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O objetivo do presente trabalho consistiu no desenvolvimento de fios de liga de cobre-cromo-zircônio (CuCrZr) em uma composição estabelecida em Cu-0,7%Cr- 0,1%Zr (em massa). Nas etapas desenvolvidas, foram feitos botões de cobrecromo (CuCr) e cobre-zircônio (CuZr) em um forno a arco elétrico de eletrodo não consumível, sendo esses botões, posteriormente, fundidos junto com cargas de cobre em um cadinho de alumina (Al2O3) inserido no interior de um vaso de aço inoxidável, que serviu como suporte. Após a fusão dos botões e cargas, o banho foi vazado em uma coquilha de cobre, obtendo-se os tarugos da liga de cobre. Dos tarugos em estado bruto de fusão, foram retiradas amostras para ensaios de dureza Vickers. Nesses tarugos foi feito um tratamento térmico de homogeneização a 910 °C por 2 h. Os tarugos foram posteriormente trabalhados mecanicamente a frio por forjamento rotativo seguido de trefilação, para obtenção final dos fios no calibre de 2,174 mm. Os fios passaram por dois tratamentos térmicos de recristalização, um a 510 °C por 1 h e outro de 480 °C por 5 h. Os fios foram caracterizados mecanicamente por ensaios de tração e de dureza e os resultados foram comparados com dados experimentais da literatura. / The objective of this work is the development of copper alloy wire-chromiumzirconium (CuCrZr) in a chemical composition Cu-0,7% Cr-0,1% Zr (weight). The main steps were, buttons were made of copper-chromium (CuCr) and copperzirconium (CuZr) in an electric arc furnace, these buttons were later melted with copper charge in a alumina crucible, placed inside a stainless steel can which served as a support. After melting buttons and charge, the bath was poured into a copper chill mold obtaining copper alloy billets. From the as cast cooper alloy billets, small samples were cut for Vickers hardness and then, a homogenizing heat treatment at 910 °C for 2 h was performed. The billets were then mechanically cold worked by swaging followed by drawing to obtain the wires with a diameter of 2,174 mm. The wires are mechanically characterized using tensile and hardness testing after recrystallization heat treatment at 510 °C for 1 h and at 480 °C for 5 h and the results were compared with experimental data from literature.

The flow pattern has widely been recognized to have an impact on the exogenous non-metallic inclusion generation in the gating system and mold flux entrapment in the uphill teeming process. Thus, a well-controlled flow pattern during the teeming process can improve the quality of ingots and further increase the yield during steel production. The current study focused on investigating and optimizing the flow pattern of steel in the gating system and molds to improve steel cleanliness during the initial filling moment. A mathematical model considering a trumpet was initially compared to a reduced model only considering part of the runner channel. Thereafter, the influence of swirl blades implemented at the bottom of the vertical runner on the improvement of initial filling conditions in the molds was investigated in a model considering the entire mold system including a trumpet. The effects of a swirl blade orientation on a swirling flow were further discussed. The simulation results, when utilizing swirl blades, were also verified by plant trials performed at Scana Steel. In addition, a new novel swirling flow generation component, TurboSwirl, was studied in a model considering the entire mold system including a trumpet. The model was based on modifications of the refractory geometry at the elbow of the runners near the mold without the usage of an inserted flow control device in the gating system. Owing to its great potential for improving the flow pattern of steel during the initial filling moment, the effect of TurboSwirl on steel cleanliness was also studied. The results showed that the initial filling conditions during the uphill teeming process can be improved by using a swirl blade or a TurboSwirl in the gating system. This makes it possible to further decrease the initial position of mold powder bags. In addition, it reduces the possibilities of exogenous non-metallic inclusion generation in the gating system as well as mold flux entrapment in the mold during the uphill teeming process. However, the utilization of swirl blades created a considerable amount of droplets when steel entered the molds during the first couple of seconds, which also was verified by the plant trials. The introduction of TurboSwirl showed a greater potential than a swirl blade due to a more evenly distributed swirling flow. The DPM model adopted in the simulations revealed that the TurboSwirl can improve steel cleanliness by increasing the non-metallic inclusion collision rate both with respect to Stokes and turbulent collisions. / <p>QC 20130204</p>

Underwater excavations of a Late Bronze Age shipwreck at Uluburun, Turkey recovered a combined 475 oxhide and plano-convex discoid copper ingots. While the hoard of ingots excavated at Uluburun brings the total number of copper ingots from the Late Bronze Age to over 1000, interestingly, only one ingot mold from the that period has been identified. Scholars have speculated over the means behind the creation of these ingots for decades, but with a relative absence of archaeological molds the most promising method of reaching any conclusions as to the types of molds used in antiquity seems to be experimentation. Experimental archaeology, has, in recent years been responsible for many breakthroughs in how the past is viewed. In the face of an overwhelming disparity of copper ingot molds from the Late Bronze Age, trials designed around testing different mold materials and casting techniques have the potential to determine, with relative certainty, how copper ingots were cast over 3000 years ago. This thesis examines the possible materials used to create copper ingot molds through a study of their prevalence in antiquity and also details experiments in which these materials were used, in concert with different casting techniques, to create copper ingots. The results of these experiments are combined with analyses of the Uluburun ingots in an effort to bring some closure to the debate surrounding copper ingot molds in the Late Bronze Age.

Este trabalho tem como objetivo avaliar o efeito do processo de agitação eletromagnética (AE) utilizado no lingotamento contínuo (LC) e nas propriedades mecânicas e metalúrgicas dos aços ABNT 1025 (com adições de manganês e silício) forjados a quente, para a confecção de flanges de tubulações industriais. As matériasprimas fornecidas foram caracterizadas através de composição química e macrografia. Compararam-se os aços provenientes de três condições de fornecimento: 1º) LC sem AE somado à laminação a quente (LQ); 2º) LC com AE; e 3º) LC sem AE. Em seguida, foram extraídos billets de seção quadrada de 120mmx120mmx58mm das três condições citadas para subsequentes forjamentos a quente e fabricação de flanges. Assim, são mostrados os resultados das propriedades obtidas e a comparação com a norma de validação ASTM A 105 (especificação padrão para forjados de aço carbono para aplicação em tubulações) utilizada nesse tipo de forjado. Através da norma, foram verificados os requisitos químicos e ensaios de tração e de dureza. As propriedades foram, também, analisadas através de metalografias (macro e micro), ensaios de impacto e ensaios não destrutivos de líquidos penetrantes. Através da teoria elementar da plasticidade, os valores requeridos para a força de forjamento da peça em estudo, durante o processo de forjamento a quente, foram estimados em caráter formativo e didático. De acordo com os fundamentos teóricos observados na revisão bibliográfica e com os resultados práticos obtidos, constatou-se a aprovação dos aços provenientes do LC com AE como alternativa aos provenientes da LQ (tradicionalmente fornecidos às forjarias) para a confecção de flanges forjados desse tipo de aço. Na análise dos forjados provenientes do LC sem AE também ocorreu a reprovação de diversos resultados, mostrando o efeito da AE como alternativa para as propriedades desse tipo de forjado. / The objective of this work is to evaluate the effect of the process of electromagnetic stirring (ES) used in continuous ingot (CI) in the mechanical and metallurgic properties of 1025 ABNT hot forged steels (with the addition of manganese and silicon) for the manufacture of flanges of industrial pipes. At first, the supplied raw materials were characterized trough chemical compound and macrograph. Then, steels from the following three supplying conditions [ 1º) CI without ES plus hot rolling (HR); 2º) CI with ES; and 3º) CI without ES] were compared. Afterwards, billets were extracted from a square section measuring 120mmx120mmx58mm, from the three previous conditions, to be hot forged and to the manufacture of connection flanges. Thus, the results from these properties and the comparison with the validation norm ASTM A 105 (standard specification for steel-carbon forgings for the application in pipes) for this type of forged are shown. Through this norm, chemical requirements, tension and hardness tests were verified. The properties were also analyzed through metallographies (macro and micro), impact tests and non-destructive tests of penetrating liquids. Through the elementary plasticity theory, the demanded values for the forging force of the studied piece, during the hot forging process, were estimated as didactic and formative natures. According to the theoretical substances observed in the bibliography and to these practical results, the steels from CI with ES were approved as an alternative to the ones from HR (traditionally supplied to forging companies) to the manufacture of forged flanges of this type of steel. Moreover, in the analysis of forgings from CI without ES, the disapproval of various results also occurred, showing the effect of ES as an alternative to the properties of this type of forging.

Este trabalho tem como objetivo avaliar o efeito do processo de agitação eletromagnética (AE) utilizado no lingotamento contínuo (LC) e nas propriedades mecânicas e metalúrgicas dos aços ABNT 1025 (com adições de manganês e silício) forjados a quente, para a confecção de flanges de tubulações industriais. As matériasprimas fornecidas foram caracterizadas através de composição química e macrografia. Compararam-se os aços provenientes de três condições de fornecimento: 1º) LC sem AE somado à laminação a quente (LQ); 2º) LC com AE; e 3º) LC sem AE. Em seguida, foram extraídos billets de seção quadrada de 120mmx120mmx58mm das três condições citadas para subsequentes forjamentos a quente e fabricação de flanges. Assim, são mostrados os resultados das propriedades obtidas e a comparação com a norma de validação ASTM A 105 (especificação padrão para forjados de aço carbono para aplicação em tubulações) utilizada nesse tipo de forjado. Através da norma, foram verificados os requisitos químicos e ensaios de tração e de dureza. As propriedades foram, também, analisadas através de metalografias (macro e micro), ensaios de impacto e ensaios não destrutivos de líquidos penetrantes. Através da teoria elementar da plasticidade, os valores requeridos para a força de forjamento da peça em estudo, durante o processo de forjamento a quente, foram estimados em caráter formativo e didático. De acordo com os fundamentos teóricos observados na revisão bibliográfica e com os resultados práticos obtidos, constatou-se a aprovação dos aços provenientes do LC com AE como alternativa aos provenientes da LQ (tradicionalmente fornecidos às forjarias) para a confecção de flanges forjados desse tipo de aço. Na análise dos forjados provenientes do LC sem AE também ocorreu a reprovação de diversos resultados, mostrando o efeito da AE como alternativa para as propriedades desse tipo de forjado. / The objective of this work is to evaluate the effect of the process of electromagnetic stirring (ES) used in continuous ingot (CI) in the mechanical and metallurgic properties of 1025 ABNT hot forged steels (with the addition of manganese and silicon) for the manufacture of flanges of industrial pipes. At first, the supplied raw materials were characterized trough chemical compound and macrograph. Then, steels from the following three supplying conditions [ 1º) CI without ES plus hot rolling (HR); 2º) CI with ES; and 3º) CI without ES] were compared. Afterwards, billets were extracted from a square section measuring 120mmx120mmx58mm, from the three previous conditions, to be hot forged and to the manufacture of connection flanges. Thus, the results from these properties and the comparison with the validation norm ASTM A 105 (standard specification for steel-carbon forgings for the application in pipes) for this type of forged are shown. Through this norm, chemical requirements, tension and hardness tests were verified. The properties were also analyzed through metallographies (macro and micro), impact tests and non-destructive tests of penetrating liquids. Through the elementary plasticity theory, the demanded values for the forging force of the studied piece, during the hot forging process, were estimated as didactic and formative natures. According to the theoretical substances observed in the bibliography and to these practical results, the steels from CI with ES were approved as an alternative to the ones from HR (traditionally supplied to forging companies) to the manufacture of forged flanges of this type of steel. Moreover, in the analysis of forgings from CI without ES, the disapproval of various results also occurred, showing the effect of ES as an alternative to the properties of this type of forging.

O objetivo do presente trabalho consistiu no desenvolvimento de fios de liga de cobre-cromo-zircônio (CuCrZr) em uma composição estabelecida em Cu-0,7%Cr- 0,1%Zr (em massa). Nas etapas desenvolvidas, foram feitos botões de cobrecromo (CuCr) e cobre-zircônio (CuZr) em um forno a arco elétrico de eletrodo não consumível, sendo esses botões, posteriormente, fundidos junto com cargas de cobre em um cadinho de alumina (Al2O3) inserido no interior de um vaso de aço inoxidável, que serviu como suporte. Após a fusão dos botões e cargas, o banho foi vazado em uma coquilha de cobre, obtendo-se os tarugos da liga de cobre. Dos tarugos em estado bruto de fusão, foram retiradas amostras para ensaios de dureza Vickers. Nesses tarugos foi feito um tratamento térmico de homogeneização a 910 °C por 2 h. Os tarugos foram posteriormente trabalhados mecanicamente a frio por forjamento rotativo seguido de trefilação, para obtenção final dos fios no calibre de 2,174 mm. Os fios passaram por dois tratamentos térmicos de recristalização, um a 510 °C por 1 h e outro de 480 °C por 5 h. Os fios foram caracterizados mecanicamente por ensaios de tração e de dureza e os resultados foram comparados com dados experimentais da literatura. / The objective of this work is the development of copper alloy wire-chromiumzirconium (CuCrZr) in a chemical composition Cu-0,7% Cr-0,1% Zr (weight). The main steps were, buttons were made of copper-chromium (CuCr) and copperzirconium (CuZr) in an electric arc furnace, these buttons were later melted with copper charge in a alumina crucible, placed inside a stainless steel can which served as a support. After melting buttons and charge, the bath was poured into a copper chill mold obtaining copper alloy billets. From the as cast cooper alloy billets, small samples were cut for Vickers hardness and then, a homogenizing heat treatment at 910 °C for 2 h was performed. The billets were then mechanically cold worked by swaging followed by drawing to obtain the wires with a diameter of 2,174 mm. The wires are mechanically characterized using tensile and hardness testing after recrystallization heat treatment at 510 °C for 1 h and at 480 °C for 5 h and the results were compared with experimental data from literature.

Este trabalho tem como objetivo avaliar o efeito do processo de agitação eletromagnética (AE) utilizado no lingotamento contínuo (LC) e nas propriedades mecânicas e metalúrgicas dos aços ABNT 1025 (com adições de manganês e silício) forjados a quente, para a confecção de flanges de tubulações industriais. As matériasprimas fornecidas foram caracterizadas através de composição química e macrografia. Compararam-se os aços provenientes de três condições de fornecimento: 1º) LC sem AE somado à laminação a quente (LQ); 2º) LC com AE; e 3º) LC sem AE. Em seguida, foram extraídos billets de seção quadrada de 120mmx120mmx58mm das três condições citadas para subsequentes forjamentos a quente e fabricação de flanges. Assim, são mostrados os resultados das propriedades obtidas e a comparação com a norma de validação ASTM A 105 (especificação padrão para forjados de aço carbono para aplicação em tubulações) utilizada nesse tipo de forjado. Através da norma, foram verificados os requisitos químicos e ensaios de tração e de dureza. As propriedades foram, também, analisadas através de metalografias (macro e micro), ensaios de impacto e ensaios não destrutivos de líquidos penetrantes. Através da teoria elementar da plasticidade, os valores requeridos para a força de forjamento da peça em estudo, durante o processo de forjamento a quente, foram estimados em caráter formativo e didático. De acordo com os fundamentos teóricos observados na revisão bibliográfica e com os resultados práticos obtidos, constatou-se a aprovação dos aços provenientes do LC com AE como alternativa aos provenientes da LQ (tradicionalmente fornecidos às forjarias) para a confecção de flanges forjados desse tipo de aço. Na análise dos forjados provenientes do LC sem AE também ocorreu a reprovação de diversos resultados, mostrando o efeito da AE como alternativa para as propriedades desse tipo de forjado. / The objective of this work is to evaluate the effect of the process of electromagnetic stirring (ES) used in continuous ingot (CI) in the mechanical and metallurgic properties of 1025 ABNT hot forged steels (with the addition of manganese and silicon) for the manufacture of flanges of industrial pipes. At first, the supplied raw materials were characterized trough chemical compound and macrograph. Then, steels from the following three supplying conditions [ 1º) CI without ES plus hot rolling (HR); 2º) CI with ES; and 3º) CI without ES] were compared. Afterwards, billets were extracted from a square section measuring 120mmx120mmx58mm, from the three previous conditions, to be hot forged and to the manufacture of connection flanges. Thus, the results from these properties and the comparison with the validation norm ASTM A 105 (standard specification for steel-carbon forgings for the application in pipes) for this type of forged are shown. Through this norm, chemical requirements, tension and hardness tests were verified. The properties were also analyzed through metallographies (macro and micro), impact tests and non-destructive tests of penetrating liquids. Through the elementary plasticity theory, the demanded values for the forging force of the studied piece, during the hot forging process, were estimated as didactic and formative natures. According to the theoretical substances observed in the bibliography and to these practical results, the steels from CI with ES were approved as an alternative to the ones from HR (traditionally supplied to forging companies) to the manufacture of forged flanges of this type of steel. Moreover, in the analysis of forgings from CI without ES, the disapproval of various results also occurred, showing the effect of ES as an alternative to the properties of this type of forging.

If these macro inclusions are not detected before the material is put in used, its mechanical properties are greatly affected and this can lead to outrageous consequences in the engineering application.

The purpose of this thesis has been to evaluate the use of a swirl blade in the uphill teeming process through plant trials. Two series of trials were carried out at Scana Steel Stavanger AS. In the trials a divergent entrance nozzle with a 62° outlet angle were used when casting duplex stainless steel on a base plate with two 6.2 tons ingots. All molds were burned onto the ingots; leading to problems with emptying the ingots from the molds and severe damages on the molds. To get a better insight during the casting and understand why the molds were burned onto the ingots; during the second series of trials one mold on each base plate were filmed in the beginning of the casting process. Evaluation of the castings indicated that splashing on the mold wall at an initial stage was one reason for the mold burned onto the ingot. Further, material samples were collected to evaluate the non-metallic inclusion composition and distribution with SEM when casting with a swirl blade compared to when casting without. The area percentage of the inclusions in the samples was 1% and 2% for samples casted with and without swirl blade respectively with d=2.8 mm. The inclusion size also varied for samples casted with and without swirl blade; 98% of the inclusions were in the size range of 0-10 μm when casted with and in the size range 0-20 μm when casted without swirl blade. / Syftet med denna uppsats har varit att utvärdera användningen av swirlblad i götgjutningsprocessen. Två serier med försök har utförts på Scana Steel Stavanger AS. I försöken användes en inloppssten med 62°-vinklat utlopp, där duplexa rostfria stål göts på stigplan med två 6,2 tons kokiller. Alla kokiller brände fast på göten, vilket ledde till svårigheter vid urtag av göten samt skador på kokillerna. För att få en bättre förståelse av varför kokillerna brände fast, filmades ett göt på vardera stigplan under den andra försöksserien. Utvärdering av försöken indikerar att en anledning till att kokillerna brände fast på göten var att det stänkte upp stål på kokillväggen i ett tidigt stadium. Vidare har materialprover samlats in för att utvärdera sammansättningen samt utspridningen av icke-metalliska inneslutningar i SEM då göt gjutits med swirlblad jämfört med utan. Area procenten i proverna var 1% och 2% då proverna gjutits med respektive utan swirlblad, med d=2.8 mm. Även storleken på inneslutningarna i prover som gjutits med och utan swirlblad skiljde sig åt, 98% av inneslutningarna var i storleksintervallet 0-10 μm för prover gjutna med swirlblad medan de som gjutits utan var i storleksintervallet 0-20 μm. / JK24053