3-D reconstruction by extended depth-of-field in failure analysis - Case study I: Qualitative fractographic investigation of fractured bolts in a partial valve

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

Desgaste de ferramentas no torneamento com alta velocidade de corte da superliga waspaloy

Nesse trabalho, procurou-se estudar os mecanismos de desgaste de diversas geometrias de ferramentas cerâmicas (Al2O3 + SiCw e Al2O3 + TiC) e ferramentas de PCBN. Para isto foram realizados ensaios de torneamento com alta velocidade de corte em uma superliga à base de níquel (Waspaloy) com dureza de aproximadamente 40 HRC sob condição de corte a seco. As superligas são conhecidas como materiais de difícil usinabilidade devido à alta dureza, alta resistência mecânica em alta temperatura, afinidade para reagir com materiais da ferramenta e baixa condutividade térmica. Os resultados mostraram que o material da ferramenta e a geometria influenciaram o comportamento dos mecanismos de desgaste. de uma maneira geral, o tipo de desgaste dominante foi o de entalhe e os mecanismos foram abrasão, attrition (aderência com arrastamento) e provável difusão na maioria das ferramentas utilizadas.

Avaliação da usinagem do INCONEL 718

The nickel superalloys are known as being a material with poor machinability, they have some properties like high hardness, good resistance at high temperature, tendency to weld with the tool material at high temperature, etc. In the aerospace, biomedical and petrochemical industry, are increasing the need to use materials that resist to aggressive process and environment. In these uses, it has increased the use of nickel-based superalloys like Inconel 718 and consequently the need to research new techniques and tools to improve the machinability of this material. For the superalloys and resistant alloys at high temperatures is considered that the difficulty in the machining regards to the combination of the relatively high cutting forces and high temperatures that grow during the machine process, causing deformation or breakage of the cutting tool. This work purpose is to develop the study of the machining of external cylindrical turning of the nickel based alloy Inconel 718, using ceramic tools, seeking the optimization of machining this alloy, looking to provide real productive increases without the need of investments in new production means. The machining test were accomplished using commercials hard metal tools and the results were compared each other to find the best tool and the best parameter. The conclusion is that the tool TNMG160408-23 -class 1005- was the better one, when used with the parameter 60_15_08

Estudo da formação do cavaco no torneamento de superligas de níquel

Pós-graduação em Engenharia Mecânica - FEG

Magnetic properties of Cu1+xMn2-xO4 and Ni1+xMn2-xO4 solid solutions

Magnetic properties of two spinel oxides solid solutions, Cul+xMn2-xO4 and Ni1+xMn2-xO4 are reported. These series are characterized by two magnetic transitions: the upper one, of ferrimagnetic type, occurs at about 85 K (for copper-based) and at 105-110 K (for nickel-based spinels), independently of the x-content: the lower transition may be related to a Neel-type collinear ordering and takes place at 30 and 45 K, respectively. Application of moderate fields (H > 250 Oe) make both transitions to merge into one broad maximum in the magnetization, which takes place at lower temperature when applying larger fields. Magnetization cycles with temperature (ZFC/FC) or field (loops) allowed us to well characterize the ordered state. The effective moment follows the expected behavior when manganese ions are being substituted by ions of lower magnetic moment (Ni(2+)andCU(2+)). (c) 2007 Elsevier Ltd. All rights reserved.

Spin reversal and magnetization jumps in ErMexMn1-xO3 perovskites (Me = Ni, Co)

The erbium-based manganite ErMnO3 has been partially substituted at the manganese site by the transition-metal elements Ni and Co. The perovskite orthorhombic structure is found from x(Ni) = 0.2-0.5 in the nickel-based solid solution ErNixMn1-xO3, while it can be extended up to x(Co) = 0.7 in the case of cobalt, provided that the synthesis is performed under oxygenation conditions to favor the presence of Co3+. Presence of different magnetic entities (i.e., Er3+, Ni2+, Co2+, Co3+, Mn3+, and Mn4+) leads to quite unusual magnetic properties, characterized by the coexistence of antiferromagnetic and ferromagnetic interactions. In ErNixMn1-xO3, a critical concentration x(crit)(Ni) = 1/3 separates two regimes: spin-canted AF interactions predominate at x < x(crit), while the ferromagnetic behavior is enhanced for x > x(crit). Spin reversal phenomena are present both in the nickel- and cobalt-based compounds. A phenomenological model based on two interacting sublattices, coupled by an antiferromagnetic exchange interaction, explains the inversion of the overall magnetic moment at low temperatures. In this model, the ferromagnetic transition-metal lattice, which orders at T-c, creates a strong local field at the erbium site, polarizing the Er moments in a direction opposite to the applied field. At low temperatures, when the contribution of the paramagnetic erbium sublattice, which varies as T-1, gets larger than the ferromagnetic contribution, the total magnetic moment changes its sign, leading to an overall ferrimagnetic state. The half-substituted compound ErCo0.50Mn0.50O3 was studied in detail, since the magnetization loops present two well-identified anomalies: an intersection of the magnetization branches at low fields, and magnetization jumps at high fields. The influence of the oxidizing conditions was studied in other compositions close to the 50/50 = Mn/Co substitution rate. These anomalies are clearly connected to the spin inversion phenomena and to the simultaneous presence of Co2+ and Co3+ magnetic moments. Dynamical aspects should be considered to well identify the high-field anomaly, since it depends on the magnetic field sweep rate. (C) 2006 Elsevier B.V. All rights reserved.

Cutting performance of diamond coated Si3N4 tool during turning

Silicon nitride cutting tools have been used successfully for machining hard materials, like: cast irons, nickel based alloys, etc. However these cutting tools with diamond coating present little information on dry turning operations of gray cast iron. In the present work, Si3N4 square inserts was developed, characterized and subsequently coated with diamond for dry machining operations on gray cast iron. All experiments were conducted with replica. It was used a 1500, 3000, 4500 m cutting length, feed rate of 0.33 mm/rev and keeping the depth of cut constant and equal to 1 mm. The results show that wear in the tool tips of the Si3N4 inserts, in all cutting conditions, was caused by both mechanical and chemical processes. To understand the tool wear mechanisms, a morphological analysis of the inserts, after experiments, has been performed by SEM and optical microscopy. Diamond coated PVD inserts showed to be capable to reach large cutting lengths when machining gray cast iron. © (2010) Trans Tech Publications.

Automatic microstructural characterization and classification using artificial intelligence techniques on ultrasound signals

Secondary phases such as Laves and carbides are formed during the final solidification stages of nickel based superalloy coatings deposited during the gas tungsten arc welding cold wire process. However, when aged at high temperatures, other phases can precipitate in the microstructure, like the γ″ and δ phases. This work presents a new application and evaluation of artificial intelligent techniques to classify (the background echo and backscattered) ultrasound signals in order to characterize the microstructure of a Ni-based alloy thermally aged at 650 and 950 °C for 10, 100 and 200 h. The background echo and backscattered ultrasound signals were acquired using transducers with frequencies of 4 and 5 MHz. Thus with the use of features extraction techniques, i.e.; detrended fluctuation analysis and the Hurst method, the accuracy and speed in the classification of the secondary phases from ultrasound signals could be studied. The classifiers under study were the recent optimum-path forest (OPF) and the more traditional support vector machines and Bayesian. The experimental results revealed that the OPF classifier was the fastest and most reliable. In addition, the OPF classifier revealed to be a valid and adequate tool for microstructure characterization through ultrasound signals classification due to its speed, sensitivity, accuracy and reliability. © 2013 Elsevier B.V. All rights reserved.

Utilização de técnicas do planejamento de experimentos na otimização de um processo de torneamento da superliga NIMONIC 80A

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Estudo da usinagem em torneamento da superliga a base de niquel NIMONIC 80

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Efeito da aplicação do fluido de corte na usinagem da superliga Nimonic 80A

The nickel alloys have a chemical composition with high tenor of alloy elements which are responsible for the material's mechanical and thermal properties, but also are the main causative of problems during the machining, making the process difficult. The objective of this work is the study of the machining by external cylindrical turning of the nickel based alloy Nimonic 80A, seeking the machining optimization of this alloy, seeking the best condition of lubricant fluid use, providing real increases of productivity without the need of investments in new production means. Besides, the results of this work should offer more detailed information regarding the behavior of this alloy in relation to machining by turning. The machining experiences were accomplished in a specimen of the nickel alloy, considering the machining parameters: cutting speed (75 and 90 m/min), cutting depth (0,8 mm) and feed rate (0,15 and 0,18 mm/v). The valuations were accomplished in a CNC lathe and tools with of hard metal inserts. After each stage of the turning the measures of the cutting length were accomplished, of the waste of the tools through a magnifying glass (8x) and the roughness of the specimen evaluated in each phase of the process, with the aid of a portable roughness meter. Through light optical microscopy it was possible to observe the wear of the cutting tools for each appraised condition. The roughness values, Ra and Ry, for the appraised conditions were always superiors to the theoretical values. After analysis of the results it was possible to end that, the best acting for this work strip tested it was obtained for ap=0,8mm: f=0,15mm/rev and VC=75m/min, what resulted in a larger cutting length (1811 m)

Usinagem da liga de níquel inconel 718 com pastilhas de cerâmica

The machining of super alloys resistant to high temperatures such as nickel alloys, inconel 718 specifically, is a very difficult job to obtain improvements in the process, due to the difficulty of machining at high cutting speeds, the use of these alloys in industries showed great developments in recent years, its application in aeronautical industry spread being used in vane turbo, compressor parts, props and set elements. The automotive, chemical, medical and others also took advantage of the great features of inconel 718 and has used the material. The high temperature resistant alloys have high machining difficulty, a fact that is associated with high cutting forces generated during machining which result in high temperatures. High levels of temperatures can cause deterioration of the cutting edge, with subsequent deformation or breakage, wear most common obtained in machining such materials are flank wear the formation of built-up edge for cutting and notch wear. The experimental part of the work consists in machining of nickel-based alloy Inconel 718 heat treated for hardness, using a tool based ceramic silicon nitride Sandvik (Si3N4) in order to compare the best results obtained in the master's thesis of SANTOS (2010) who used a tool ceramics also the basis of silicon nitride which was developed in the doctoral thesis of SOUZA (2005). Assays were performed on a CNC lathe and was noted for each cutting edge results obtained. Tests were made starting from an initial condition of the tool with cutting speed of 200 m/min, feed 0.5 mm and 0.5 mm depth of cut was reduced cutting speed for the subsequent tests with the same conditions of feed and depth of cut. The tool presented wear instant under two 200 m/min and 100 m/min, premature rupture of 50 m/min and finally cut provided with difficulty... (Complete abstract click electronic access below)

Utilização de metaheurísticas combinada a diferentes métodos de aglutinação para a otimização de um processo de torneamento com múltiplas respostas

Pós-graduação em Engenharia Mecânica - FEG

Ultrasonic sensor signals and optimum path forest classifier for the microstructural characterization of thermally-aged inconel 625 alloy

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

An electrochemical sensor for dipyrone determination based on nickel-salen film modified electrode

An amperometric dipyrone sensor based on a polymeric nickel-salen (salen = N,N'-ethylenebis(salicydeneiminato)) film coated platinum electrode was developed. The sensor was constructed by electropolymerization of nickel-salen complex at a platinum electrode in acetonitrile/tetrabuthylamonium perchlorate by cyclic voltammetry. After cycling the modified electrode in a 0.50 mol L-1 KCl solution, the estimated surface concentration was found to be equal to 1.29 x 10(-9) mol cm(-2). This is a typical behavior of an electrode surface immobilized with a redox couple that can usually be considered as a reversible single-electron reduction/oxidation of the nickel(II)/nickel(III) couple. A plot of the anodic current versus the dipyrone concentration for chronoamperometry (potential fixed = +0.50 V) at the sensor was linear in the 4.7 x 10(-6) to 1.1 x 10(-4) mol L-1 concentration range and the concentration limit was 1.2 x 10(-6) mol L-1. The proposed electrode is useful for the quality control and routine analysis of dipyrone in pharmaceutical formulations.