edited by N. J. Grant and B. C. Giessen. Section I. / Includes bibliographical references and index.

Orientador: Luís Rogério de Oliveira Hein / Coorientador: Peterson Luiz Ferrandini / Banca: Antonio Jorge Abdalla / Banca: Ricardo Risso Chaves / Resumo: O nível de qualidade de peças produzidas a partir de grandes lingotes está intimamente relacionado à qualidade dos lingotes em si. Dentre os diversos defeitos inerentes ao processo de solidificação, destacam-se as microssegregações de elementos de liga, que causam uma deterioração nas propriedades do produto final. Uma maneira de reduzir o dano causado pela microssegregação é através do Tratamento Térmico de Homogeneização, este por sua vez demanda elevados tempos de processo, elevando custos e tempos de fabricação. Uma das formas de reduzir os tempos de homogeneização, uma vez que este apresenta caráter difusional, é através da redução do espaçamento interdendrítico. Neste trabalho foi analisada a influência da deformação plástica como forma de reduzir o espaçamento entre dendritas no tratamento térmico de homogeneização. Para tal fim, utilizou-se um lingote fundido em aço ferramenta de composição química similar ao AISI A2. As amostras foram retiradas do núcleo do lingote no estado bruto de solidificação e sofreram deformações de 0,6 e 1,3 através do processo de laminação a quente, sendo temperadas em água na sequência. Após laminadas as amostras passaram por um tratamento térmico de homogeneização na temperatura de 1200°C por 8h ou 16h e foram novamente temperadas em água. As análises foram feitas através de Microscopia Óptica, Dureza Vickers, Difratometria de Raios-X e Microscopia Eletrônica de Varredura. Foi observado em todas as amostras a presença de microrechupes, e u... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: The quality of pieces produced from large ingots is closely related to the quality of ingots itself. Among the various defects inherent to the solidification process, there is the microsegregation of alloying elements, causing a deterioration in the properties of the final product. One way to reduce the damage caused by microsegregation is through the homogenization heat treatment, this in turn demands long time of process, increasing costs and lead-times for manufacture. One way to reduce the homogenization time, since it has a diffusive character, is by reducing the interdendritic spacing. In this study was analyzed the influence of plastic deformation as a mean to reduce the spacing between dendrites in the homogenization heat treatment. For this purpose it was used a cast ingot of chemical composition similar to the AISI A2 tool steel. Samples were cut from the ingot center in the as-cast state and suffered deformations of 0.6 and 1.3 through the hot rolling process and quenched in water in the sequence. After rolling the samples passed through a homogenization heat treatment at a temperature of 1200°C for 8h and 16h and again were quenched in water. Analyses were performed by Optical Microscopy, Vickers Hardness, X-Ray Diffractometry and Scanning Electron Microscopy. It was observed in all samples the presence of microcavities, and a microstructure consisting predominantly by solidifications dendrites identified by a martensitic phase, involved by a retained austenite matrix containing carbides and sulfides. The plastic deformation broke the dendritic structure, and approached the segregated regions to the non-segregated regions. The heat treatment for 8h was not sufficient to homogenize the microstructure and reduce the microsegregation, independently of the deformation state of the samples. The heat treatment for 16h ... (Complete abstract click electronic access below) / Mestre

Made available in DSpace on 2014-10-09T12:38:44Z (GMT). No. of bitstreams: 0 / Made available in DSpace on 2014-10-09T14:05:20Z (GMT). No. of bitstreams: 1 06007.pdf: 6761154 bytes, checksum: 544e5e82c9fa4e346e3dac046b8ce34f (MD5) / Tese (Doutoramento) / IPEN/T / Instituto de Pesquisas Energeticas e Nucleares - IPEN/CNEN-SP

Made available in DSpace on 2014-10-09T12:43:04Z (GMT). No. of bitstreams: 0 / Made available in DSpace on 2014-10-09T14:05:35Z (GMT). No. of bitstreams: 1 06124.pdf: 4912252 bytes, checksum: a10b5a0b5037f2df963acd926b7b2c97 (MD5) / Dissertacao (Mestrado) / IPEN/D / Instituto de Pesquisas Energeticas e Nucleares - IPEN/CNEN-SP

Made available in DSpace on 2014-10-09T12:53:25Z (GMT). No. of bitstreams: 0 / Made available in DSpace on 2014-10-09T14:09:32Z (GMT). No. of bitstreams: 1 12213.pdf: 5005382 bytes, checksum: c4bde457760b3a6d6f53b64c21e33010 (MD5) / Dissertação (Mestrado) / IPEN/D / Instituto de Pesquisas Energeticas e Nucleares - IPEN-CNEN/SP

Thesis submitted in fulfilment of the requirements for the degree Master of Technology: Mechanical Engineering in the Faculty of Engineering at the Cape Peninsula University of Technology 2013 / High temperatures encountered in combustion chambers of jet engines has demanded the creation of new technologies and new materials for the construction of one of the most critical elements of these systems - the stator and rotor turbine blades. They have to withstand extreme temperatures for extended periods without the loss of mechanical strength, conditions under which many steels and alloys fail. Such failure is ascribed to the combination of high temperatures and high centrifugal forces, resulting in creep. The high temperature creep mechanism of grain boundary sliding has limited the operation capability of fine-grained equiaxed castings. Higher operating temperatures were achieved with higher alloy contents and coarse-grained equiaxed castings. This is especially prevalent in multi-crystalline structures in which grain boundaries present weaknesses in the structure. However, notwithstanding these improvements, high temperature resistant alloys formed as single crystal structures offer the necessary material properties for safe performance under these extreme conditions. Damage to turbine blade surfaces is often caused by oxidation and hot corrosion. For this reason, turbine blades are coated with a thermal barrier coating (TBC), which consists of ceramic materials that reduce the heat flux through the airfoil. In this research work, modelling and simulation techniques were initially used to study the directional solidification (DS) of crystal structures during vacuum investment casting. The modelling of the solidification process was implemented using a Finite Element casting simulation software, ProCAST, to predict thermal and flow profiles. These models allowed the study of the dendritic growth rate, the formation of new grains ahead of the solid/liquid interface and the morphology of the dendritic microstructure. These studies indicated the opportunity to optimise the velocity of the solidification front (solidification rate) for single crystal structures. The aim of this research was therefore to investigate the effect of the solidification rate (or withdrawal velocity) on the quality of SC castings. The investigations were carried out for nickel-based superalloy CMSX-4 turbine blade casts and rods using the Bridgman process for vacuum investment casting. The SC castings were heat treated to improve the grain structure for enhanced creep resistance. The heat treated SC castings were inspected by X-ray diffraction to analyse crystallographic orientation and chemical composition; and by SEM, OP (optical microscopy) and microprobe analysis to analyse the microstructure; in addition to macrostructural investigations. In the experimental analysis, the formation of new grains ahead of the solidi/liquid interface and the effect of dendrite packing patterns on the primary dendrite spacing were investigated. Creep tests were conducted to compare the creep properties of the SC castings for different withdrawal rates, and to draw conclusions regarding the effect of withdrawal rate on the microstructure (and hence the creep properties) of SC castings.

Aluminium applications can be found in the vast majority of industries – particularly the automotive, aerospace and building sectors. Light weight, good corrosion resistance, high strength with good machining and weldability has led 6xxx series alloy to be the most widely used for extrusion products. Semi-continuous direct-chill (DC) casting is a well established process and the most widely used in the production of wrought aluminium extrusion billets. The techniques have continuously evolved since its invention in the 1930s. To ensure high productivity and a quality billet by DC casting, grain refiners are added during casting prior to solidification. It is efficient, cost effective and considered optimized in modern production techniques. However, some problems still persist, for example, macrosegregation, centerline cracking, porosity, hot tearing, etc. For surface finish critical products, particles in added grain refiners may cause surface defects during downstream processing. Additions of grain refiners are also not desirable for recycling of the end use products. As a novel DC casting technology, the melt conditioned DC casting (MC-DC) technology is developed to achieve uniform fine equiaxed grains without deliberate additions of grain refiners. The MC-DC process is implemented by submerging a rotor-stator high shear device into the mould assembly of a conventional hot-top vertical DC caster. In this work, the fundamentals of MC-DC process has been investigated by studying the flow patterns in the sump using computer modelling in combination with thermal field measurement and delineation of the sump profile. Followed is the microstructural evolution of the MC-DC castings. Then the formation of Fe-bearing intermetallics which are critical to the arrangement of homogenisation treatment are presented. The grain refining mechanism by MC-DC is due to enhanced heterogeneous nucleation on dispersed oxides and grain fragments by intensive melt shearing, in combination with dendrite fragmentation and transportation in a uniform temperature and solute field. By optimising MC-DC parameters, alleviation of macrosegregation can be achieved even compared with DC-GR castings. Another finding is the correlation between grain structure and the distribution of the Fe-intermetallic particles. It has been demonstrated that equiaxed dendritic grains with fine secondary dendritic arm spacings achieved in MC-DC are preferred rather than finer granular grains in grain refined material. MC-DC also promotes the formation of α- Fe-bearing intermetallics. All these offer the potential for the reduction of homogenisation practices currently required as part of the DC process.

Em processo de fabricação de polióis, são gerados dois resíduos de catalisadores (RNi e RAl) considerados perigosos ao meio ambiente, devido aos seus respectivos altos teores de níquel e alumínio. A presente Tese trata do estudo da solidificação/estabilização simultânea desses dois resíduos catalíticos com cimento Portland tipo II, com o intuito de minimizar os impactos ambientais e verificar a possibilidade de uso do produto solidificado como elemento estrutural. Os ensaios realizados consistiram em: análise térmica diferencial não convencional (NCDTA), análises termogravimétricas (TG/DTG), análise de difração de raios X (DRX), ensaios de fluorescência de raios X (FRX), ensaio de lixiviação e resistência mecânica. A análise das primeiras etapas de hidratação do cimento assim como de amostras hidratadas em diferentes idades nos primeiros 28 dias, possibilitou avaliar os efeitos da presença dos rejeitos no processo, identificar as etapas onde ocorrem e permitiu quantificar as principais fases do cimento hidratado. Pastas com relação água/cimento igual a 0,5 foram utilizadas, às quais diferentes quantidades de cada resíduo foram adicionadas. Foi verificado que nos estágios iniciais de hidratação do cimento ocorrem efeitos de retardamento e aceleração, respectivamente, devido à presença de RNi e RAl. A utilização simultânea dos dois resíduos de catalisadores no processo de solidificação/estabilização em cimento, indica a ocorrência de um efeito sinérgico, permitindo melhores condições de solidificação do que quando cada resíduo é tratado separadamente. Os ensaios de lixiviação feitos para pastas e argamassas após 28 dias de solidificação, prazo padrão para avaliação de processos de solidificação, apresentaram valores abaixo dos limites permitidos para a concentração final de Ni e Al nos extratos de lixiviação, indicando que o processo de solidificação simultânea dos rejeitos atende à legislação ambiental e elimina o seu impacto ambiental original. Pastas e argamassas analisadas também após 28 dias por testes de resistência à compressão, apresentaram resultados aceitáveis para possível uso na construção civil. / In polyols production two catalyst wastes (RNi and RAI) are obtained, which are considered hazardous, due to their respective high nickel and aluminum contents. This Thesis presents the study of the simultaneous solidification/stabilization of both wastes with type II Portland cement (CPII), in order to avoid environmental impacts and to check the possibility of the use of the solidified products as structural elements. The experimental research performed for this study consisted of non-conventional differential thermal analysis, thermogravimetric analysis, X ray diffraction, X ray fluorescence, leaching and compressive strength tests. The analysis of the first stages of the cement hydration, as well as of samples hydrated at different ages during the first 28 days of hydration, allowed evaluate the effects of the presence of the wastes on the process, identify the steps where the changes occur and have a quantitative information about the main cement hydrated phases. Pastes with water/cement ratio equal to 0.5 were used, into which different amounts of each waste were added. In the early stages of cement hydration retarding and accelerating effects occur, respectively due to RNi and RAl presence. During the simultaneous use of the two waste catalysts for their solidification/stabilization in cement, there is a synergic effect, which allows better operating conditions than when each waste is solidified separately. The leaching tests done for solidified pastes and mortars, after the standard evaluation period of 28 days of solidification, presented values for the final concentration of Ni and Al below accepted limits, indicating that the simultaneous solidification process attends environmental legislation, as well as eliminates the original environmental impact of the wastes. Pastes and mortars analyzed also after 28 days by compressive strength tests, presented acceptable results for the possible use of the solidified products in construction industry.

Orientador: José Luiz Boldrini / Tese (doutorado) - Universidade Estadual de Campinas, Instituto de Matemática, Estatística e Computação Científica / Made available in DSpace on 2018-08-16T04:16:02Z (GMT). No. of bitstreams: 1 Souza_FernandoPereirade_D.pdf: 1266767 bytes, checksum: b584f3645886881d382881c8b1ee2d7c (MD5) Previous issue date: 2010 / Resumo: Neste trabalho estudamos quatro modelos do tipo campo de fases para a evolução de processos de solidificação/liquefação de certos materiais, tanto puros quanto ligas binárias, com a possibilidade de movimentação da fase não-sólida. As equações que governam o comportamento de materiais puros incluem a equação para o campo de fases, uma equação para a temperatura e uma equação singular do tipo de Navier- Stokes com um termo do tipo Carman-Kozeni e também um termo do tipo Boussinesq. Para ligas binárias, uma equação extra para a concentração do soluto _e incluída. Para materiais puros, tanto no caso bidimensional quanto no caso tridimensional, provamos a existência de soluções globais no tempo; no caso tridimensional, consideramos um modelo com dissipação mais intensa (não linear) do que no caso bidimensional. Para ligas binárias, obtivemos apenas a existência de soluções locais no tempo. Tais soluções são obtidas da seguinte forma: primeiramente o problema _e penalizado e uma sequência de soluções aproximadas _e obtida usando o teorema do ponto fixo de Leray- Schauder; então, usando argumentos de compacidade, provamos que esta sequência tem um ponto limite, o qual _e uma solução do problema original em um sentido generalizado. / Abstract: In this work we study four phase field models for the evolution of a solidification/liquefaction process of certain pure material or certain binary alloys, with the possibility of motion of the melt phase. The governing equations for pure materials include a phase-field equation, a heat equation and a singular Navier-Stokes system with a term of Carman-Kozeni type and a Boussines type term. For binary alloys, an extra equation for solute concentration is included. For pure materials, both in the two and three-dimensional cases we prove the existence of global in time solutions; in the three-dimensional, we consider a model with stronger (nonlinear) dissipation than in the two-dimensional case. For alloys, both in the two-dimensional and three-dimensional case, we obtain just local in time solutions. These solutions are obtained as follows: firstly the problem is penalized and a sequence of approximate solutions is obtained by using the Leray-Schauder's fixed point theorem; then, by using compactness arguments, we prove that this sequence has a limit point which is a solution of the original problem in a generalized sense. / Doutorado / Equações Diferenciais Parciais / Doutor em Matemática

Orientador: Rezende Gomes dos Santos / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-06T09:53:26Z (GMT). No. of bitstreams: 1 Sousa_TonnyfranXavierdeAraujo_M.pdf: 6216112 bytes, checksum: 8c56f86b7dd957a9bef95dc947db6ed6 (MD5) Previous issue date: 2006 / Resumo: O objetivo do trabalho é o desenvolvimento de uma análise comparativa do processo de solidificação de uma liga de alumínio a partir de diferentes graus de superaquecimento. São determinados experimentalmente os principais parâmetros do processo de solidificação afetados pelo grau de superaquecimento e sua influência na formação da microestrutura. Foi escolhida a liga AA5052, contendo cerca de 3% de magnésio pelo seu interesse comercial. A liga foi vazada com três diferentes graus de superaquecimento, em um dispositivo que permite a solidificação unidirecional e o monitoramento, através de um sistema de aquisição de dados, das variações de temperatura em diferentes posições da peça. A partir dos resultados de temperatura são determinados outros parâmetros do processo. Os espaçamentos interdendriticos são determinados a partir das micrografias. Através da análise experimental é determinada a influência do grau de superaquecimento nos seguintes parâmetros relativos ao processo de solidificação: coeficiente de transferência de calor na interface metal/molde, velocidade de avanço da frente de solidificação, gradiente de temperatura em frente à isoterma liquidus, taxa de resfriamento, tempo local de solidificação e espaçamentos interdendriticos primário e secundário. Também é analisada a transição entre a estrutura colunar e equiaxial / Abstract: The objective of this work is the development of a comparative analysis of solidification process of the aluminum 5052 alloy with different overheating ranges. The main parameters of the solidification process, experimentally determined, are affected by the overheating range and its influence on the microstructure arrangement. lt was selected the 5052 alloy, containing about 3% of magnesium, used for commercial purposes. The al1oy was poured with three different overheating ranges in a device which allows the unidirectional solidification and its monitoring through an acquisition data system thru the temperature variation from different positions on the sample. From the temperature results, the process parameters are determined. The dendritic spacing is determined using the micrographs. Through experimental analysis is established the influence of the overheating range at the fol1owing parameters related to solidification process: heat transfer coefficient at the metal/mold interface, solidification rate, thermal gradient at the liquidus isotherm, cooling rate, local solidification time and secondary arm spacing. The change between the structure columnar and equiaxed is also studied. / Mestrado / Materiais e Processos de Fabricação / Mestre em Engenharia Mecânica