Three monolithic refractories (a 90+ wt.% alumina Castable, a 50+ wt.% alumina castable, and a 90+ wt.% alumina phosphate-bonded ramming mix) doped with up to 2.0 wt.% Fe and 2.0 Fe wt.% Fe₂O₃ were tested for CO disintegration in a 100 hr. test similar to. ASTM C-288. The effects of CO₂, NH₃, H₂, H₂S, and H₂O on CO disintegration were observed. Prefired samples of all three refractories were found to be susceptible to disintegration in a CO atmosphere when 0.5 wt.% Fe or more was added. Castables doped with up to 2.0 Fe wt.% Fe₂O₃ were not affected by CO, while the ramming mix doped with 1.5 Fe wt.% Fe₂O₃ or more was. H₂ and H₂O proved most effective in retarding CO disintegration in all three refractories. CO₂, H₂S, and NH₃, in descending order, also retarded CO disintegration in both castables. The retarding effect of up to 15% CO₂ in CO is questionable for the ramming mix. NH3 did not slow CO disintegration in this refractory and H₂S actually accelerated the disintegration process. The effect of gas pressure is also found to be especially important, for it greatly accelerates CO disintegration in all three monoliths and appears to be a more significant factor than the disintegration~inhibiting gases. An optimum iron-impurity size range, neither a maximum nor a minimum, for which CO disintegration resistance was greatest was also found for the 90+ wt.% alumina castable. / Master of Science

A operação de fresamento de faceamento tem como objetivo proporcionar superfícies planas isentas de deformação residual na seção transversal da peça usinada. Por outro lado, as evidências apresentadas neste trabalho demonstram que tal deformação existe e seu comportamento pode ser relacionado com grandezas tecnológicas como o tipo de ferramenta utilizada, a velocidade de avanço e de corte do processo além das propriedades mecânicas e metalúrgicas do material da peça.Foram realizados ensaios de fresamento de faceamento, em condições convencionais de usinagem, em duas superligas, sendo uma a base de níquel e outra a base de cobalto, além de uma liga de titânio. As relações de avanço por faca, ângulo de hélice e velocidade de corte foram manipuladas com o objetivo de se avaliar as deformações residuais sob diferentes taxas de deformação. Os corpos de prova foram avaliados em seu estado deformado e através de microscopia eletrônica de varredura, foi possível junto da modelagem matemática, concluir que a hipótese de deformação plana na seção transversal da peça é válida, e esta poderá ser avaliada através do uso da teoria de Slip Lines. O comportamento plástico do material foi avaliado através da teoria de Slip Lines com a implementação do modelo constitutivo Johnson-Cook, enquanto a estimativa de força no processo de usinagem foi feita com o uso da teoria da zona de planos de cisalhamentos paralelos modificada, conforme P.L.B Oxley e Lee e Shaffer. Os diversos pontos apresentados nesta tese que formam o conceito de contribuição foram identificados ao longo do texto, inclusive uma nova abordagem sobre a área de corte de uma fresa com canal helicoidal, bem como as críticas voltadas à definição do ângulo inicial do plano de cisalhamento e da temperatura para obtenção das tensões. A plasticidade do contínuo foi o principal aspecto tanto para estimar as tensões bem como para avaliar as deformações, seja no cavaco bem como na peça. O índice de plastificação do material se demonstrou como principal fator para uma reavaliação da proposta de P.L.B Oxley e, o entendimento de como as demais propriedades mecânicas associadas à este índice influenciam na deformação plana residual e demais condições de equilíbrio de tensões durante a usinagem são sugeridas para complementar o entendimento e uso desta contribuição. / The face milling operation purpose is providing flat machined surfaces free from residual strains at the cross section of the workpiece. On the other hand, the evidences presented in this thesis are enough to demonstrate that the strain exists and its behavior can be related to technical measurements such as the cutting tool helical profile, the feed rate, the cutting speed beyond the materials mechanical and metallurgical properties. Several face milling operation under conventional cutting conditions onto two super alloys have been performed. A nickel base alloy and a cobalt base were observed. A titanium base alloy has also been observed. The feed rate, the rake angle and the cutting speed were manipulated aiming the evaluation of the residual strains under different strain rates. The specimen has been evaluated in its strained condition throughout the use of scanning electronic microscopy. Furthermore with the mathematical modeling it has been possible to conclude that the residual strain at the cross sectional surface is supportable and the strained profile can be evaluated through the use of the Slip Line Field plasticity theory. The plastic behavior of the material has been evaluated with the Slip Line Field plasticity theory with the Johnson-Cook´s constitutive material´s model. The cutting force estimation has used the modified parallel shear plane zone machining model assured by P.L.B. Oxley and an ancient Slip Line solution presented by Lee and Shaffer. All of the details of this thesis which collaborate with the contribution concept have been pointed out along this research, especially the derivation of the helical area profile as well as the criticism related with the shear plane initial value definition and temperature estimation. The continuum plasticity has been the main aspect to evaluate the stresses and also the strains in the workpiece and also at the chip. The materials strain hardening index is main point for a new evaluation of the P.L.B Oxley machining model, and the understanding of how the mechanical properties related with this index influence the residual plane strain and the other convergence conditions of strain during the machining are suggested in order to build up the understanding of this contribution.

An in-depth study has been carried out to investigate refractory degradation during continuous steel casting processes. Slag/refractory interactions have been investigated through a study of the wetting behaviour and gas generation phenomena at the slag/refractory interface at 1550oC using sessile drop experiments. The influence of carbon content and slag composition was investigated. Two different steel casting slags (slag1: MnO 50%, SiO2 25%, Al2O3 25%; and slag2: MnO 40%, SiO2 60%) have been studied along with yttria stabilized zirconia refractory substrates respectively containing 10%, 15% and 20% carbon. The gas generation has been measured using the Infrared gas analyser, and its influence has also been investigated by taking optical images at varying times. The total amount of gases emitted has shown the dependence on the compositions of refractory substrates and the existence of casting slags. Under the investigation of zirconia-carbon refractory, a new phenomenon that the gas generated can push the liquid slags away and minimise the contact of slags and refractory substrates has been proven.

Planar optical waveguides fabricated by K$ sp+$-Na$ sp+$ ion-exchange in soda-lime glass substrates are investigated. / Experimental characterizations of planar waveguide with respect to a wide range of fabrication conditions have been carried out, including detailed measurements of the refractive index anisotropy resulting from the large induced surface stresses. / Parallel to this, the non-linear diffusion process of ion-exchange was simulated numerically to provide, along with the results of the characterizations, a complete description of the refractive index profile from any set of fabrication conditions. / The magnitude of the maximum surface index change observed was shown theoretically to be almost entirely due to the induced stress at the surface of the substrate, arising from the presence of the larger potassium ions. / Finally, a novel class of single-mode channel waveguides, made by a "two-step" ion-exchange was analyzed. A simple model for these waveguides was developed and used in the design of two directional coupler structures which were fabricated and measured. / The two-step process was conceived because it relaxes waveguides' dimensional control, yielding single-mode guides of larger size, better suited for low-loss connections to optical fibers. It also provides an additional degree of freedom to adjust device properties.

An in-depth study has been carried out to investigate refractory degradation during continuous steel casting processes. Slag/refractory interactions have been investigated through a study of the wetting behaviour and gas generation phenomena at the slag/refractory interface at 1550oC using sessile drop experiments. The influence of carbon content and slag composition was investigated. Two different steel casting slags (slag1: MnO 50%, SiO2 25%, Al2O3 25%; and slag2: MnO 40%, SiO2 60%) have been studied along with yttria stabilized zirconia refractory substrates respectively containing 10%, 15% and 20% carbon. The gas generation has been measured using the Infrared gas analyser, and its influence has also been investigated by taking optical images at varying times. The total amount of gases emitted has shown the dependence on the compositions of refractory substrates and the existence of casting slags. Under the investigation of zirconia-carbon refractory, a new phenomenon that the gas generated can push the liquid slags away and minimise the contact of slags and refractory substrates has been proven.

A operação de fresamento de faceamento tem como objetivo proporcionar superfícies planas isentas de deformação residual na seção transversal da peça usinada. Por outro lado, as evidências apresentadas neste trabalho demonstram que tal deformação existe e seu comportamento pode ser relacionado com grandezas tecnológicas como o tipo de ferramenta utilizada, a velocidade de avanço e de corte do processo além das propriedades mecânicas e metalúrgicas do material da peça.Foram realizados ensaios de fresamento de faceamento, em condições convencionais de usinagem, em duas superligas, sendo uma a base de níquel e outra a base de cobalto, além de uma liga de titânio. As relações de avanço por faca, ângulo de hélice e velocidade de corte foram manipuladas com o objetivo de se avaliar as deformações residuais sob diferentes taxas de deformação. Os corpos de prova foram avaliados em seu estado deformado e através de microscopia eletrônica de varredura, foi possível junto da modelagem matemática, concluir que a hipótese de deformação plana na seção transversal da peça é válida, e esta poderá ser avaliada através do uso da teoria de Slip Lines. O comportamento plástico do material foi avaliado através da teoria de Slip Lines com a implementação do modelo constitutivo Johnson-Cook, enquanto a estimativa de força no processo de usinagem foi feita com o uso da teoria da zona de planos de cisalhamentos paralelos modificada, conforme P.L.B Oxley e Lee e Shaffer. Os diversos pontos apresentados nesta tese que formam o conceito de contribuição foram identificados ao longo do texto, inclusive uma nova abordagem sobre a área de corte de uma fresa com canal helicoidal, bem como as críticas voltadas à definição do ângulo inicial do plano de cisalhamento e da temperatura para obtenção das tensões. A plasticidade do contínuo foi o principal aspecto tanto para estimar as tensões bem como para avaliar as deformações, seja no cavaco bem como na peça. O índice de plastificação do material se demonstrou como principal fator para uma reavaliação da proposta de P.L.B Oxley e, o entendimento de como as demais propriedades mecânicas associadas à este índice influenciam na deformação plana residual e demais condições de equilíbrio de tensões durante a usinagem são sugeridas para complementar o entendimento e uso desta contribuição. / The face milling operation purpose is providing flat machined surfaces free from residual strains at the cross section of the workpiece. On the other hand, the evidences presented in this thesis are enough to demonstrate that the strain exists and its behavior can be related to technical measurements such as the cutting tool helical profile, the feed rate, the cutting speed beyond the materials mechanical and metallurgical properties. Several face milling operation under conventional cutting conditions onto two super alloys have been performed. A nickel base alloy and a cobalt base were observed. A titanium base alloy has also been observed. The feed rate, the rake angle and the cutting speed were manipulated aiming the evaluation of the residual strains under different strain rates. The specimen has been evaluated in its strained condition throughout the use of scanning electronic microscopy. Furthermore with the mathematical modeling it has been possible to conclude that the residual strain at the cross sectional surface is supportable and the strained profile can be evaluated through the use of the Slip Line Field plasticity theory. The plastic behavior of the material has been evaluated with the Slip Line Field plasticity theory with the Johnson-Cook´s constitutive material´s model. The cutting force estimation has used the modified parallel shear plane zone machining model assured by P.L.B. Oxley and an ancient Slip Line solution presented by Lee and Shaffer. All of the details of this thesis which collaborate with the contribution concept have been pointed out along this research, especially the derivation of the helical area profile as well as the criticism related with the shear plane initial value definition and temperature estimation. The continuum plasticity has been the main aspect to evaluate the stresses and also the strains in the workpiece and also at the chip. The materials strain hardening index is main point for a new evaluation of the P.L.B Oxley machining model, and the understanding of how the mechanical properties related with this index influence the residual plane strain and the other convergence conditions of strain during the machining are suggested in order to build up the understanding of this contribution.

Mathematical models of heat flow and elastic stress generation based on the finite-element method have been developed and utilized to analyze the Epic-3 Monofrax-S casting process (Monofrax-S is primarily composed of 47-57% A1₂O₃, 34-41% ZrO₂ and 10-15% SiO₂). The results of the mathematical analysis, in conjunction with information obtained from a comprehensive industrial study, has led to the development of mechanisms for the formation of the various crack types found in this casting process. Thermal stresses have been predicted to be generated early in the solidification process in association with rapid cooling of the refractory surface as it contacts the initially cool mould and again later in the solidification process in conjunction with the tetragonal-to-monoclinic phase transformation which occurs in the zirconia component of Monofrax-S. The mathematical analysis has also helped to identify indirectly a potential mechanism for the generation of mechanical stresses. Based on an understanding of the generation of tensile stresses, recommendations have been made for modifications to the moulding and casting procedures in order to reduce the propensity for the formation of cracks. The modifications have included changes to the mould construction and geometry to reduce the generation of mechanical stresses and changes to the moulding materials to impact on the flow of heat at key times during solidification and cooling. With the recommendations in place, the casting process has been re-examined with the mathematical models to verify the impact of the modifications. The predictions show that the modifications have acted to reduce tensile stresses associated with the formation of Type-A and -B cracks. Preliminary industrial trials with the modified mould have yielded blocks free of these defects. / Applied Science, Faculty of / Materials Engineering, Department of / Graduate

Diploma thesis contains introduction of a company P-D Refractories CZ a. s., where the manufacture of ceramic chimney liners is. Followed by a description and analysis of the product in the entire production cycle, material and product spectrum. Based on the results of current production is created proposal to streamline the machining technology with a view to increase productivity and reduce defective products, which means determine the material of a tool and the method of machining. The work is finished by technical-economic assessment, where the summary and recommendation of the proposed solution are.

No description available.

Submitted by Cátia Araújo (catia.araujo@unipampa.edu.br) on 2017-01-25T12:34:29Z No. of bitstreams: 2 license_rdf: 1232 bytes, checksum: 66e71c371cc565284e70f40736c94386 (MD5) Desenvolvimento de materiais cerâmicos refratários com adição da sílica residual proveniente da queima da casca de arroz.pdf: 10705111 bytes, checksum: f3dc853aa0f1b672236697852c098384 (MD5) / Approved for entry into archive by Cátia Araújo (catia.araujo@unipampa.edu.br) on 2017-01-25T12:37:45Z (GMT) No. of bitstreams: 2 license_rdf: 1232 bytes, checksum: 66e71c371cc565284e70f40736c94386 (MD5) Desenvolvimento de materiais cerâmicos refratários com adição da sílica residual proveniente da queima da casca de arroz.pdf: 10705111 bytes, checksum: f3dc853aa0f1b672236697852c098384 (MD5) / Made available in DSpace on 2017-01-25T12:37:45Z (GMT). No. of bitstreams: 2 license_rdf: 1232 bytes, checksum: 66e71c371cc565284e70f40736c94386 (MD5) Desenvolvimento de materiais cerâmicos refratários com adição da sílica residual proveniente da queima da casca de arroz.pdf: 10705111 bytes, checksum: f3dc853aa0f1b672236697852c098384 (MD5) Previous issue date: 2014-03-20 / Com a intenção de agregar valor à cinza da casca de arroz, subproduto da indústria orizícola, e colaborar para um desenvolvimento sustentável do país, esta pesquisa buscou desenvolver materiais cerâmicos refratários com a substituição parcial da argila pela sílica de casca de arroz (SCA) produzida a partir da geração de energia elétrica. Atualmente, na região da fronteira oeste do Estado do Rio Grande do Sul, existem várias usinas termoelétricas de biomassa para geração de energia elétrica através da queima da casca de arroz. Essa tecnologia vem ao encontro da necessidade de diversificação da matriz energética no país. A indústria orizícola produz no Brasil aproximadamente 12 milhões de toneladas por ano de arroz, e aproximadamente 2,5 milhões de toneladas por ano são convertidos em casca. Caso toda esta casca fosse queimada, gerar-se-iam aproximadamente 500 mil toneladas de cinza, a qual é rica em sílica. Portanto, viabilizar seu aproveitamento tende a reduzir o passivo ambiental, além dos benefícios econômicos. No presente trabalho foi analisado o efeito da substituição parcial da argila refratária por sílica da casca de arroz (SCA) nas propriedades mecânicas e termomecânicas dos materiais cerâmicos refratários produzidos, em percentuais de 5, 10 e 20%. Foram analisadas as propriedades mecânicas desses materiais através de ensaios de resistência à compressão, tração direta, flexão em três pontos e dureza superficial Vickers. Analisaram-se também a retração linear, absorção de água, porosidade aparente e resistência ao choque térmico. Conforme se aumentou a substituição parcial de argila refratária por SCA, foi obtido um melhor empacotamento da mistura granular e, consequentemente, ocorreu uma melhora nas propriedades mecânicas das amostras. Por outro lado, o material apresentou-se mais frágil, com menor resistência ao choque térmico. Não foi encontrada variação na retração linear após a queima, já a absorção de água e porosidade aparente diminuíram conforme se aumentou a substituição da argila pela SCA. A microestrutura do material foi analisada através de análise por microscopia eletrônica de varredura (MEV) e difração de raios-x, onde se identificaram as fases cristalinas na mineralogia do material resultante. Na análise da mineralogia do material observou-se um aumento de pico de cristobalita conforme se aumentou o teor de SCA na mistura, em função da cristalização da sílica livre. Um menor volume de porosidade foi encontrado conforme se aumentou o teor de substituição de argila pela SCA. / With the intention of adding value to rice husk ash, a byproduct of paddy industry, and contribute to sustainable development of the country, this research sought to develop refractory ceramic materials with refractory partial replacement of clay by silica from rice husk (SCA) produced from electricity generation. Currently on the western border of the State of Rio Grande do Sul, there are several biomass power plants for generating electricity by burning rice husk. This technology comes against the need for diversification of energy sources in the country. The paddy industry in Brazil produces approximately 12 million tons of rice per year, of which approximately 2.5 million tons per year are converted into shell. If all this bark was burned, it would generate approximately 500 tons of ash, which is rich in silica. Thus enabling its use tends to reduce the environmental liability beyond economic benefits. In the present work, the effect of partial replacement of silica refractory clay for rice husk (SCA) on the mechanical and thermomechanical properties of refractory ceramic materials was analyzed for percentages of 5, 10 and 20%. The mechanical properties of these materials were analyzed by testing compressive strength, direct-drive, three point bending and superficial hardness. We also analyzed the linear shrinkage, water absorption, apparent porosity and resistance to thermal shock. As increased the partial replacement of refractory clay for SCA in the mixture was obtained a better packing of the granular mixture and, consequently, better results in mechanical properties were found. On the other hand, the material appeared more brittle, with a lower thermal shock resistance. Was not found in the linear shrinkage after firing, the water absorption and apparent porosity decreased as the clay was increased by replacement SCA. The microstructure of the material was analyzed by scanning electron microscopy (MEV) and x-ray diffraction where the crystalline phases identified in the mineralogy of the resulting material. The analysis of the mineralogy of the material was observed an increase of cristobalite peak was increased as the content of SCA, depending on the crystallization of the free silica. A smaller volume of porosity is found according to the increased content of clay replacement SCA.