of studied materials. The cp Ti pieces casted by plasma/vacuum-pressure presents larger porosities number (50%) than that casted by induction/centrifugation (16.66%). For the pieces casted in Co-Cr alloy, according to the used methodology, wasn't possible to observe the occurrence of porosities. The pieces casted by plasma/vacuum-pressure presents larger flexibility and that casted by induction/centrifugation present larger rigidity. Consequently, the retention forces were, in general, larger for the samples obtained by induction/centrifugation than for those obtained by plasma/vacuum-pressure, except for the experimental condition with 0.75 mm retention. The samples casted by induction/centrifugation present, as for cp Ti as for Co-Cr alloy, larger Vickers microhardness values Vickers than that casted by plasma/vacuum-pressure. The cp Ti casted by induction/centrifugation method resulted in Widmanstätten microstructural aspect, while when casted by plasma/vacuum-pressure method has feather-like aspect. For Co-Cr alloy, both methods resulted in dendritic microstructure, finer for plasma/vacuum-pressure method. The cp Ti and Co-Cr alloy seem to be affected by the cooling rate associate to the used equipment. In the chemical analysis weren't detected materials composition alterations that indicate resultant contamination for the used casting methods. Thus, however still present technical problems to be solved, both casting methods, induction/centrifugation and plasma/vacuum-pressure, allow the obtainment of satisfactory results in the RPD metal frameworks production in cp Ti.

O objetivo deste trabalho é realizar um estudo comparativo das propriedades mecânicas e metalúrgicas em duas peças de ligas de Al-Si produzidas por injeção sob baixa pressão. As peças estudadas referem-se às placas acessórias utilizadas para fornecer sustentação durante a entrada e saída de vaus por carros de combate do Exército Brasileiro, sendo uma nacional e a outra importada. Para a caracterização metalúrgica foram realizados ensaios metalográficos (microscopia óptica e eletrônica). Para a obtenção das propriedades mecânicas foram realizados ensaios de tração, microdureza Vickers e impacto. Quanto aos resultados metalográficos observou-se: na peça nacional, a presença de uma estrutura predominantemente eutética com silício em forma acicular e a fase Al15 (Fe, Mn)3Si2 com morfologia tipo escrita chinesa; na peça importada, foi identificado silício disperso com formato arredondado. A análise da porosidade por gases realizada no canal de alimentação indicou baixos índices para as duas peças. De outro modo, foi observada a presença de porosidades por contração na peça nacional. Nos resultados mecânicos, a peça importada apresentou valores significativamente superiores para a tensão de escoamento e máxima, energia de impacto e deformação. A partir dos resultados obtidos nos ensaios mecânicos realizaram-se simulações no software Solidworks, módulo Simulation, para a determinação da ocorrência de falha quando utilizado por dois carros de combate: o Leopard 1A5, sobre lagartas, e o URUTU, sobre roda. As simulações indicaram falha da peça nacional pelo uso do carro sobre rodas. O resultado em peso da composição química da peça nacional revelou uma liga de alumínio com 12%Si e 0,88%Fe, enquanto a peça importada apresentou 10,38%Si, 0,294%Mg e somente 0,12%Fe. Com a análise dos resultados, conclui-se que os principais fatores da baixa durabilidade da peça nacional foram, preponderantemente, a composição química e a morfologia do silício. / The objective of this research is to perform a comparative study of the mechanical and metallurgical properties in two castings of Al-Si alloys produced by injection under low pressure. The pieces studied refer to soil reinforcing plates used as accessory plates used to provide support during the entry and exit of the Brazilian Army combat vehicles, one national and other imported. For the metallurgical characterization, metallographic analysis by electron and optical microscopy were performed and. To obtain the mechanical properties tensile tests, Vickers microhardness and impact were performed. Regarding the metallographic results, it was observed: In the national piece, the presence of a predominantly eutectic structure with needle-shaped silicon and the Al15(Fe,Mn)3Si2 phase with Chinese writing morphology; In the imported part, dispersed silicon with a rounded shape was identified. The gas porosity analysis performed on the feed channel indicated low indexes for the two pieces.Otherwise, the presence of porosities by contraction in the national piece was observed. In the mechanical results, the imported part presented values significantly higher for the yield stress and maximum, impact energy and deformation. From the results obtained in the mechanical tests it was able to perform simulations on the Solidworks software, Simulation mode, to determine the failures occurrence when used by two battle cars: Leopard 1A5, on caterpillars, and URUTU, on wheels. The simulations indicated failure of the national part by the use of the car on wheels. The weight result of the chemical composition of the domestic part revealed an aluminum alloy with 12% Si and 0.88% Fe, while the imported piece revealed 10.38% Si, 0.294% Mg and only 0.12% Fe. Analyzing the results, it is concluded that the main factors of the low durability of the national piece were, predominantly, the chemical composition and the morphology of the silicon.

Orientador: Carlos Kiyan / Banca: Messias Borges da Silva / Banca: Luis Rogério de Oliveira Hein / Banca: Olivério Moreira de Macedo Silva / Resumo: O estudo do processamento de compósitos de matriz metálica pelo método de fundição com agitação é de grande interesse em engenharia pelo seu baixo custo e possibilidade de utilizar equipamentos convencionais de fundição. Nesse trabalho é feito o estudo do processo de síntese de compósitos da matriz da liga A356 reforçada com partículas de alumina, focalizando a influência dos fatores de processo na fração de partícula incorporada. Foram sintetizados lingotes de compósitos variando as condições de processo. Foram desenvolvidos métodos específicos de amostragem estatística associados à análise e processamento de imagens e utilizados na obtenção de estimativas confiáveis da fração volumétrica. Para investigar a influência dos fatores e suas interações foi projetado um experimento fatorial com 4 fatores, definidos em ensaios preliminares. Os resultados confirmam achados teóricos e experimentais anteriores e indicam novos caminhos para se obter uma melhor incorporação de partículas, além de um entendimento do mecanismo da molhabilidade da liga no estado semissólido. Compósitos com maior grau de partículas incorporadas foram examinados por microscópio eletrônico de varredura e microscópio óptico, mostrando que a partícula se aloja preferencialmente na região interdendrítica da matriz. / Abstract: The study of metal matrix composite processing through stir casting method is of great interest for engineering because of its low cost and possibility of using conventional casting equipment as well. The synthesis of hypoeutectic A356 matrix alloy reinforced with alumina particle was done in this work focusing the influence of the processing factors on the incorporated particle fraction. Ingots of composites were synthesized by varying the process conditions. Methods of statistic sampling connected to the analysis and processing images were developed and used for reliable estimate of volumetric fraction. To investigate the influence of the factors and their interactions, a factorial experiment was planned with four factors defined in a preliminary test. The results confirm theorical and experimental findings and points to a new way of getting better particle incorporation and an insight of the wettability mechanism. Composites with high level of particle incorporation were checked through electronic and optical microscopes showing that the particle stays mainly in interdendritic regions. / Doutor

I investigated two unique processes developed throughout this body of work. The first technique is the cracking and lifting of an electroformed layer from a core vessel form. The second process, that I named “crunch-raising”, is used to form vessels. General data is gathered through research of traditional metalsmithing processes. Using an individualized approach, new data is gathered through extensive experimentation to develop a knowledge base because specific reference information does not currently exist. I find that an electroformed layer can be lifted from a core form with extreme torch heat to reveal the underlining vessel. I also find that the “crunch-raising” technique leaves a rippled texture in the surface of a vessel as it is being formed. I conclude that the project is successful. It is quite significant in that it has given me a personal vocabulary to define my current work.

Non-traditional casting has been a controversial practice in film, television and theatre that was implemented to offer people of color and women opportunities which had previously been available to white or male performers. The following is a case study documenting the process by which I have discovered that non-traditional casting as a practice contributes to the oppression of people of color as well as supports the status quo of the white patriarchy. This case study is analyzed from the historical, sociological, psychological and philosophical theories and ideologies relevant to the unsuccessful attempt of a female actor of African-American descent at portraying a white, Evangelical, male minister. It concludes with an invitation and an approach to making better people.