Analytical/numerical hybrid solution for one-dimensional ablation problem

Ablation is a thermal protection process with several applications in engineering, mainly in the field of airspace industry. The use of conventional materials must be quite restricted, because they would suffer catastrophic flaws due to thermal degradation of their structures. However, the same materials can be quite suitable once being protected by well-known ablative materials. The process that involves the ablative phenomena is complex, could involve the whole or partial loss of material that is sacrificed for absorption of energy. The analysis of the ablative process in a blunt body with revolution geometry will be made on the stagnation point area that can be simplified as a one-dimensional plane plate problem, hi this work the Generalized Integral Transform Technique (GITT) is employed for the solution of the non-linear system of coupled partial differential equations that model the phenomena. The solution of the problem is obtained by transforming the non-linear partial differential equation system to a system of coupled first order ordinary differential equations and then solving it by using well-established numerical routines. The results of interest such as the temperature field, the depth and the rate of removal of the ablative material are presented and compared with those ones available in the open literature.

Estudo analítico/numérico do problema de ablação em corpos rombudos com simetria axial

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Processing and characterization of ablative composites used in rocket motors

The main objective of this research work was to obtain two formulations of ablative composites. These composites are also known as ablative structural composites, for applications in atmospherically severe conditions according to the high-temperature, hot gaseous products flow generated from the burning of solid propellants. The formulations were manufactured with phenolic resin reinforced with chopped carbon fiber. The composites were obtained by the hot compression molding technique. Another purpose of this work was to conduct the physical and chemical characterization of the matrix, the reinforcements and the composites. After the characterization, a nozzle divergent of each formulation was manufactured and its performance was evaluated through the rocket motor static firing test. According to the results found in this work, it was possible to observe through the characterization of the raw materials that phenolic resins showed peculiarities in their properties that differentiate one from the other, but did not exhibit significant differences in performance as a composite material for use in ablation conditions. Both composites showed good performance for use in thermal protection, confirmed by firing static tests (rocket motor). Composites made with phenolic resin and chopped carbon fiber showed that it is a material with excellent resistance to ablation process. This composite can be used to produce nozzle parts with complex geometry or shapes and low manufacturing cost.

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.

Corrosion protection of stainless steel by polysiloxane hybrid coatings prepared using the sol-gel process

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Ceramic coating for refractories protection against carbon oxidation, Part 1: Protection mechanisms

For retarding carbon oxidation in refractories during the preheating of metallurgical furnaces, a ceramic coating, made mainly of sodium phosphosilicate and clay was developed. The coating presents high adherence to the substrate with no swelling. The coating was characterized by thermal analysis, X-ray diffraction at room temperature (XRD) and at high temperature (HTXRD), X-ray fluorescence and scanning electronic microscopy (SEM). The glass transition temperature is reached at 800 °C and only glassy phase is observed above this temperature. Thus the mechanism of protection seems to be the formation of a glassy phase on the surface of the refractory, and the coating tends to be more efficient at temperatures higher than 800 °C.

Effects of tungsten carbide thermal spray coating by HP/HVOF and hard chromium electroplating on AISI 4340 high strength steel

In cases of decorative and functional applications, chromium results in protection against wear and corrosion combined with chemical resistance and good lubricity. However, pressure to identify alternatives or to improve conventional chromium electroplating mechanical characteristics has increased in recent years, related to the reduction in the fatigue strength of the base material and to environmental requirements. The high efficiency and fluoride-free hard chromium electroplating is an improvement to the conventional process, considering chemical and physical final properties. One of the most interesting, environmentally safer and cleaner alternatives for the replacement of hard chrome plating is tungsten carbide thermal spray coating, applied by the high velocity oxy-fuel (HVOF) process. The aim of this study was to analyse the effects of the tungsten carbide thermal spray coating applied by the HP/HVOF process and of the high efficiency and fluoride-free hard chromium electroplating (in the present paper called 'accelerated'), in comparison to the conventional hard chromium electroplating on the AISI 4340 high strength steel behaviour in fatigue, corrosion, and abrasive wear tests. The results showed that the coatings were damaging to the AISI 4340 steel behaviour when submitted to fatigue testing, with the tungsten carbide thermal spray coatings showing the better performance. Experimental data from abrasive wear tests were conclusive, indicating better results from the WC coating. Regarding corrosion by salt spray test, both coatings were completely corroded after 72 h exposure. Scanning electron microscopy technique (SEM) and optical microscopy were used to observe crack origin sites, thickness and adhesion in all the coatings and microcrack density in hard chromium electroplatings, to aid in the results analysis. © 2001 Elsevier Science B.V. All rights reserved.

Influence of thermal treatments in the corrosion behaviour of HVOF Cr 3C2-NiCr coatings

Thermal spray coatings as Cr3C2-NiCr obtained by high velocity oxy-fuel spraying (HVOF) are mainly applied due to their behaviour against aggressive erosive-abrasive and corrosive atmospheres and their thermal stability at high temperatures [1]. In order to increase the corrosion protection that it offers to the substrate trying to close the interconnected pores, it is possible to apply a thermal treatment with the gun during the spraying of the coating. This treatment could be applied in different ways. One of these ways consists of spraying only a few layers of coating followed by thermal treatment and finally the spray of the rest of layers. This thermal treatment on spraying is studied related to the corrosion properties of the system. The study comprises the electrochemical characterisation of the system by open circuit potential (OC), polarisation resistance (Rp), cyclic voltammetry (CV) and impedance spectroscopy measurements (EIS). Optical and scanning electron microscopy characterisation (OM and SEM) of the top and cross-section of the system has been used in order to justify the electrochemical results.