Modelagem e otimização por metodologia de superfícies de resposta: um estudo em arames de aço SAE 9254 para molas automobilísticas

Pós-graduação em Engenharia Mecânica - FEG

Redução de empeno em barra trefiladas do aço SAE 9254

In this paper we study the process of manufacture of wire drawn steel bars 9254, from rolled wire rod. These bars are used in the automotive industry for the manufacture of coil springs, which make up the system damping of several vehicles. The wire drawing process consists of the steps of pre-straightening, shot peening, drawing, cutting and polishing. The study aims to search for the configuration of process variables, which present the best result with respect to bending. To this were maintained settings prestraightening and mechanical stripping and varied angles and stringer polish being studied to replace the spinneret with a working angle, for a string with two working angles. To assist in the analysis of the results was the tool used DOE Software Minitab, which assesses the variation in results according to each parameter and the interaction parameters. It was thus possible to determine the best condition for wire drawing

Processamento de peças em materiais compósitos para o projeto BAJA SAE

The weight of a vehicle has always been considered an extreme important factor, because it interferes in the performance, steering, consume, environmental impact, wear of components, among the others. Because of the new demand, consume reduction aim and gases emission increased the necessity to manufacture lighter vehicles, guaranteeing the complying with the gas emission international law. Besides the legal demand, the low weight will certainly be essential for the competitiveness for the next generation of vehicles. It is with this thinking the composite materials have been introduced in the automobilist industry, because those materials show an excellent relation of strength/weight, providing a reduction of consume and the increase of load capacity. Those factors justify the increase of interest of industry and the necessity of optimization of those materials and of their process. For this research, the field of application will be the Baja SAE Project, a project that is fully developed by engineering students, where they build a prototype single seat, off-road category, for use on hilly slopes with obstacle. This research aims to study two key components of the prototype are made of composite materials, analyzing all the processing. In addition, there is the analysis of the viability of this production parts to a Baja SAE vehicle, in order to increase their performance and reduce their weight without reducing the safety and robustness of the prototype. It was possible to achieve weight reduction of the steering subsystem with manufacturing the flywheel hybrid composite (carbon/glass) and the replacement of SAE 1010 steel by hybrid composite (carbon/aramid) in CVT box. The importance of this study is to obtain a good project for the vehicle of technical and scientific manner, contributing to the know-how to the team and providing a basis for optimization for upcoming projects

Analise de desgaste em materiais aplicados em discos de freio

Baja SAE competitions challenge engineering students to design and build offroad vehicles, preparing them for the competitive job market. This monograph aims to study a part of the braking of a Baja SAE vehicle system, the brake disc. Giving attention to the wear suffered by discs of two different materials, steel 1045 and stainless steel 304, helping the team Piratas do Vale Bardahl in the best selection between them. Braking tests were performed on a test bench. Both discs have suffered the same braking conditions. Brake pads material, brake line pressure, braking time, number of braking, were parameters which were repeated in the testing of different types of disk, in order to ensure a high power comparison between the obtained data. Before and after the disk tests were weighed and measured, to make a comparison. After the brake tests, the disks were subjected to hardness and surface roughness testing. With the data collected and observations made in the worn parts, the comparison between these two materials was made, obtaining a selection of the best material for the team. The tests showed that steel 1045 has more advantages, compared to stainless steel 304, when applied to brake discs, on the tested conditions

Influência da adição do nióbio no comportamento mecânico e microestrutural do aço SAE 6150

Pós-graduação em Engenharia Mecânica - FEG

Activity of disinfectants against foodborne pathogens in suspension and adhered to stainless steel surfaces

The purpose of this study was to investigate and compare the efficacy of various disinfectants on planktonic cells and biofilm cells of Listeria monocytogenes, Staphylococcus aureus and Escherichia coli. Numbers of viable biofilm cells decreased after treatment with all tested disinfectants (iodine, biguanide, quaternary ammonium compounds, peracetic acid and sodium hypochlorite). Sodium hypochlorite was the most effective disinfectant against biofilm cells, while biguanide was the least effective. Scanning electron microscopy observations revealed that cells adhered on stainless steel surface after treatment with the disinfectants. No viable planktonic cells were observed after treatment with the same disinfectants. Based on our findings, we concluded that biofilm cells might be more resistant to disinfectants than plancktonic cells.

Surface finishing of flat pieces when submitted to lapping kinematics on abrasive disc dressed under several overlap factors

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Experience gained and difficulties in performing dynamic load test in composite piles made with steel rails

The results of dynamic instrumentation in two construction sites that used steel rails as pile foundation are presented in this paper. The first dynamic load tests were executed in piles made by single steel rails of the type TR32 and TR37. In the second group of dynamic tests, the piles were made by a composition of two and three steel rails of the same type TR37. The difficulties in placing the sensors, the effect of hammer blow eccentricity and the influence of the non-uniform welding along the pile length are presented in detail and discussed.

Enhanced corrosion resistance of AISI H13 steel treated by nitrogen plasma immersion ion implantation

Electrochemical corrosion measurements of AISI H13 steel treated by Pill process in 3.5% (wt) NaCl solution were investigated. So far the corrosion behavior of AISI H 13 steel by Pill has not been studied. The electrochemical results are correlated with the surface morphology, nitrogen content and hardness of the nitride layer. Ion implantation of nitrogen into H 13 steel was carried out by Pill technique. SEM examination revealed a generalized corrosion and porosity over all analyzed sample surfaces. Penetration of nitrogen reaching more than 20 gm was achieved at 450 degrees C and hardness as high as 1340 HV (factor of 2.7 enhancement over standard tempered and annealed H 13) was reached by a high power, 9 h Pill treatment. The corrosion behavior of the samples was studied by potentiodynamic polarization method. The noblest corrosion behavior was observed for the samples treated by PIII at 450 degrees C, during 9 h. Anodic branches of polarization curves of PIII processed samples show a passive region associated with the formation of a protective film. The passive region current density of PIII treated H13 samples (3.5 x 10(-6) A/cm(2)) is about 270 times lower than the one of untreated specimens, which demonstrates the higher corrosion resistance for the Pill treated H 13 samples. (c) 2007 Elsevier B.V. All rights reserved.

Effects of the high temperature plasma immersion ion implantation (PIII) of nitrogen in AISI H13 steel

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

FeNbP in ultra-low carbon Nb-added steel containing high P

Precipitation of FeTiP is reported to occur in Ti-added IF steels containing high P during thermomechanical processing. An ultra-low carbon (ULC) Nb-added steel ingot containing a higher P content (< 0.8 wt-%) was produced via aluminothermic reduction of Fe2O3 followed by double electron beam melting (EBM). FeNbP coarse precipitates were observed in the as-cast microstructure. After soaking at 1050C for 1 h, the plate was hot rolled from 31 mm down to 7 mm in thickness (total reduction of 77%). During cold rolling of these hot bands we observed embrittlement. We believe that this embrittlement can be attributed to the presence of the FeNbP precipitates. Light optical and scanning electron microscopy (SEM/EDS) were used to characterize the microstructure of this ULC steel. (C) 2000 Elsevier B.V. All rights reserved.

Effect of electroless nickel interlayer on the fatigue strength of chromium electroplated AISI 4340 steel

Deposition of wear-resistant hard chromium plating leads to a decrease in the fatigue strength of the base material. Despite the effective protection against wear and corrosion, fatigue life and environmental requirements result in pressure to identify alternatives or to improve conventional chromium electroplating mechanical characteristics. An interesting, environmentally safer and cleaner alternative for the replacement of hard chronic plating is tungsten carbide thermal spray coating, applied by high velocity oxyfuel (HVOF) process.To improve the fatigue strength of aeronautical steel chromium electroplated, shot peening is a successfully used method. Multiple lacer systems of coatings are considered to have larger resistance to crack propagation in comparison with simple layer.The aim of this study was to analyze the effect of nickel underplate on the fatigue strength of hard chromium plated AISI 4340 steel in two mechanical conditions: HRc 39 and HRc 52.Rotating bending fatigue tests results indicate that the clectroless nickel plating underlayer is responsible for the increase in fatigue strength of AISI 4340 steel chromium electroplated. This behavior may be attributed to the largest toughness/ductility and compressive residual stresses which, probably, arrested or delayed the inicrocrack propagation from the hard chromium external layer. The compressive residual stress field (CRSF) induced by the electroplating process was determined by X-ray diffraction method. The evolution of fatigue strength compressive residual stress field CRSF and crack sources are discussed and analyzed by SEM. (c) 2006 Elsevier Ltd. All rights reserved.

The effect of WC-17Co thermal spray coating by HVOF and hard chromium electroplating on the fatigue life and abrasive wear resistance of AISI 4340 high strength steel

One of the most interesting alternatives for replacement of hard chrome plating is tungsten carbide thermal spray coating applied by the high velocity oxy-fuel (HVOF) process which presents a safer, cleaner and less expensive alternative to chromium plating. The objective of this research is to compare the influence of the tungsten carbide-17cobalt (WC- 17Co) coating applied by high velocity oxy fuel (HVOF) process with that of hard-chromium electroplating on the fatigue strength and abrasive wear of AISI 4340 steel.

Effects of surface treatments on the fatigue strength of AISI 4340 aeronautical steel

Internal residual stresses significantly influence the fatigue strength of coated materials. It is well known that chromium plating is the most used electrodeposited coating for important industrial applications. However, pressure to identify alternatives or to improve the chromium electroplating process have increased in recent years, related to the reduction in fatigue strength of the base material and to environmental requirements. The high efficiency and fluoride free hard chromium electroplating there called accelerated) is an improvement to the conventional process. One environmentally safer and cleaner alternative to hard chromium plating is tungsten carbide thermal spray coating applied by the High Velocity Oxy-Fuel (HVOF) process. To increase the fatigue strength of chromium plated materials, coating thickness and microcracks density are important parameters to be controlled. Techniques as compressive residual stresses induced by shot peening and multilayers, are also used. The aim of this study was to analyse the effects on AISI 4340 steel, in the rotating bending fatigue behaviour, of the: tungsten carbide thermal spray coating applied by HP/HVOF process; chemical nickel underplate, and shot peening process applied before coating deposition, in comparison to hard chromium electroplatings. Rotating bending fatigue test results indicate better performance for the conventional hard chromium plating in relation to the accelerated hard chromium electroplating. Tungsten carbide thermal spray coating and accelerated hard chromium plate over nickel resulted in higher fatigue strength when compared to samples conventional or accelerated hard chromium plated. Shot peening showed to be an excellent alternative to increase fatigue strength of AISI 4340 steel hard chromium electroplated. (C) 2001 Elsevier B.V. Ltd. All rights reserved.

Evaluation of WC-17Co and WC-10Co-4Cr thermal spray coatings by HVOF on the fatigue and corrosion strength of AISI 4340 steel

It is known that chromium electroplating is related to the reduction in the fatigue strength of base metal. However, chromium results in protection against wear and corrosion combined with chemical resistance and good lubricity. Environmental requirements are an important point to be considered in the search for possible alternatives to hard chrome plating. Aircraft landing gear manufactures are considering WC thermal spray coating applied by the high-velocity oxygen-fuel (HVOF) process an alternative candidate, which shows performance at least comparable to results, obtained for hard chrome plating. The aim of this study is to compare the influence of WC-17Co and WC-10Co-4Cr coatings applied by HVOF process and hard chromium electroplating on the fatigue strength of AISI 4340 steel, with and without shot peening. S-N curves were obtained in axial fatigue test for base material, chromium plated and tungsten carbide coated specimens. Tungsten carbide thermal spray coating results in higher fatigue strength when compared to hard chromium electroplated. Shot peening prior to thermal spraying showed to be an excellent alternative to increase fatigue strength of AISI 4340 steel. Experimental data showed higher axial fatigue and corrosion resistance in salt fog exposure for samples WC-10Co-4Cr HVOF coated when compared with WC-17Co. Fracture surface analysis by scanning electron microscopy (SEM) indicated the existence of a uniform coverage of nearly all substrates. (C) 2004 Elsevier B.V. All rights reserved.