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Spot Welding of Advanced High Strength Steels (AHSS)Khan, Mohammad Ibraheem 20 April 2007 (has links)
Efforts to reduce vehicle weight and improve crash performance have resulted in increased application of advanced high strength steels (AHSS) and a recent focus on the weldability of these alloys. Resistance spot welding (RSW) is the primary sheet metal welding process in the manufacture of automotive assemblies. Integration of AHSS into the automotive architecture has brought renewed challenges for achieving acceptable welds. The varying alloying content and processing techniques has further complicated this initiative. The current study examines resistance spot welding of high strength and advance high strength steels including high strength low alloy (HSLA), dual phase (DP) and a ferritic-bainitic steel (590R). The mechanical properties and microstructure of these RSW welded steel alloys are detailed. Furthermore a relationship between chemistries and hardness is produced.
The effect of strain rate on the joint strength and failure mode is also an important consideration in the design of welded structures. Current literature, however, does not explain the effects of weld microstructure and there are no comprehensive comparisons of steels. This work details the relationship between the joint microstructure and impact performance of spot welded AHSS. Quasi-static and impact tests were conducted using a universal tensile tester and an instrumented drop tower, respectively. Results for elongation, failure load and energy absorption for each material are presented. Failure modes are detailed by observing weld fracture surfaces. In addition, cross-sections of partially fractured weldments were examined to detail fracture paths during static loading. Correlations between the fracture path and mechanical properties are developed using observed microstructures in the fusion zone and heat-affected-zone.
Friction stir spot welding (FSSW) has proven to be a potential candidate for spot welding AHSS. A comparative study of RSW and FSSW on spot welding AHSS has also been completed. The objective of this work is to compare the microstructure and mechanical properties of Zn-coated DP600 AHSS (1.2mm thick) spot welds conducted using both processes. This was accomplished by examining the metallurgical cross-sections and local hardnesses of various spot weld regions. High speed data acquisition was also used to monitor process parameters and attain energy outputs for each process.
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Spot Welding of Advanced High Strength Steels (AHSS)Khan, Mohammad Ibraheem 20 April 2007 (has links)
Efforts to reduce vehicle weight and improve crash performance have resulted in increased application of advanced high strength steels (AHSS) and a recent focus on the weldability of these alloys. Resistance spot welding (RSW) is the primary sheet metal welding process in the manufacture of automotive assemblies. Integration of AHSS into the automotive architecture has brought renewed challenges for achieving acceptable welds. The varying alloying content and processing techniques has further complicated this initiative. The current study examines resistance spot welding of high strength and advance high strength steels including high strength low alloy (HSLA), dual phase (DP) and a ferritic-bainitic steel (590R). The mechanical properties and microstructure of these RSW welded steel alloys are detailed. Furthermore a relationship between chemistries and hardness is produced.
The effect of strain rate on the joint strength and failure mode is also an important consideration in the design of welded structures. Current literature, however, does not explain the effects of weld microstructure and there are no comprehensive comparisons of steels. This work details the relationship between the joint microstructure and impact performance of spot welded AHSS. Quasi-static and impact tests were conducted using a universal tensile tester and an instrumented drop tower, respectively. Results for elongation, failure load and energy absorption for each material are presented. Failure modes are detailed by observing weld fracture surfaces. In addition, cross-sections of partially fractured weldments were examined to detail fracture paths during static loading. Correlations between the fracture path and mechanical properties are developed using observed microstructures in the fusion zone and heat-affected-zone.
Friction stir spot welding (FSSW) has proven to be a potential candidate for spot welding AHSS. A comparative study of RSW and FSSW on spot welding AHSS has also been completed. The objective of this work is to compare the microstructure and mechanical properties of Zn-coated DP600 AHSS (1.2mm thick) spot welds conducted using both processes. This was accomplished by examining the metallurgical cross-sections and local hardnesses of various spot weld regions. High speed data acquisition was also used to monitor process parameters and attain energy outputs for each process.
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Estudo da substituição de aço convencional por aço de baixa liga e alta resistência (BLAR) em módulo estruturalCruz, Magnus Geder Henz 26 June 2006 (has links)
Foram estudados dois tipos de aços, aço convencional ZAR 230 (ZAR - Zincagem de alta resistência) e aço microligado ZSTE 380 (segundo norma SEW 093), sendo que foram avaliadas as suas propriedades mecânicas visando a substituição do aço convencional por aço microligado na estrutura tubular de uma carroceria para veículos de transporte coletivo de passageiros. O aço convencional vem sendo utilizado pela indústria de carrocerias há vários anos, já o aço microligado é utilizado basicamente em estruturas específicas que requeiram boas propriedades mecânicas e conseqüentemente redução de peso. A análise de viabilidade para a substituição de aço convencional por aço microligado em um módulo estrutural completo requereu uma série de ensaios: ensaios padronizados em laboratório foram executados para avaliação de suas principais propriedades mecânicas e químicas; ensaios de nós estruturais submetidos a uma carga forneceram informações para o uso em software de elementos finitos tanto para execução de cálculos estruturais, quanto para calibração de resultados. Os módulos estruturais foram preparados de acordo com as regulamentações ECE R66-00 (mercado europeu) e CONTRAN 811/96 (mercado brasileiro) e foram ensaiados exaustivamente até se obter o melhor resultado de deslocamento comparativamente aos dois materiais analisados. A validação da estrutura tubular foi obtida com a utilização do software Ansys Workbench 9.0 e a confecção de estrutura representativa de uma carroceria ensaiada conforme regulamentação CONTRAN 811/96. / Submitted by Marcelo Teixeira (mvteixeira@ucs.br) on 2014-05-05T19:51:22Z
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Dissertacao Magnus Geder Henz Cruz.pdf: 4706762 bytes, checksum: 44526b5417018356b3a33f57c828c75e (MD5) / Two kinds of steel were studied, conventional steel ZAR 230 (a standard for high strength galvanizing) and microalloyed steel ZSTE 380 (according to the regulation SEW 093). The study of its mechanical properties aimed to replace the steel for microalloyed steel in bodywork s tubular structure for collective transport vehicles of passengers. The conventional steel has been used for the bodywork industry for years, and the microalloyed steel is basically used in specific structures, those who require good mechanical properties and mass reduction. The analysis of the feasibility for the replacement of conventional steel for microalloyed steel in a complete structural model requires a series of tests. Lab tests were done to evaluate their main mechanical and chemical properties. The tests of the structural nodes and the structural behaviour when subjected to a load provided information to be used in the finite elements method software to do structural calculation and to calibrate the results. The structural modules were prepared according to the regulations ECE R66-00 (European market) and CONTRAN 811/96 (Brazilian market) and these modules were tested exhaustively to achieve the best displacement between the two materials that were analysed comparatively. The validation of the tubular structure was obtained using the software Ansys Workbench 9.0 and the production of the representative structure of a bodywork tested according the regulation CONTRAN 811/96.
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Caracterização microestrutural e mecânica em juntas soldadas por arco submerso em chapas de aço microligado API 5l x70 utilizadas em minerodutosBusso, Nicolangelo Del 01 February 2016 (has links)
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Previous issue date: 2016-02-01 / The present work investigates the possible changes that occur in the mechanical properties and microstructure of welded joints through the process of submerged arc in steel plates High Strength Low Alloy (HSLA) type API 5L X70, used in pipelines. These are usually constructed starting from calendered plates and welded through submerged arc process, forming 600 mm diameter pipes, with 12 m long. To reproduce faithfully the pipes manufacturing processes, for further characterization of test bodies were produced, welding plate supplied by USIMINAS, through the submerged arc welding, and withdrawing samples to perform the characterization of the regions of the weld metal (WM), the heat affected zone (HAZ) and the base metal (BM). Conventional tensile and Charpy V-Notch were performed to determine mechanical and impact properties of the tested materials, as well as macrograph tests and Optical microscopy (OM) and weld metal (WM), the heat affected zone (HAZ) and the base metal (BM). The metallographic examination showed banded microstructure consisting of polygonal ferrite, pearlite and bainite with small grain size. The results showed increased strength and hardness influenced by the presence of acicular ferrite. The fractography analysis after impact tests revealed ductile-brittle behavior. Impact tests were performed at temperatures of 0°C and -20°C, which exhibited significant toughness decrease, that is 260J to 202J for the BM, 106J to 81J for HAZ and 25J to 19J to the WM, while the Vickers hardness testing (HV10) was increased from the fusion zone to the base metal (194HV for WM, 202 HV for HAZ and 218 HV for BM). / O presente trabalho investiga as alterações que ocorrem nas propriedades mecânicas e na microestrutura em juntas soldadas por Arco Submerso, em chapas de aço ARBL (Alta Resistência e Baixa Liga) tipo API 5L X70, utilizadas em tubos de minerodutos. Estes são geralmente construídos a partir de chapas calandradas e soldadas de topo, pelo processo de Arco Submerso, formando tubos com diâmetro de cerca de 600mm, por 12 metros de comprimento. Objetivando reproduzir fidedignamente o processo de fabricação dos tubos, foram produzidos corpos de provas, soldando-se, pelo processo arco submerso, chapas fornecidas pela USIMINAS, e, destas foram retiradas amostras para se efetuar a caracterização das soldas, nas regiões da zona fundida (ZF), da zona termicamente afetada (ZTA), e do material base (MB). Foram efetuados os ensaios mecânicos de tração, dureza, dobramento e impacto, bem como a caracterização por macrografia e microscopias, ótica (MO) e de varredura (MEV). O exame metalográfico apresentou microestrutura bandeada, consistindo de ferrita poligonal, perlita e bainita com pequeno tamanho de grão. Os resultados obtidos mostraram o aumento da resistência mecânica e da dureza, influenciados pela presença de ferrita acicular. As análises fratográficas, após ensaios de impacto revelaram comportamento ductil-frágil. Os ensaios de impacto foram realizados às temperaturas de 0ºC e de -20ºC, onde apresentaram quedas significativas da tenacidade na região da solda, decrescendo da região do metal base (260J e 202J) para a zona termicamente afetada (106J e 81J) e para a zona fundida (25J e 19J), respectivamente, para 0ºC e -20ºC. Os resultados dos ensaios de dureza Vickers (HV10) apresentaram um ligeiro aumento da dureza, crescendo no sentido MB-ZTA-ZF (194 HV, 202 HV e 218 HV, respectivamente).
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Caracterização microestrutural do aço para tubo API 5L-X65 em diferentes regiões da chapa como laminada e após austenitização e resfriamento sob diversas taxas de resfriamento. / Microstructural characterization of a plate of microalloyed pipeline steel that conforms to API 5L X65 in different regions of the plate as rolled and after austenitization and continous cooling under different cooling rates.Paulo Henrique Ogata 14 August 2009 (has links)
Este trabalho tem por objetivo caracterizar e comparar as microestruturas de diferentes regiões de uma chapa de aço microligado para tubo API 5L X65, empregado no transporte de gás natural e petróleo, como recebido e submetido a tratamentos térmicos de austenitização e resfriamento contínuo sob diferentes taxas de resfriamento. O aço em estudo apresenta uma linha de segregação central, originada durante o processo de produção do aço. Corpos de prova de dilatometria foram usinados da região central e de outras regiões da chapa. As amostras foram previamente austenitizadas a 1200°C e temperadas em água, visando solubilizar grande parte dos precipitados presentes no aço. Após este tratamento, as amostras foram austenitizadas em um dilatômetro de têmpera a 950°C por 180s, e em seguida resfriadas nas seguintes taxas de resfriamento: 0,5°C/s, 1°C/s, 5°C/s, 10°C/s, 20°C/s, 30°C/s, 40°C/s, 50ºC/s e 60ºC/s. Valores de temperatura e tempo correspondentes a inflexões da curva dilatométrica foram obtidas e correlacionadas com a microestrutura, para cada taxa de resfriamento. Com base nesta análise foi traçado um diagrama de Transformação por Resfriamento Contínuo (TRC) do material. / This work aims to characterize and compare the microstructures of different regions of a plate of microalloyed pipeline steel that conforms to API 5L X65, employed in the transportation of natural gas and oil, as received and after being subjected to heat treatments of austenitization and continuous cooling under different cooling rates. The steel under study presents a central line of segregation that was originated during production. Specimens for dilatometry were machined from the central region and from different regions of the plate. The samples were austenitized at 1200°C and in quenched in water, with the purpose of solubilizing most of the precipitates in the steel. After the preliminary heat treatment, the specimens were austenitized at 950°C for 180s and cooled under the cooling rates: 0.5°C/s, 1°C/s, 5°C/s, 10°C/s, 20°C/s, 30°C/s, 40°C/s, 50ºC/s and 60ºC/s in a quench dilatometer. Values of temperature and time correspond of transformation for each rate of cooling were used for the determination of the Continuous Cooling Transformation (CCT) diagram.
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Estudo da substituição de aço convencional por aço de baixa liga e alta resistência (BLAR) em módulo estruturalCruz, Magnus Geder Henz 26 June 2006 (has links)
Foram estudados dois tipos de aços, aço convencional ZAR 230 (ZAR - Zincagem de alta resistência) e aço microligado ZSTE 380 (segundo norma SEW 093), sendo que foram avaliadas as suas propriedades mecânicas visando a substituição do aço convencional por aço microligado na estrutura tubular de uma carroceria para veículos de transporte coletivo de passageiros. O aço convencional vem sendo utilizado pela indústria de carrocerias há vários anos, já o aço microligado é utilizado basicamente em estruturas específicas que requeiram boas propriedades mecânicas e conseqüentemente redução de peso. A análise de viabilidade para a substituição de aço convencional por aço microligado em um módulo estrutural completo requereu uma série de ensaios: ensaios padronizados em laboratório foram executados para avaliação de suas principais propriedades mecânicas e químicas; ensaios de nós estruturais submetidos a uma carga forneceram informações para o uso em software de elementos finitos tanto para execução de cálculos estruturais, quanto para calibração de resultados. Os módulos estruturais foram preparados de acordo com as regulamentações ECE R66-00 (mercado europeu) e CONTRAN 811/96 (mercado brasileiro) e foram ensaiados exaustivamente até se obter o melhor resultado de deslocamento comparativamente aos dois materiais analisados. A validação da estrutura tubular foi obtida com a utilização do software Ansys Workbench 9.0 e a confecção de estrutura representativa de uma carroceria ensaiada conforme regulamentação CONTRAN 811/96. / Two kinds of steel were studied, conventional steel ZAR 230 (a standard for high strength galvanizing) and microalloyed steel ZSTE 380 (according to the regulation SEW 093). The study of its mechanical properties aimed to replace the steel for microalloyed steel in bodywork s tubular structure for collective transport vehicles of passengers. The conventional steel has been used for the bodywork industry for years, and the microalloyed steel is basically used in specific structures, those who require good mechanical properties and mass reduction. The analysis of the feasibility for the replacement of conventional steel for microalloyed steel in a complete structural model requires a series of tests. Lab tests were done to evaluate their main mechanical and chemical properties. The tests of the structural nodes and the structural behaviour when subjected to a load provided information to be used in the finite elements method software to do structural calculation and to calibrate the results. The structural modules were prepared according to the regulations ECE R66-00 (European market) and CONTRAN 811/96 (Brazilian market) and these modules were tested exhaustively to achieve the best displacement between the two materials that were analysed comparatively. The validation of the tubular structure was obtained using the software Ansys Workbench 9.0 and the production of the representative structure of a bodywork tested according the regulation CONTRAN 811/96.
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Atlas microestrutural para otimização de procedimentos de soldagemAmaral, Thiago de Souza 08 January 2016 (has links)
More complex and bigger structures have increased the applicability of low alloy high
strength steels due to weight and cost reductions in these projects. One of the requirements
for the use of these materials is the preservation of performance after welding. Meanwhile, the
norms on which the Welding Procedures Specifications (WPS) are based have not yet
considered the development of modern steel and its new production process, resulting in
unnecessary welding costs that diminish the profits of the application of this type of steel. This
thesis aimed to develop and evaluate an experimental methodology to guide the creation and
control of welding procedures for structural steel through a microstructural atlas of the heat
affected zone (HAZ) in a thermomechanical control process (TMCP), 65 ksi steel (ASTM A572
Grade 65). This steel was used in the project of an industrial building for CBMM in Araxá,
Minas Gerais, Brazil.
It is proposed that through a microstructural atlas of a given steel, it is possible to
determine the range of cooling rates that the steel may suffer during welding without affecting
mechanical properties and without risking cold cracks. When comparing the microstructure of
steel welds performed in field conditions, it is possible to determine the heat input range for a
given process in the preparation of a WPS.
The selected case study is from a high strength low alloy class 65 ksi steel (ASTM A572
Grade 65) that was used in the structure of an industrial building. The steel was produced
using TMCP. The atlas was created via the construction of a continuous cooling transformation
diagram using physical simulation (dilatometer and Gleeble) of the coarse grain HAZ
(GCHAZ). The characterization of the simulated region was performed by metallography and
mechanical tests. The microstructure of real welds made by a qualified WPS were compared
to the atlas in order to certify the correct use of parameters and to validate the method. The
methodology was also qualified and the potential economic benefits were quantified (based
only on the reduction of consumables used and the increased availability of the welding
process machine) for the selected industrial project.
The mapped microstructures varied from martensite (at high cooling rates) to
pearlite/ferrite with large grain size (at low cooling rates). There was remarkable prevalence of
bainitic microstructure in a wide range of cooling rates, consistent with the chemical
composition of the steel studied. Comparisons with real weld microstructures showed the atlas
is compatible with them, and that it can more accurately describe the effective thermal cycle
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that occurs in the coarse grain region of the HAZ (other regions were not included). The
application of this methodology in the development of new WPS would allow greater flexibility
in the welding procedures, including welding without preheating. In this respect alone, it was
possible to forecast savings of approximately R$200,000.00, 1,000 hours of processing and
172 tonnes of carbon equivalent emissions. / Estruturas cada vez mais complexas e de maiores dimensões vêm aumentando a
aplicabilidade de aços de baixa liga e alta resistência, devido à redução de peso e custo
dessas estruturas. Um dos requisitos para o uso desses materiais é a manutenção do
desempenho após soldagem. Entretanto, as normas em que se baseiam as Especificações
de Procedimentos de Soldagem (EPS) ainda não consideram aços mais modernos em termos
de rota de fabricação, o que pode fazer com que custos desnecessários de soldagem
minimizem os ganhos da aplicação desses aços.
Este trabalho teve como objetivo o desenvolvimento e avaliação de uma metodologia
para, experimentalmente, orientar a elaboração e o controle da aplicação de procedimentos
de soldagem para aços estruturais, através de atlas microestrutural de regiões da zona
afetada pelo calor (ZAC). Propõe-se que, através de um atlas microestrutural de um dado aço,
seja possível determinar a faixa otimizada de energia de soldagem para um dado processo
na elaboração e aplicação da EPS e, consequentemente, as velocidades de resfriamento que
o aço possa sofrer durante a soldagem, sem perder as propriedades mecânicas e sem colocálo
em risco quanto a trincas a frio.
Tomou-se como estudo de caso o aço produzido por laminação controlada de classe
de resistência de 65 ksi (ASTM A572 Grau 65), utilizado em um projeto de um prédio industrial
na empresa CBMM. Trata-se de um aço fabricado pelo processo TMCP com resfriamento
acelerado. A elaboração do Atlas se deu através da construção de um diagrama CCT, por
simulação física (dilatômetro e Gleeble), da região de grãos grosseiros da zona afetada pelo
calor (ZAC GG). Foram feitas caracterizações metalográficas e mecânicas das regiões
simuladas. Microestruturas de soldas realizadas com EPS qualificadas foram comparadas
com as do Atlas para se certificar da adequabilidade dos parâmetros utilizados e validação da
abordagem. Foram realizadas ainda a qualificação e quantificação de potenciais benefícios
econômicos no citado projeto industrial, obtidos pelo uso desta metodologia.
As microestruturas apresentadas no mapa variavam de martensíta, para altas taxas
de resfriamento, até perlita/ferrita de tamanho de grão elevado, para baixas taxas de
resfriamento. Observou-se notável predominância da microestrutura bainítica em uma larga
faixa de taxas de resfriamento, compatível com as propriedades e composição do aço
estudado (alta soldabilidade). As comparações com as microestruturas de soldas reais
mostraram que o Atlas pode descrever de forma precisa o ciclo térmico efetivamente imposto
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na ZAC GG. Concluiu-se que a aplicação desta metodologia na elaboração de novas EPS
permitiria uma maior flexibilidade nos procedimentos de soldagem, admitindo inclusive
soldagem sem pré-aquecimento. Em relação a não necessidade de pré-aquecimento, podese
prever uma economia significante de custos e redução de emissão de gases que provocam
efeito estufa. / Mestre em Engenharia Mecânica
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