This work aims to investigate the effects of current density, electrolyte temperature and substrate composition on the morphology of porous anodic films formed on AA 2024-T3 alloy in sulphuric acid electrolytes and the factors that determine the transition between linear and sponge-like film porosities. Comparisons were made with pure aluminium. Particular attention is given to understanding the rising voltage that occurs during galvanostatic hard anodizing of the alloy and the role of oxygen in the anodizing process. Conditions were selected to be representative of typical hard and conventional anodizing processes. SEM was employed to observe the film morphology, which was then correlated with the voltage-time responses. The anodic film composition was investigated by TEM/EDX and SEM/EDX to determine the effect of alloy element enrichment and cell diameter on the distribution of copper species in the film. A real-time gravimetric method was developed to measure the rate of oxygen evolution during anodizing and its influence on the anodizing voltage and film morphology. Results showed that hard anodic films on AA 2024-T3 alloy formed at relatively high voltages have linear pores and cells, contrasting with sponge-like porosity under conventional anodizing. The linear porosity is shown to depend on the voltage, with a morphological transition occurring in the range 25 to 30 V, with linear cells promoted by a high current density and/or low electrolyte temperature. As the film thickens with time, pore blockage by oxygen bubbles, impedes oxidation of the alloy leading to current re-distribution and hence localized increases in the current density producing a rise of the anodizing voltage as anodizing proceeds. The rise of the anodizing voltage, which leads to an increasing call diameter and barrier layer thickness, has a minor influence on the rate of oxygen evolution, which typically consumes about 20 % of the applied current density. In contrast, the voltage rise in the presence of sponge-like films is comparatively negligible, which is suggested to be due to easier escape of oxygen from the film. The films comprising linear cells contain more copper than the sponge-like films, with copper being enriched at the cell boundaries. Moreover, a model is proposed to explain the enrichment of copper, suggesting that above a critical cell diameter, an alloy enrichment sufficient for oxidation of the alloying element can be maintained across the alloy/film interface. Below this diameter, the enrichment is less than that necessary for oxidation, and the alloying element is then incorporated into the film at the cell boundaries.

The content of this thesis deals with the manufacturing of the prototyped series of low friction ring, proposing of the serial production and economical and technical evaluation. This thesis also solves the surfacing of low friction rings and testing. The thesis is devided into two main parts. First part deals with selection of material, tools and process of manufacturing low friction ring. Second part concerns surfacing and after testing. The thesis ends with economic and technical evaluation.

Made available in DSpace on 2014-12-17T14:57:41Z (GMT). No. of bitstreams: 1 JoseFTJ.pdf: 1695651 bytes, checksum: 0a95ed624ef6e5342ad90e1b6193878e (MD5) Previous issue date: 2007-12-17 / This a study on the achievement of alumina membranes by the method of anodizing. From this method got up a layer of aluminum oxide on the anodic metal, who presented the basic properties necessary for the application as a support for the production and acquisition of nanomaterials, such as porosity nano and resistance to high temperature, and other properties, as resistance to corrosion, and chemical, high ranking of the structure and pore size of the pores. The latter, ranging from 10 to 100nm depended on the electrolyte used, which in this study was the H2SO4. To remove all remaining aluminum, it is a bath of dissolution with HCl and CuCl where the residual aluminum has been withdrawn, and the deep pores were opened after chemical treatment with NaOH. After the dissolution, the membranes were calcined at temperatures of 300, 600 and 900? C, and sintered at temperatures of 1200 and 1300? C to win mechanical strength, porosity and observe the desired crystallization. Then went through analyses of composition through X-ray diffraction and morphology of the microstructure through a scanning electron microscope. The method was effective for obtaining alumine membranes applied in the processes of production of materials in nano / Trata de um estudo sobre a obten??o de membranas de alumina atrav?s do m?todo da anodiza??o. A partir deste m?todo obteve-se uma camada de ?xido an?dico sobre o alum?nio met?lico, que apresentou as propriedades b?sicas necess?rias ? aplica??o como suporte para produ??o e obten??o de nanomateriais, tais como: porosidade nanom?trica e resist?ncia a altas temperaturas, al?m de outras propriedades, como resist?ncia ? corros?o, e qu?mica, alta ordena??o da estrutura dos poros e tamanho dos poros. Este ?ltimo, variando de 10 at? 100nm dependeu do eletr?lito usado, o qual neste estudo foi o H2SO4. Para retirar todo alum?nio restante, procedeu-se um banho de dissolu??o com HCl e CuCl no qual o alum?nio residual foi retirado, e os poros profundos foram abertos ap?s o tratamento qu?mico com NaOH. Ap?s a dissolu??o, as membranas foram calcinadas nas temperaturas de 300, 600 e 900? C, e sinterizadas nas temperaturas de 1200 e 1300? C para ganhar resist?ncia mec?nica, porosidade desejada e observar a cristaliza??o. Em seguida passou por an?lises de composi??o atrav?s da Difra??o de Raios-X e morfologia da microestrutura por meio de um microsc?pio eletr?nico de varredura. O m?todo se mostrou eficiente para obten??o de membranas de alumina aplicadas nos processos de produ??o de materiais em escala nanom?trica

Das Ziel dieser Dissertation besteht darin, einen Beitrag zur technologischen, ökonomischen und ökologischen Weiterentwicklung der anodischen Verfahren zur Oberflächenkeramisierung von Aluminium zu leisten. Die Arbeit ist in zwei thematische Schwerpunkte untergliedert. Im ersten Teil wird für die Hartanodisation eine hinsichtlich eines geringeren Energieeinsatzes optimierte Elektrolytzusammensetzung identifiziert und mit einem optimierten galvanostatischen Pulsmuster simultan appliziert. Im Ergebnis kann die Gesamtleistungsaufnahme um ca. 6 % reduziert werden, ohne die mechanischen Eigenschaften der Oxidschichten zu mindern. Im zweiten Schwerpunkt werden das Lichtbogen- und das Flammspritzen mit der plasmaelektrolytischen anodischen Oxidation kombiniert, um verschleißbeständige Aluminiumoxidschichten auf Stahl-, Titan- und Magnesiumsubstraten zu applizieren. Neben einer umfangreichen Mikrostrukturanalyse (REM, EDX, XRD, EBSD) werden die mechanischen Eigenschaften der Schichten untersucht und mit atmosphärisch plasmagespritzten Al2O3-Schichten verglichen. Insbesondere Oxidschichten auf lichtbogengespritztem AlCu4Mg1 zeigen dabei eine hohe Härte sowie eine sehr gute Verschleißbeständigkeit. / The aim of the present work is to contribute to the technological, economic and ecological improvement of the anodic processes for the surface ceramization of aluminum. The work is subdivided into two thematic priorities. In the first part, for the hard anodizing process an optimized electrolyte composition for a lower energy input is identified and applied simultaneously with an optimized galvanostatic pulse regime. As a result, the total power consumption can be reduced by approximately 6% without reducing the mechanical properties of the oxide coatings. In the second focus, arc and flame spraying are combined with plasma electrolytic anodic oxidation to apply wear resistant aluminum oxide coatings on steel, titanium and magnesium substrates. In addition to a comprehensive microstructural analysis (SEM, EDX, XRD, EBSD), the mechanical properties of the layers are investigated and compared with atmospheric plasma sprayed Al2O3 coatings. In particular, oxide layers formed on arc sprayed AlCu4Mg1 coatings show a high hardness as well as very good wear resistance.

Das Ziel dieser Dissertation besteht darin, einen Beitrag zur technologischen, ökonomischen und ökologischen Weiterentwicklung der anodischen Verfahren zur Oberflächenkeramisierung von Aluminium zu leisten. Die Arbeit ist in zwei thematische Schwerpunkte untergliedert. Im ersten Teil wird für die Hartanodisation eine hinsichtlich eines geringeren Energieeinsatzes optimierte Elektrolytzusammensetzung identifiziert und mit einem optimierten galvanostatischen Pulsmuster simultan appliziert. Im Ergebnis kann die Gesamtleistungsaufnahme um ca. 6 % reduziert werden, ohne die mechanischen Eigenschaften der Oxidschichten zu mindern. Im zweiten Schwerpunkt werden das Lichtbogen- und das Flammspritzen mit der plasmaelektrolytischen anodischen Oxidation kombiniert, um verschleißbeständige Aluminiumoxidschichten auf Stahl-, Titan- und Magnesiumsubstraten zu applizieren. Neben einer umfangreichen Mikrostrukturanalyse (REM, EDX, XRD, EBSD) werden die mechanischen Eigenschaften der Schichten untersucht und mit atmosphärisch plasmagespritzten Al2O3-Schichten verglichen. Insbesondere Oxidschichten auf lichtbogengespritztem AlCu4Mg1 zeigen dabei eine hohe Härte sowie eine sehr gute Verschleißbeständigkeit. / The aim of the present work is to contribute to the technological, economic and ecological improvement of the anodic processes for the surface ceramization of aluminum. The work is subdivided into two thematic priorities. In the first part, for the hard anodizing process an optimized electrolyte composition for a lower energy input is identified and applied simultaneously with an optimized galvanostatic pulse regime. As a result, the total power consumption can be reduced by approximately 6% without reducing the mechanical properties of the oxide coatings. In the second focus, arc and flame spraying are combined with plasma electrolytic anodic oxidation to apply wear resistant aluminum oxide coatings on steel, titanium and magnesium substrates. In addition to a comprehensive microstructural analysis (SEM, EDX, XRD, EBSD), the mechanical properties of the layers are investigated and compared with atmospheric plasma sprayed Al2O3 coatings. In particular, oxide layers formed on arc sprayed AlCu4Mg1 coatings show a high hardness as well as very good wear resistance.