Nanocompósitos de alumina-zircônia (Al2O3-ZrO2) exibem altos valores de tenacidade a fratura (4-8 MPa/m) e resistência a flexão (> 500 MPa), biocompatibilidade e bioatividade, o que propicia seu uso em aplicações biomédicas. Além disso, a literatura indica que altas taxas de formação de fosfatos de cálcio podem ser obtidas mediante associação de tratamento químico de superfície à determinados substratos como, sílica (SiO2), titânio (TiO2) e ZrO2. No entanto, tal influência não foi verificada em sistemas nanoestruturados com matriz de Al2O3. Nesse sentido, o objetivo deste trabalho foi avaliar a influência da ZrO2 em diferentes percentuais de inclusões, quanto a formação dos fosfatos de cálcio sobre a superfície do nanocompósito cerâmico de Al2O3-ZrO2 pelo método biomimético. Para tal, pós cerâmicos foram obtidos pela dispersão de 0, 5, 10 e 15% em volume de ZrO2 nanométrica em matriz de Al2O3, conformados e sinterizados (1050 °C/1 h e 1450° para Al2O3 e 1050 °C/1 h e 1550°C para as demais composições). Após esta etapa, os corpos de prova foram submetidos a tratamento químico superficial com H3PO4 durante 4 dias a 90 °C e, posteriormente, recobertos biomimeticamente em SBF 1,0x, 1,5x e 5,0x, durante 14, 21 e 28 dias. Ao final deste período, as camadas de fosfatos de cálcio depositadas foram caracterizadas por Infravermelho Médio por Transformada de Fourier (FT-MIR) e Difração de Raios-X (DRX), para determinação das áreas de fosfatos totais e fases, em todos os períodos de incubação. De forma geral, observou-se maior deposição de fosfatos de cálcio sobre a superfície dos nanocompósitos com maiores percentuais de inclusões de ZrO2. Além disso, os recobrimentos com todas as soluções de SBF propiciaram a formação de grupos fosfatos (PO43-) e carbonatos (CO32-), Independentemente da concentração de SBF, ou percentual de inclusões de ZrO2 na matriz de Al2O3, apenas três fases foram observadas em função do período de incubação: hidroxiapatita (HA), alfa e beta-fosfatotricálcico (α-TCP e β-TCP). Aos 28 dias de incubação, em todas as condições, maiores teores de ZrO2 influíram para formação da fase α-TCP (r > 0,88). Os resultados obtidos sugerem que a ZrO2 influenciou de forma significativa na formação dos fosfatos de cálcio de interesse biológico (α/β-TCP e HA) na superfície dos nanocompósitos, o que proporciona melhores condições de bioatividade, solubilidade e osteocondução às superfícies dos corpos de prova cerâmicos. Nesse sentido, as biocerâmicas de Al2O3-ZrO2 recobertas com promissoras às aplicações de substituição e remodelação do tecido ósseo. / Alumina-zirconia (Al2O3-ZrO2) nanocomposites exhibit high values of fracture toughness (4-8 MPa/m) and flexural strength (> 500 MPa), biocompatibility and bioactivity, which favors its use in biomedical applications. Furthermore, the literature indicates that high rates of formation of calcium phosphates can be obtained by associating chemical surface treatment with certain substrates such as silica (SiO2), titanium (TiO2) and ZrO2. However, such influence was not verified in nanostructured systems with Al2O3 matrix. In this sense, the objective of this work was to evaluate the influence of ZrO2 on different percentages of inclusions, regarding the formation of calcium phosphates on the surface of the ceramic Al2O3-ZrO2 nanocomposite by the biomimetic method. Then, the ceramic powders were obtained by the dispersion of 0, 5, 10 and 15% by volume of nanometer ZrO2 in Al2O3 matrix, conformed and sintered (1050 °C / 1 h and 1450 °C for Al2O3 and 1050 °C / 1h and 1550°C for other compositions). After this step, the test specimens were submitted to superficial chemical treatment with H3PO4 for 4 days at 90 °C and then, biomimetically coated in 1.0x, 1.5x and 5.0x SBF for 14, 21 and 28 days. At the end of this period, deposited calcium phosphate layers were characterized by Fourier-transform infrared spectroscopy (FT-MIR) and X-ray Diffraction (XRD) for determination of total phosphate and phase areas in all periods of incubation. In general, higher deposition of calcium phosphates on the surface of nanocomposites with higher percentages of ZrO2 inclusions was observed. Regardless of the concentration of SBF or percentage of ZrO2 inclusions in Al2O3 matrix, only three layers were observed as a function of incubation period, hydroxyapatite (HA), alpha and beta-phosphate-calcium (α-TCP and β-TCP). At 28 days of incubation, under all conditions, higher ZrO2 contents influenced the α-TCP phase formation (r > 0.88). The results suggest that ZrO2 significantly influenced the formation of calcium phosphates of biological interest (α / β-TCP and HA) on the surface of the nanocomposites, which provides better conditions of bioactivity, solubility and osteoconduction to the surfaces of the proof ceramic tiles. In this sense, the Al2O3-ZrO2 bioceramics coated with promising to the bone tissue replacement and remodeling applications.

Inconel 718 has widespread use in critical industries like aerospace, marine, and power generation. However, its challenging machinability, characterized by tool chipping/failure, and poor surface quality, remains a significant concern. Despite numerous efforts to enhance tool performance in machining hard-to-machine materials, the issue of sudden tool failure and chipping persists. This study presents an innovative in-situ tool treatment method, complemented by an optimized recoating strategy, aimed at tackling these challenges. The approach involves the application of a lubricating soft metallic Al-Si alloy coating to the tool’s faces, which can be recoated when needed. During subsequent Inconel machining, the Al-Si layer deposited on the tool melts due to high temperatures. The molten material fills microcracks on the tool surface, preventing their propagation. Moreover, the tool can slide on the beneficial tribo-films Al-Si layer which reduces friction, sticking, seizure, and built-up edge formation, resulting in decreased tool wear and chipping. The newly developed pre-machined recoating method has yielded promising outcomes, reducing cutting force and significantly improving tool lifespan compared to the PVD benchmark and uncoated tools. Additionally, this novel method enhances surface quality and minimizes undesirable microstructural alterations induced by machining. / Thesis / Master of Applied Science (MASc) / Chipping and excessive tool wear pose significant challenges in machining high-strength alloys like Inconel 718, limiting their applicability across various industries. According to research, conventional strategies used to deal with the machining challenges posed by Inconel 718 have not produced the best results. The goal of this research is to overcome the machining issues associated with such a difficult-to-cut material innovatively by depositing soft metallic coatings as a solid lubricant to enhance the machining performance. In this study, a cost-effective novel in-situ deposition technique with recoating capability as an alternative to conventional coatings is presented to achieve this goal. This innovative approach aims to improve tool performance during Inconel 718 machining significantly. This study also provides a thorough insight into the application of solid lubricants in machining, discussing their mechanisms, effectiveness, constraints, and potential to boost productivity and environmental sustainability. Furthermore, comprehensive investigations have been conducted to gain deeper insights into the prevalent wear mechanisms and surface treatments that can lead to improved machining performance for Inconel 718.

The thesis deals with the design, construction and testing of two different metal powder coating equipment, which is able to work with SLM 280HL metal 3D printer. Since the field of multimaterial metal printing by selective laser melting (SLM) has not been significantly investigated yet, an overview of existing patents and possible approaches to the solution has been developed. The device has been successfully designed and a series of tests was carried out defining the issue of applying an improved head that uses a nozzle and an eccentric vibration motor. Based on the experiments performed, the coating parameters of the multimaterial layer of FeAm and 316L materials were defined. A control system for the partial process automation was created for the proposed device. The device was implemented in a printer that demonstrated both the ability to apply a single multimaterial layer of at least 50 m thickness, and the ability to produce a 3D multimaterial component comprised of up to 200 layers and containing material change across all axes.