Conselho Nacional de Desenvolvimento Científico e Tecnológico / This work aims to study the tribological behavior of two solid lubricant materials used in different conditions: nanoparticles as additives for lubrication fluids and self-lubricating sintered steels. The synthetic base oil with different concentrations and kinds of nanoparticles (MoS2 particles, MoS2 nanoflowers, carbon nanotubes+MoS2, silver nanoparticles) was extensively evaluated through tribological tests: ball on disk scuffing; ball on disk constant load (250 N, 20min. duration) and constant load (2N, 20min. duration) reciprocating linear sliding tests assessing friction coefficient. None of the nanoparticles affected the friction coefficient in a significant way. The nanoparticles were found to be an aggregated state. On the other hand, the effect of sintering temperatures (1100, 1150 and 1200 °C) and precursor content (0-5%) on the tribological behavior of self-lubricating sintered steels, produced by metal injection molding (MIM), was analyzed by using linear reciprocating sliding tests (constant load 7N, 60 min. duration). Solid lubrication effect was produced by in situ formation of graphite nodules due to the dissociation of precursor (SiC particles) during sintering. It was shown that presence of the graphite nodules significantly improved the friction coefficient and the wear rate of the alloys and that the sintering temperature little affected these parameters. Chemical analyses of the wear scars by scanning electron microscopy (SEM-EDX) and auger electron spectroscopy (AES) showed the presence of a tribolayer composed predominantly by carbon and oxygen. The graphite on the samples contributed to the formation of the tribolayer on the contact interface. It is suggested that during sliding graphite foils are removed from the in situ generated graphite nodules and remain at the interface thus contributing to the formation of the protective tribolayer. This tribolayer breaks up and forms during sliding and it is continuously replenished by graphite. Analyses of the wear scars showed the presence of plastic deformation traces on the samples and counter-bodies and the predominance of the wear mechanism by abrasion. Study of the influence of roughness surface showed that polishing the surfaces closed the graphite sources due to plastic deformation. This fact has resulted in a friction coefficient higher than 0.2, which means that, in this condition, this material does not act anymore as solid lubricant. / Este trabalho tem como objetivo estudar o comportamento tribológico de dois materiais lubrificantes sólidos usados em diferentes condições: nanopartículas como aditivos de lubrificantes fluidos e aços sinterizados autolubrificantes. O óleo sintético, com diferentes concentrações e tipos de nanopartículas (partículas MoS2, nanoflores de MoS2, nanotubos de carbono + MoS2, nanopartículas de prata), foi extensivamente avaliado por meio de testes tribológicos: pino sobre disco sob carga variável (scuffing) e constante (250N, durante 20 minutos) e deslizamento linear alternado (2N, durante 20 minutos). O coeficiente de atrito não apresentou alterações significativas com a presença das nanopartículas no óleo, sendo esse comportamento atribuído ao estado de aglomeração das mesmas. Por outro lado, o efeito da temperatura de sinterização (1100, 1150 e 1200 ° C) e do teor de precursor (0-5%) no comportamento tribológico dos aços sinterizados autolubrificantes, produzidos por moldagem de pós por injeção (MIM), foram analisados por meio de testes de deslizamento linear alternado sob carga constante (7N, durante 60 minutos). O efeito de lubrificação sólida foi produzido pela formação in situ de nódulos de grafita devido à dissociação do precursor (SiC) durante a sinterização. Foi mostrado que a presença de nódulos de grafita melhorou significativamente o coeficiente de atrito e a taxa de desgaste das ligas, e que a temperatura de sinterização pouco afetou estes parâmetros. As análises químicas das marcas de desgaste por microscopia eletrônica de varredura (SEM-EDX) e espectroscopia por elétron auger (AES) mostraram a presença de uma tribocamada composta predominantemente por carbono e oxigênio. Sugeriu-se que durante o deslizamento as folhas de grafita são removidas dos nódulos gerados in situ e permanecem na interface contribuindo assim para a formação da tribocamada protetora. Esta, por sua vez, rompe-se e forma-se durante o deslizamento sendo continuamente reabastecida pela grafita. As análises das marcas de desgaste das amostras e dos contra-corpos mostraram a presença de sulcos produzidos por deformações plásticas e a predominância do mecanismo de desgaste por abrasão. Estudos da influência da rugosidade superficial mostraram que as superfícies polidas apresentaram o fechamento das fontes de grafita devido à deformação plástica. Este fato deu origem a um coeficiente de atrito superior a 0.2, o que significa que, nestas condições, o material deixa de atuar como lubrificante sólido. / Doutor em Engenharia Mecânica

In der vorliegenden Arbeit wurde die Verwendung der kostengünstigen aber sauerstoffaffinen Legierungselemente Mangan, Silizium und Chrom in pulvermetallurgisch hergestellten Sinterstählen untersucht. Das Einbringen der Legierungselemente erfolgte mit Hilfe unterschiedlicher Masteralloysysteme. In der vorliegenden Arbeit wurden insgesamt 18 chemisch unterschiedliche, niedriglegierte Sinterstähle entwickelt und untersucht.

In der vorliegenden Arbeit wurde die Verwendung der kostengünstigen aber sauerstoffaffinen Legierungselemente Mangan, Silizium und Chrom in pulvermetallurgisch hergestellten Sinterstählen untersucht. Das Einbringen der Legierungselemente erfolgte mit Hilfe unterschiedlicher Masteralloysysteme. In der vorliegenden Arbeit wurden insgesamt 18 chemisch unterschiedliche, niedriglegierte Sinterstähle entwickelt und untersucht.

The pores in pressed and sintered components constitute weak points in the material since the stress concentration is larger than the nominal stress there. Therefore, fatigue cracks initiate at the pores. Specifically, it can be assumed that the fatigue cracks initiate at the largest pore in the stressed volume. Studies have previously looked at finding ways to model the fatigue strength of the material based on the largest pore. This thesis looks at a model previously derived for hardened pressed and sintered materials that is based on linear elastic fracture mechanics and investigates if said model can be modified to include non-hardened pressed and sintered materials that do not necessarily behave linear elastically. A model describing the influence of the size of the largest pore on the fatigue limit using empirical coefficients is suggested. Furthermore, the area of the largest pore is modelled using extreme value statistics. The model proved successful in modelling the density effect of the porosity on the fatigue strength for two materials with different microstructures: one with a homogeneous microstructure and one with a heterogeneous microstructure. For the material with the homogenoeous microstructure the model also accounted well for the notch effect when tested on samples with a different geometry. However, for the heterogeneous material the model did not account for the notch effect. Deformation hardening due to local plastic deformation in the softer phases was suggested as a possible explanation and was supported by tensile tests.