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 xi 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 ix 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

Le travail mené dans le cadre de cette thèse porte sur l’évaluation de la sensibilité à la fissuration assistée par l’environnement (FAE) d’aciers mis en œuvre pour le stockage géologique profond des déchets radioactifs selon un concept multi-barrières. On s’intéresse ici aux aciers faiblement alliés du conteneur et du chemisage qui seront placés dans des micro-tunnels creusés dans la roche à 500 mètres de profondeur. Le concept actuel prévoit un matériau de remplissage cimentaire entre l’argile et le chemisage afin de neutraliser l’acidité potentielle issue de la re-saturation en eau de la roche après le forage. Malgré la présence d’un milieu peu agressif (pH proche de la neutralité, faible teneur en carbonate), le choix des aciers a été dicté par leur sensibilité à la corrosion et à la FAE, qui est caractérisée dans ce travail. Les microstructures ferrito-perlitiques en bande ont ainsi été éliminées au profit de structures plus homogènes et deux aciers de référence ont été définis : l’API 5L X65 (ferrite-bainite) pour le chemisage et le P285NH (ferrite-perlite) pour le conteneur. Ces études ont également montré la formation de couches de produits de corrosion principalement composées de sidérite et de magnétite conférant une pseudo-passivité. Le caractère protecteur de ces couches vis-à-vis de la fissuration a été étudié et validé, sur la base d’une élaboration de couches représentatives par voie électrochimique. Enfin, les aciers de référence ont été caractérisés du point de vue de leur sensibilité à la corrosion et à la FAE en milieu cimentaire. Ils n’ont alors pas montré de sensibilité particulière du point de vue de la fissuration dans ces conditions, où la corrosion sous dépôt semble être la forme la plus présente en milieu aéré. Néanmoins, l’influence de la présence de faibles teneurs en oxygène dans le concept de stockage doit encore être explorée. / The aim of the work is to assess the susceptibility to environmental assisted cracking (EAC) of steels used for the deep geological storage of radioactive waste. The storage concept is based on the encapsulation of the waste in a carbon steel containers then placed in micro-tunnels drilled 500 meter deep in Clay. These micro-tunnels are built with a micro-alloyed casing steel. Recently, the storage concept has evolved with the injection of a cementitious bentonite grout between the clay and the casing to balance the potential acidity resulting from the excavation of the micro-tunnels and the gradual saturation of rock with water. Effect of this grout on the risk of corrosion and EAC is also evaluated in the PhD work. In the mild disposal environment considered (pH close to neutrality, low carbonate content), formation of a corrosion product scale composed of siderite and magnetite has been identified. This scale leads to a pseudo-passive state of both steel grades with thus a possible risk of EAC. The risk of EAC was thus first studied and a material selection for the disposal concept was thus first made accordingly. The protective nature of the siderite/magnetite corrosion scale was then studied and reproduced in laboratory using electrochemical techniques. This work allowed for the evaluation of the resistance of each selected steel with respect to general corrosion and EAC. The results did not underlined significant cracking susceptibility of the considered steel grades. Under deposit corrosion seems to be the main form of attack in aerated waste disposal environments but the influence of the presence of low oxygen levels has to be further explored.

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