Turning of compacted graphite iron using commercial tiN coated Si 3N4 under dry machining conditions

Due to their high hardness and wear resistance Si3N4 based ceramics are one of the most suitable cutting tool materials for machining hardened materials. Therefore, their high degree of brittleness usually leads to inconsistent results and sudden catastrophic failures. Improvement of the functional properties these tools and reduction of the ecological threats may be accomplished by employing the technology of putting down hard coatings on tools in the state-of-the-art PVD processes, mostly by improvement of the tribological contact conditions in the cutting zone and by eliminating the cutting fluids. However in this paper was used a Si3N4 based cutting tool commercial with a layer TiN coating. In this investigation, the performance of TiN coating was assessed on turning used to machine an automotive grade compacted graphite iron. As part of the study were used to characterise the performance of cutting tool, flank wear, temperature and roughness. The results showed that the layer TiN coating failed to dry compacted graphite iron under aggressive machining conditions. However, using the measurement of flank wear technique, the average tool life of was increased by VC=160 m/min.The latter was also observed using a toolmakers microscope and scanning electron microscopy (SEM).

Comparative study on turning CI and CGI using silicon nitride cutting tools

There has been a great interest for improving the machining of cast iron materials in the automotive and other industries. Comparative studies for tool used to machine grey cast iron (CI) and compacted graphite iron (CGI) on dry machining were also performed in order to find out why in this case the tool lifetime is not significantly higher. However the machining these materials while considering turning with the traditional high-speed steel and carbide cutting tools present any disadvantages. One of these disadvantages is that all the traditional machining processes involve the cooling fluid to remove the heat generated on workpiece due to friction during cutting. This paper present a new generation of ceramic cutting tool exhibiting improved properties and important advances in machining CI and CGI. The tool performance was analyzed in function of flank wear, temperature and roughness, while can be observed that main effects were found for tool wear, were abrasion to CI and inter-diffusion of constituting elements between tool and CGI, causing crater. However the difference in tool lifetime can be explained by the formation of a MnS layer on the tool surface in the case of grey CI. This layer is missing in the case of CGI.

Properties advanced of the silicon nitride based ceramics and recent performance on automotive parts manufacture by machining process: Advanced Ceramics, demand Forecast

Automotive parts manufacture by machining process using silicon nitride-based ceramic tool development in Brazil already is a reality. Si 3N4-based ceramic cutting tools offer a high productivity due to their excellent hot hardness, which allows high cutting speeds. Under such conditions the cutting tool must be resistant to a combination of mechanical, thermal and chemical attacks. Silicon nitride based ceramic materials constitute a mature technology with a very broad base of current and potential applications. The best opportunities for Si3N 4-based ceramics include ballistic armor, composite automotive brakes, diesel particulate filters, joint replacement products and others. The goal of this work was to show latter advance in silicon nitride manufacture and its recent evolution on machining process of gray cast iron, compacted graphite iron and Ti-6Al-4V. Materials characterization and machining tests were analyzed by X-Ray Diffraction, Scanning Electron Microscopy, Vickers hardness and toughness fracture and technical norm. In recent works the authors has been proved to advance in microstructural, mechanical and physic properties control. These facts prove that silicon nitride-based ceramic has enough resistance to withstand the impacts inherent to the machining of gray cast iron (CI), compacted graphite iron (CGI) and Ti-6Al-4V (6-4). Copyright © 2008 SAE International.

Desenvolvimento de pastilhas cerâmicas à bases de Si3N4 para aplicações tribológicas

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Estudo da utilização de ferramentas a base de nitreto de silício (Si3N4) e alumina (Al2O3) na usinagem do ferro fundido vermicular

Machining is one of the most commonly manufacturing processes used in the modern world, consuming millions of dollars annually. Because of this, it is crucial for the automotive industry to reduce costs on their heat-resistant alloy machining processes, such as compacted graphite iron (CGI), which has shown an increasing trend of its application in diesel engine blocks, brakes disks, among other applications, due to its superior mechanical properties to gray cast iron. Despite this advantage, its use is still limited due to its difficulty of machining, moreover, cutting tools are displayed as the main factor in increasing the machining cost. Seeking an alternative to a better machinability of CGI, this paper aims to study two types of ceramic tools developed in Brazil, and benchmark their performance by dry turning. For this, were used CGI class 450 and two tools: ceramic of silicon nitride (Si3N4) and alumina-based (Al2O3), with a cutting speed (Vc) of 300, 400 and 500 m / min; feed (f) of 0.2 mm / rev and depth of cut (ap) of 0.5 mm, using three replicates and starting with new cutting edges. The results showed that the Al2O3 tool had the best performance in Vc of 500 m / min, while the Si3N4 tool had the best results in Vc of 300 m / min. This can be explained by the tool of Si3N4 based include soft intergranular phase, called amorphous, while alumina has higher abrasion resistance due to its high refractoriness. The results make it clear that the tools have significant potential for machining of compacted graphite iron, being necessary a strict control of the cutting parameters used

Electrocatalytic and voltammetric determination of sulfhydryl compounds through iron nitroprusside modified graphite paste electrode

Iron nitroprusside Fe(II)NP was incorporated into a carbon paste electrode and the electrochemical studies were performed with cyclic voltammetry. The cyclic voltammogram of Fe(II)NP exhibits two redox couple with formal potential (E0')1 = 0.24 e (E0')2 = 0.85 V vs SCE attributed to Fe(II)/Fe(II) and Fe (II)(CN)5NO/Fe(III)(CN)5NO, respectively. The redox couple with (E0')2 = 0.85 V presents an electrocatalytic response for sulfhydryl compounds. The electrocatalytic oxidation of sulfhydryl compounds by the mediator has been used for the determination of L-cysteine and N-acetylcysteine. The modified graphite paste electrode gives a linear range from 9.2 x 10-4-2.0 x 10-2;; 9.6 x 10-4-1.4 x 10-2mol L-1 for the determination of L-cysteine and N-acetylcysteine, respectively, with detection limit of 1.9 x 10-4 mol L-1;; 1.5 x 10 -4 mol L-1 and relative standard desviations ± 5% and 1.5 x 10-3 mol L-1 ± 4% (n=3). The amperometric sensitivities are 0.024 and 0.027 μA/μmol L-1 for L-cysteine and N-acetylcysteine, respectively. The application of this electrode was tested and a commercial pharmaceutical product (Fluimucil) has been determined.

Cutting forces in turning of gray cast iron using silicon nitride based cutting tool

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Corrosion behavior in graphite refractories impregnated with ZrO 2 and CeO 2 carrying solutions

This paper investigates corrosion behavior in graphite refractory hot metal impregnated with ZrO 2 and CeO 2 carrying solutions used in Blast Furnace hearth, consisting of 50% graphite and 50% anthracite. Corrosions tests were carried out by means of finger test method in an induction furnace, using bar-shaped 30×30×280 mm test specimens and hot metal from CSN#2 Blast Furnace runner. The temperature chosen for this test was 1520°C and sixty-minute isotherm. Upon test completion, test specimens were characterized by their dimensional variation, X-ray diffractometry and Scanning Electronic Microscopy (SEM).

α-SiAION: Development and machining test on gray cast iron

The α-SiAlON ceramic cutting tool insert is developed. Silicon nitride and additives powders are pressed and sintered in the form of cutting tool inserts at temperature of 1900 °C. The physics and mechanical properties of the inserts like green density, weight loss, relative density, hardness and fracture toughness are evaluated. Machining studies are conducted on grey cast iron workpiece to evaluate the performance of α-SiAlON ceramic cutting tool. In the paper the cutting tool used in higher speed showed an improvement in the tribological interaction between the cutting tools and the grey cast iron workpiece resulted in a significant reduction of flank wear and roughness, because of better accommodation and the presence of the graphite in gray cast iron. The above results are discussed in terms of their affect at machining parameters on gray cast iron.

Computer techniques towards the automatic characterization of graphite particles in metallographic images of industrial materials

The automatic characterization of particles in metallographic images has been paramount, mainly because of the importance of quantifying such microstructures in order to assess the mechanical properties of materials common used in industry. This automated characterization may avoid problems related with fatigue and possible measurement errors. In this paper, computer techniques are used and assessed towards the accomplishment of this crucial industrial goal in an efficient and robust manner. Hence, the use of the most actively pursued machine learning classification techniques. In particularity, Support Vector Machine, Bayesian and Optimum-Path Forest based classifiers, and also the Otsu's method, which is commonly used in computer imaging to binarize automatically simply images and used here to demonstrated the need for more complex methods, are evaluated in the characterization of graphite particles in metallographic images. The statistical based analysis performed confirmed that these computer techniques are efficient solutions to accomplish the aimed characterization. Additionally, the Optimum-Path Forest based classifier demonstrated an overall superior performance, both in terms of accuracy and speed. © 2012 Elsevier Ltd. All rights reserved.

Direct determination of Cu, Cd, Ni and Pb in aquatic humic substances by graphite furnace atomic absorption spectrometry

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

Enhanced solubilization of iron and calcium phosphates by Aspergillus niger by the addition of alcohols

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

Nickel adsorption by soils in relation to pH, organic matter, and iron oxides

There is little information on nickel adsorption by Brazilian soils. The objective of this experiment was to determine the effect of pH, organic matter, and iron oxides on nickel adsorption by three soils: a clayey Anionic Rhodic Acrudox, a sandy clay loam Anionic Xanthic Acrudox, and a clayey Rhodic Hapludalf. Soil samples were collected from the 0-0.2 in layer and treated to eliminate organic matter and iron oxides. The nickel adsorption was evaluated in the original samples and in those treated to remove organic matter and to remove both, organic matter and iron oxides, using 2 g soil + 20 mL of 0.01 mol L-1 CaCl2 solution containing 5 mg L-1 Ni, pH varying from 3.5 to 7.5. The nickel adsorption decreased with the elimination of organic matter. For the samples without organic matter and iron oxides, adsorption decreased only in the Anionic Rhodic Acrudox. The pH was the main factor involved in nickel adsorption variation, and for soil samples without organic matter and iron oxides, the maximum adsorption occurred at higher pH values.

Tolerance to iron chlorosis in non-grafted quince seedlings and in pear grafted onto quince plants

Grafting is a technique that may affect plant tolerance to iron chlorosis in plants cultivated for their fruit. Therefore, the objective of this study was to evaluate the tolerance of non-grafted quince seedlings and pear grafted onto quince plants cultivated in pots with alkaline soil. The experiment was conducted in a greenhouse at the University of Cordoba, Spain, in pots (3 L) filled with alkaline soil, with one plant per pot. The treatments consisted of two genotypes, quince (Cydonia oblonga Mill) semi-woody rooted cuttings, cultivar BA29, and pear (Pyrus Communis L.), cultivar Ercolini, grafted onto quince cultivar BA29 (rootstock), and two nutrient solutions with and without iron (80 mu M Fe-EDDHA) arranged in a completely random design with eight repetitions. Each pot received 250 mL of the nutrient solution on June 3rd, 2010. Chlorophyll indirect measurements and the main stem length were evaluated for six weeks after the commencement of the treatments. During the last week, the main stem dry matter weight and the leaf total iron content were determined. It was found that grafting pear seedlings onto quince rootstock resulted in a higher tolerance to iron deficiency than when quince was not grafted. Non-grafted quince plants without iron in the nutrient solution, compared to the results with its application, showed low SPAD (Soil-Plant Analyses Development) values and resulted in plants with a lower leaf iron content and lower dry matter production; however, decreased seedling stem growth was observed only in the last week of cultivation.

Comparison of the properties of compacted and porous lamellar chitosan-xanthan membranes as dressings and scaffolds for the treatment of skin lesions

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