Esta dissertação apresenta um estudo da modelagem de experimentos aplicados a um processo industrial de tratamento térmico. A motivação deste trabalho surgiu diante das dificuldades associadas aos processos de recozimento industrial de aços do tipo baixa liga, na tentativa de encontrar temperaturas nas quais as durezas superficiais dos aços atingissem valores suficientemente baixos, adequados para etapas posteriores de fabricação, em especial a usinagem. Inicialmente forem realizados diversos experimentos com diferentes aços, onde a dureza superficial é obtida em função da temperatura de recozimento e dos teores de carbono e silício das amostras utilizadas. Em seguida propôs-se um modelo quadrático para modelar a dureza superficial como função dessas três variáveis. A estimação de parâmetros do modelo proposto foi realizada com o emprego do algoritmo Simulated Annealing, uma meta-heurística para otimização global que procura imitar o processo de recozimento de um material sólido. Finalmente, usando-se o modelo proposto, foi resolvido o chamado problema inverso, o qual consiste na estimação da temperatura de recozimento em função dos teores de carbono e silício e da dureza desejada. / This dissertation presents a study for experiments modeling applied for a heat treatment industrial process. The driving force to this work have raised from usual difficulties while low-alloy steels annealing industrial processes get on, trying to find out temperatures which the superficial hardness measurements reaches low values enough and suitable for the following stages, in special focus, the machining. At the first time, some experiments have been done with several steel grades, where superficial hardness is achieved as a function by annealing temperature, percent carbon content and percent silicon content of the samples. There was purposed a quadratic model for modeling the hardness as a function of that three parameters. The parameter estimation of the purposed model was done by the simulated annealing algorithm, a metaheuristic for global optimization which can be as the same as annealing of a solid material. Starting at the purposed model, the inverse problem was solved, where the estimated annealing temperature was achieved by the carbon and silicon percent contents and the suitable hardness.

Esta dissertação apresenta um estudo da modelagem de experimentos aplicados a um processo industrial de tratamento térmico. A motivação deste trabalho surgiu diante das dificuldades associadas aos processos de recozimento industrial de aços do tipo baixa liga, na tentativa de encontrar temperaturas nas quais as durezas superficiais dos aços atingissem valores suficientemente baixos, adequados para etapas posteriores de fabricação, em especial a usinagem. Inicialmente forem realizados diversos experimentos com diferentes aços, onde a dureza superficial é obtida em função da temperatura de recozimento e dos teores de carbono e silício das amostras utilizadas. Em seguida propôs-se um modelo quadrático para modelar a dureza superficial como função dessas três variáveis. A estimação de parâmetros do modelo proposto foi realizada com o emprego do algoritmo Simulated Annealing, uma meta-heurística para otimização global que procura imitar o processo de recozimento de um material sólido. Finalmente, usando-se o modelo proposto, foi resolvido o chamado problema inverso, o qual consiste na estimação da temperatura de recozimento em função dos teores de carbono e silício e da dureza desejada. / This dissertation presents a study for experiments modeling applied for a heat treatment industrial process. The driving force to this work have raised from usual difficulties while low-alloy steels annealing industrial processes get on, trying to find out temperatures which the superficial hardness measurements reaches low values enough and suitable for the following stages, in special focus, the machining. At the first time, some experiments have been done with several steel grades, where superficial hardness is achieved as a function by annealing temperature, percent carbon content and percent silicon content of the samples. There was purposed a quadratic model for modeling the hardness as a function of that three parameters. The parameter estimation of the purposed model was done by the simulated annealing algorithm, a metaheuristic for global optimization which can be as the same as annealing of a solid material. Starting at the purposed model, the inverse problem was solved, where the estimated annealing temperature was achieved by the carbon and silicon percent contents and the suitable hardness.

O presente trabalho avalia e compara os resultados da tenacidade à fratura da zona termicamente afetada (ZTA) de soldas múltiplos passes por meio de ensaios de CTOD. Para este estudo, foi utilizado um aço alta resistência e baixa liga (ARBL) resistente à corrosão ambiental. As soldas foram realizadas com insumo de calor de 30 e 50 kJ/cm em um chanfro 1/2 K. Os resultados dos ensaios de CTOD mostraram que a solda produzida com maior insumo de calor apresenta tenacidade à fratura mais elevada. A análise microestrutural revelou que as microestruturas de elevada dureza e baixa tenacidade, formadas na ZTA de granulação grosseira, para a condição de 30 kJ/cm, deram lugar às microestruturas de tenacidade mais elevada, para o insumo de calor de 50 kJ/cm. / In this work the fracture toughness results of the heat affected zone (HAZ) in a multiple pass welds using a crack tip opening displacement (CTOD) concept were evaluated and compared. It was used an ambiental resistent high strengh low alloy steel. The welds were carried out using a heat input of 30 and 50 kJ/cm in a bevel preparation 1/2 K. The results of CTOD testing showed that increasing heat input, caused an improvement in the weldments fracture toughness. Microstructural analysis revealed that the high hardness and low toughness microstructures formed at coarse grain HAZ, near fusion line, for welding condition 30 kJ/cm were changed to higher toughness microstructure using a heat input of 50 kJ/cm.

Les manilles utilisées pour l'assemblage et l'amarrage des plates-formes pétrolières nécessitent des propriétés mécaniques de plus en plus élevées. Mais les défauts de fabrication de ces manilles, responsables de leur rupture prématurée, engendrent des coûts d'intervention très élevés. Afin de comprendre et d'anticiper ces défauts de fabrication, trois outils numériques ont été développés permettant de simuler (i) le procédé de fabrication, (ii) le traitement thermique et (iii) le chargement mécanique de la manille. Le procédé de fabrication des manilles est constitué d'une succession de différentes étapes de forgeage à chaud et a été caractérisé avec des mesures de température, géométrie et efforts durant toutes les étapes. Un modèle numérique thermo- mécanique du procédé de fabrication a été développé en 3D et permet de prédire tous les paramètres de forge. Une étude numérique d'influence de certains paramètres du procédé a permis de comprendre les différentes causes de mise au rebut. Des mesures de température, des observations métallographiques au microscope et au MEB ainsi que des essais mécaniques ont été effectués sur des lopins après différents cycles de traitement thermique. Un modèle numérique de traitement thermique a été développé en 1D et permet de simuler les changements de phases pendant la normalisation et la trempe, et ainsi d'obtenir la dureté résultante en tout point du lopin. Finalement, une cartographie des propriétés mécaniques d'une manille a été obtenue et les modes de déformation de la manille en condition de chargement ont été évalués par le biais d'un essai de tension sur banc. Le modèle numérique de la manille sous tension a été développé en 3D et permet d'évaluer la charge maximale en service, la charge à rupture ainsi que la zone critique de la manille étudiée / Shackles used for the assembly or the mooring of petroleum platforms require constantly higher mechanical properties. But the manufacturing defects often lead to premature failure which can cost 1M€/day. Thus, in order to understand and anticipate those manufacturing defects, three numerical tools have been developed to simulate (i) the manufacturing process, (ii) the heat treatment and (iii) the mechanical behavior of the shackle. A shackle is manufactured via a sequence of hot forming stages and the manufacturing process has been characterized during all the stages, with measures of temperature, geometry and loads. The numerical thermo-mechanical model has been developed in 3D and gives a very good prediction of each forging parameters. A numerical study of influence of some process parameters has led to a better understanding of scrapping. Temperature measurements, metallographic observations as well as mechanical testing have been carried out on cylindrical rods after various heat treatment cycles. The numerical heat treatment model has been developed in 1D and predicts phase transformations during normalizing and quenching, as well as the hardness at each point of the rod. Finally, the distribution of the mechanical properties over a shackle has been characterized and the deformation modes of the shackle were evaluated via a load test on a dedicated bench. The numerical model of the shackle under tension has been developed in 3D and allows to evaluate the working load limit, the break load as well as the critical zone of the shackle.

Atlas Copco Secoroc AB are searching after new bulk materials for drill heads that are used in percussive drilling in order to improve their strength and durability. The aim of this project is to assist Atlas Copco in this search and provide them with further information regarding material properties, alloying elements, suppliers, etc. A literary study was carried out in order to identify materials that had UTS and KIC more than or equal to 1700 MPa and 70 MPa*m^1/2, respectively. Materials that fulfilled these criteria were T250 grade maraging steel, Cobalt free maraging steel, High cobalt maraging steel, 300 grade maraging steel, AerMet 100, AF1410, S53, M54, 300M, 4340M and PremoMet. These were categorized into maraging steels, high alloy secondary hardened steels, and low alloy steels, and were then further researched. The material with the highest combination of UTS and KIC was M54 followed by AerMet 100; while AF1410 had the highest KIC but a low UTS, and PremoMet had the highest UTS but a low KIC. Maraging steels and HASH steels have a similar price range, while low alloy steels are much cheaper.

京都大学 / 新制・課程博士 / 博士(工学) / 甲第23507号 / 工博第4919号 / 新制||工||1768(附属図書館) / 京都大学大学院工学研究科材料工学専攻 / (主査)教授 辻 伸泰, 教授 安田 秀幸, 教授 奥田 浩司 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

The present study focuses on developing a relationship between process variables, mechanical properties and post weld microstructure in Friction Stir Welded HSLA 65 steel. Fully consolidated welds can be produced in HSLA 65 steel by PCBN Convex-Scrolled-Shoulder-Step-Spiral (CS4) tool over a wide range of parameters. Microstructures in the nugget center (NC) are dominated by lath bainite and a few polygonal/allotriomorphic grain boundary ferrites. FSW dependent variables are related to FSW independent variables by non-linear relationship. Heat input is identified to be the best parameter index to correlate with microstructures. With increasing heat input, the volume of bainite is reduced, the shape of bainite is more curved and grain/lath size become coarser. A linear relationship was established between heat input and semi-quantitative post-weld microstructures based on the optical microstructures. Further analysis has been applied on the NC to obtain more fundamental understanding of FSW. The new approach via Orientation Imaging Microscopy (OIM) was developed to acquire quantitative microstructural data including bainite lath/packet and prior austenite grain size (PAG). A linear relationship between heat input and quantitative microstructural features in the NC have been established. Mechanical properties exhibits linear relationship with heat input. These correlations can be utilized to determine FSW weld parameter to get desired mechanical properties welds.

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No description available.

Ageing of low alloy steel in nuclear applications commonly takes the form as a hardening and an embrittlement of the material. This is due to the evolution of the microstructure during irradiation and at purely thermal conditions, as a combination or separate. Irradiation introduces evenly distributed solute clusters, while thermal ageing has been shown to yield a more inhomogeneous distribution. These clusters affect the dislocation motion within the material and results in a hardening and in more severe cases of ageing, also a decreased work hardening slope due to plastic strain localization into bands/channels. Embrittlement corresponds to decreased fracture toughness due to microstructural changes resulting from ageing. The thesis presents a possible framework for modeling of ageing effects in low alloy steels.In Paper I, a strain gradient plasticity framework is applied in order to capture length scale effects. The constitutive length scale is assumed to be related to the dislocation mean free path and the changes this undergoes during plastic deformation. Several evolution laws for the length scale were developed and implemented in a FEM-code considering 2D plane strain. This was used to solve a test problem of pure bending in order to investigate the effects of the length scale evolution. As all length scale evolution laws considered in this study results in a decreasing length scale; this leads to a loss of non-locality which causes an overall softening at cases where the strain gradient is dominating the solution. The results are in tentative agreement with phenomena of strain localization that is occurring in highly irradiated materials.In Paper II, the scalar stress measure for cleavage fracture is developed and generalized, here called the effective normal stress measure. This is used in a non-local weakest link model which is applied to two datasets from the literature in order to study the effects of the effective normal stress measure, as well as new experiments considering four-point bending of specimens containing a semi-elliptical surface crack. The model is shown to reproduce the failure probability of all considered datasets, i.e. well capable of transferring toughness information between different geometries. / Åldring av låglegerade stål i kärntekniska användningsområden framträder typiskt som ett hårdnande och en försprödning av materialet. Detta på grund av utvecklingen av mikrostrukturen under bestrålning och under rent termiska förhållanden. Bestrålning introducerar jämt fördelade kluster av legeringsämnen. Termisk åldring har däremot visats ge upphov till en mer ojämn fördelning. Klustren hämmar dislokationsrörelsen i materialet och ger därigenom upphov till en ökning av materialets sträckgräns, vid en mer påtaglig åldring det även leda till ett sänkt arbetshårdnande på grund av lokalisering av plastisk töjning i s.k. kanaler/band. Försprödning är en sänkning av materialets brottseghet som en följd av de mikrostrukturella förändringar som sker vid åldring. Arbetet som presenteras i den här avhandlingen har gjorts i syfte till att ta fram ett möjligt ramverk för modellering av låglegerade stål.I Artikel I, används en töjningsgradientbaserad plasticitetsteori för att kunna fånga längdskalebeteenden. Längdskalan i teorin antas vara relaterad till dislokationernas medelfria väg och den förändring den genomgår vid plastisk deformation. Flera utvecklingslagar för längdskalan har analyserats och implementerats i en finita element kod för 2D plan deformation. Denna implementering har använts för att lösa ett testproblem bestående av ren böjning med syfte att undersöka effekterna av utvecklingen hos längdskalan. Alla de utvecklingslagar som presenteras i artikeln ger en minskande längdskala, vilket leder till vad som valt att kallas förlust av icke-lokalitet. Fenomenet leder till ett övergripande mjuknande vid fall där den plastiska töjningsgradienten har stor inverkan på lösningen. Resultaten är i preliminär överenstämmelse med de typer av lokalisering av plastisk töjning som observerats i starkt bestrålade material.I Artikel II utvecklas ett generaliserat spänningsmått i syfte att beskriva klyvbrott, här benämnt effektivt normalspänningsmått. Detta har använts i samband med en icke-lokal svagaste länk modell, som har applicerats på två experimentella studier från den öppna litteraturen i syfte att studera effekterna av det effektiva normalspänningsmåttet. Utöver detta presenteras även nya experiment på ytspruckna provstavar under fyrpunktsböj. I artikeln visas att modellen återskapar sannolikheten för brott för alla undersökta experimentuppställningar, d.v.s. modellen visas vara väl duglig för att överföra brottseghet mellan geometrier. / <p>QC 20190312</p>