Role of abrasive material on micro-abrasion wear tests

Micro-abrasion wear tests with ball-cratering configuration are widely used. Sources of variability are already studied by different authors and conditions for testing are parameterized by BS EN 1071-6: 2007 standard which refers silicon carbide as abrasive. However, the use of other abrasives is possible and allowed. In this work, ball-cratering wear tests were performed using four different abrasive particles of three dissimilar materials: diamond, alumina and silicon carbide. Tests were carried out under the same conditions on a steel plate provided with TiB2 hard coating. For each abrasive, five different test durations were used allowing understanding the initial wear phenomena. Composition and shape of abrasive particles were investigated by SEM and EDS. Scar areas were observed by optical and electronic microscopy in order to understand the wear effects caused by each of them. Scar geometry and grooves were analyzed and compared. Wear coefficient was calculated for each situation. It was observed that diamond particles produce well-defined and circular wear scars. Different silicon carbide particles presented dissimilar results as consequence of distinct particle shape and size distribution.

Influence of the abrasive particles size in the micro-abrasion wear tests of TiAlSiN thin coatings

Ball rotating micro-abrasion tribometers are commonly used to carry out wear tests on thin hard coatings. In these tests, different kinds of abrasives were used, as alumina (Al2O3), silicon carbide (SiC) or diamond. In each kind of abrasive, several particle sizes can be used. Some studies were developed in order to evaluate the influence of the abrasive particle shape in the micro-abrasion process. Nevertheless, the particle size was not well correlated with the material removed amount and wear mechanisms. In this work, slurry of SiC abrasive in distilled water was used, with three different particles size. Initial surface topography was accessed by atomic force microscopy (AFM). Coating hardness measurements were performed with a micro-hardness tester. In order to evaluate the wear behaviour, a TiAlSiN thin hard film was used. The micro-abrasion tests were carried out with some different durations. The abrasive effect of the SiC particles was observed by scanning electron microscopy (SEM) both in the films (hard material) as in the substrate (soft material), after coating perforation. Wear grooves and removed material rate were compared and discussed.

Micro-abrasion wear behaviour of TiAlCrSiN nanostructured coatings

The injection process of glass fibres reinforced plastics promotes the moulds surface degradation by erosion. In order to improve its wear resistance, several kinds of PVD thin hard coatings were used. It is well-known that nanostructures present a better compromise between hardness and toughness. Indeed, when the coating is constituted by a large number of ultra-thin different layers, cracks and interface troubles tend to decrease. However, it is not clear that these nanostructures present a better wear behaviour in erosion processes. In order to study its wear behaviour, a sputtered PVD nanostructured TiAlCrSiN coating was used. The substrate and film surfaces topography were analyzed by profilometry and atomic force microscopy techniques. Film adhesion to the substrate was evaluated by scratch tests. The surface hardness was measured with a Vickers micro-hardness tester. The wear resistance was evaluated by micro-abrasion with a rotating ball tribometer tests. Slurry of SiC particles in distilled water was used in order to provoke the surface abrasion. Different duration tests were performed in order to analyze the wear evolution. After these tests, the wear mechanisms developed were analyzed by scanning electron microscopy. Wear craters were measured and the wear rate was calculated and discussed. With the same purpose, coated inserts were mounted in an injection mould working with a 30% glass fibres reinforced polypropylene. After 45 000 cycles no relevant wear was registered.

Shear strength of adhesively bonded polyolefins with minimal surface preparation

Interest in polyethylene and polypropylene bonding has increased in the last years. However, adhesive joints with adherends which are of low surface energy and which are chemically inert present several difficulties. Generally, their high degree of chemical resistance to solvents and dissimilar solubility parameters limit the usefulness of solvent bonding as a viable assembly technique. One successful approach to adhesive bonding of these materials involves proper selection of surface pre-treatment prior to bonding. With the correct pre-treatment it is possible to glue these materials with one or more of several adhesives required by the applications involved. A second approach is the use of adhesives without surface pre-treatment, such as hot melts, high tack pressure-sensitive adhesives, solvent-based specialty adhesives and, more recently, structural acrylic adhesives as such 3M DP-8005® and Loctite 3030®. In this paper, the shear strengths of two acrylic adhesives were evaluated using the lap shear test method ASTM D3163 and the block shear test method ASTM D4501. Two different industrial polyolefins (polyethylene and polypropylene) were used for adherends. However, the focus of this study was to measure the shear strength of polyethylene joints with acrylic adhesives. The effect of abrasion was also studied. Some test specimens were manually abraded using 180 and 320 grade abrasive paper. An additional goal of this work was to examine the effect of temperature and moisture on mechanical strength of adhesive joints.

Increasing the wear resistance of molds for injection of glass fiber reinforced plastics

Abrasion by glass fibers during injection molding of fiber reinforced plastics raises new challenges to the wear performance of the molds. In the last few decades, a large number of PVD and CVD coatings have been developed with the aim of minimizing abrasion problems. In this work, two different coatings were tested in order to increase the wear resistance of the surface of a mold used for glass fiber reinforced plastics: TiAlSiN and CrN/CrCN/DLC. TiAlSiN was deposited as a graded monolayer coating while CrN/CrCN/DLC was a nanostructured coating consisting of three distinct layers. Both coatings were produced by PVD unbalanced magnetron sputtering and were characterized using scanning electron microscopy (SEM) provided with energy dispersive spectroscopy (EDS), atomic force microscopy (AFM), micro hardness (MH) and scratch test analysis. Coating morphology, thickness, roughness, chemical composition and structure, hardness and adhesion to the substrate were investigated. Wear resistance was characterized through industrial tests with coated samples and an uncoated reference sample inserted in a feed channel of a plastic injection mold working with 30 wt.% glass fiber reinforced polypropylene. Results after 45,000 injection cycles indicate that the wear resistance of the mold was increased by a factor of 25 and 58, by the TiAlSiN and CrN/CrCN/DLC coatings, respectively, over the uncoated mold steel.

Caracterização mecânica e análise da resistência à corrosão em diferentes solos, de aços inoxidáveis duplex

O aço inoxidável é um material de alta durabilidade e resistência, utilizado nos mais diversos setores comerciais. O conhecimento das suas características e propriedades é essencial para uma escolha mais seletiva e vantajosa. Pretende‐se com este trabalho, estudar as propriedades mecânicas, a resistência ao desgaste e o comportamento, em ambientes mais agressivos de três tipos de aços inoxidáveis duplex, produzidos pela OUTOKUMPU e comercialmente conhecidos pelas designações LDX 2101, SAF 2507 e o SAF 2205. Para tal efeito foram realizados ensaios de Dureza Vickers, antes e após dobragem; ensaios de tracção em duas diferentes situações: seguindo a norma NP EN 10002‐ 1:2006 e após a realização de alguns ciclos de carga e descarga; ensaio de Impacto à temperatura ambiente e após arrefecimento criogénico; ensaio de resistência à corrosão. Também foi feito o estudo de resistência ao desgaste com base na técnica de micro‐abrasão por esfera rotativa e o estudo metalográfico. Foi também objetivo deste trabalho, relacionar o uso dos referidos aços duplex e as consequências que esse uso tem para o meio ambiente, bem como o seu comportamento quando exposto a condições extremas. Para tal, foram colocadas amostras dos referidos aços, em dois tipos de solos com condições de humidade e acidez diferentes analisando o seu estado após imersão em solo com condições controladas durante 272 dias.

Uma abordagem à incorporação de lenhinosulfonatos e materiais reciclados em misturas de SBR para produção sustentável de solas

Mestrado em Engenharia Química - Ramo Otimização Energética na Indústria Química

Otimização do Funcionamento da ETAR das Termas de S. Vicente, Penafiel

A água é um recurso natural único, escasso e essencial a todos os seres vivos, o que a torna um bem de extrema importância. Nos dias de hoje, o desperdício deste bem, aliado ao aumento da sua procura, tornou-se um problema devido à decrescente disponibilidade de água doce no nosso planeta. Todas as águas que rejeitamos depois da sua utilização para diversos fins, designadas de águas residuais, necessitam de tratamento antes de serem devolvidas ao meio ambiente. O seu tratamento é realizado numa Estação de Tratamento de Águas Residuais (ETAR) e o processo de tratamento depende das suas características. A ETAR das Termas de S. Vicente, em Penafiel, trabalha no seu limite de capacidade, apresenta uma sobrecarga hidráulica gerada por uma afluência de águas pluviais e o processamento das lamas geradas não permite uma secagem tão completa como seria desejável. Assim, este trabalho teve como objetivo o estudo do funcionamento desta ETAR com a finalidade de propor soluções que o possam otimizar. As soluções propostas para otimizar o funcionamento da ETAR em estudo são: i) a substituição de grades de limpeza manual por grades de limpeza automática de forma a reduzir a necessidade da intervenção do operador ao nível da remoção e condicionamento dos gradados; ii) a construção de um desarenador arejado que além de remover areias de diâmetro superior a 0,2 mm promove também a remoção de gorduras, protegendo desta forma os equipamentos a jusante da abrasão/desgaste prematuros e reduzindo a formação de depósitos nas tubagens; iii) a construção de um tanque de equalização de forma a garantir uma distribuição mais uniforme dos caudais e da carga poluente; iv) a substituição do enchimento do leito percolador por um meio de suporte plástico que permite atingir melhores eficiências de remoção neste tratamento biológico; v) a alteração do agente de desinfeção para radiação ultravioleta, evitando a adição de produtos químicos na água residual e possível formação de subprodutos prejudiciais ao ambiente, como ocorreria no caso da cloragem; e vi) a substituição da desidratação de lamas em leitos de secagem por filtros de banda, que é um processo mais rápido, que ocupa menos espaço e permite atingir elevadas eficiências de remoção de humidade. Para cada uma das sugestões são apresentadas as correspondentes especificações técnicas e dimensionamento. As sugestões de melhoria apresentadas neste trabalho constituem uma alternativa mais económica do que a ampliação da ETAR, que genericamente corresponde à duplicação da linha de tratamento atual. Devido à menor complexidade em termos de construção, estas sugestões podem vir a ser implementadas num futuro próximo, prolongando assim um pouco mais a vida útil da ETAR atual.