Hygrotermal effects evaluation using the losipescu shear test for glare laminates

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

Utilização de lama vermelha para oxidação eletrolítica assistida por plasma de liga de alumínio

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Neural models for predicting hole diameters in drilling processes

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

Neural models for predicting hole diameters in drilling processes

Conselho Nacional de Desenvolvimento Científico e Tecnológico (CNPq)

Usinagem do alumínio da classe 6005 com uso de ferramenta cerâmica

The machining process is so much important in the economic world. Many machining parameters have been studied to maximize results, in terms of cost and lifetime. (decrease of cutting tool wear, improved surface finish, among others). The objective of this study is to evaluate the wear of a ceramic tool in the machining of the aluminum alloy 6005 A. The analysis of the wear of the cutting tools is very important due to its big impact on the final finishing of the piece as a whole. The evaluation took place in two stages, first it was done a detailed study of the literature of the whole machining process, where the study of the formation and swarf classification were among the most important steps in this phase. The second step consisted in the machining of the piece of aluminum 6005 A with a ceramic cutting tool constituded of aluminum oxide and magnesium oxide with silicon carbide impregnation. The swarf generated in this process was then photographed with a Zeiss optical microscope and analyzed for its size and shape. Through this comparison it was concluded that the swarf are generated shear swarfs, shaped like a tangled, fragmented and arcs connected, thus classifying the material as medium difficulty machining. Through the image analysis tool it was concluded that the parameter of lower wear was the: Vc = 500m / min, f = 0.10mm / rev and ap = 0.5mm

Torneamento da liga de alumínio da classe 6005 utilizando ferramenta cerâmica

Machining processes are one of the most important manufacturing processes in the modern world. In these processes, there are many elements which will influence in the final result of the machined part. Among them, the tools are the principal factor of the rising cost, because its global influence on the process. In aeronautical industries, this can be more evidenced due the need to machining several alloys, between them, aluminum alloys. These alloys have to demonstrate a specific surface finishing to be used in aircraft's fuselage. This kind of industry is one of the segments which is still rising in Brazil, and they are looking viable alternatives in the manufacturing processes of materials, due the need to produce more and more parts and equipment, with costs increasingly reduced. The purpose of this project is the development of a ceramic with differentiated properties. The ceramics were developed using a pre-sintering at 1200 °C, with posterior sintering at 1600°C, and subjected to dry turning process on aluminum alloy 6005. The characterizations showed that ceramics presented with toughness on the center of 1700 MPa and on the surface of 1950 MPa, density 98,5 ±0,14. g/cm³. Ceramics were grinded and faceted, according to ISO standard 1832, and subjected to turning tests in a ROMI lathe brand, model GL240M, using cutting speeds of 500, 800 and 1000 m/min with different feed rates. The machining results showed low occurrence of flank wear to all cutting speeds, and better surface finishing average values of Ra = 0,4935 μm and Rt = 8,112 μm. In general, it could be seen that the tool presents important potential to machining 6005 alloy, and that the use of correct parameters can decrease and/or eliminate subsequent processes, providing important reductions in costs related to the machining processes

Análise e comparação de orelhamento na liga AA3104 após laminação a quente

Aluminum has been widely used in the forming and manufacture of beverage cans, specific aluminum alloy AA3104, which manufacturers are increasingly demanding as to mechanical properties, quality and reducing waste. This work describes the analysis and comparison of the behavior of earing AA3104 aluminum alloy samples of final thicknesses of 1.80 and 2.10 mm. Were obtained after a hot rolling process, a total population of 86 samples for the two different thicknesses, of which 23 samples of 1.80 mm and 2.10 mm 63 samples. After removal of samples, there was a mechanical test inlay, then characterizing the earing in them. The results earing to the thicknesses of 1.80 and 2.10 mm were analyzed and compared statistically to give 7.1% and 7.4% on average, respectively, correlated with the hot rolling process variables, showing that they are statistically equal and that the process variables do not affect the end result desired, ranging from 7.0 to 7,5%

Usinagem do alumínio da classe 6005 com uso de ferramenta cerâmica

The machining process is so much important in the economic world. Many machining parameters have been studied to maximize results, in terms of cost and lifetime. (decrease of cutting tool wear, improved surface finish, among others). The objective of this study is to evaluate the wear of a ceramic tool in the machining of the aluminum alloy 6005 A. The analysis of the wear of the cutting tools is very important due to its big impact on the final finishing of the piece as a whole. The evaluation took place in two stages, first it was done a detailed study of the literature of the whole machining process, where the study of the formation and swarf classification were among the most important steps in this phase. The second step consisted in the machining of the piece of aluminum 6005 A with a ceramic cutting tool constituded of aluminum oxide and magnesium oxide with silicon carbide impregnation. The swarf generated in this process was then photographed with a Zeiss optical microscope and analyzed for its size and shape. Through this comparison it was concluded that the swarf are generated shear swarfs, shaped like a tangled, fragmented and arcs connected, thus classifying the material as medium difficulty machining. Through the image analysis tool it was concluded that the parameter of lower wear was the: Vc = 500m / min, f = 0.10mm / rev and ap = 0.5mm

Torneamento da liga de alumínio da classe 6005 utilizando ferramenta cerâmica

Machining processes are one of the most important manufacturing processes in the modern world. In these processes, there are many elements which will influence in the final result of the machined part. Among them, the tools are the principal factor of the rising cost, because its global influence on the process. In aeronautical industries, this can be more evidenced due the need to machining several alloys, between them, aluminum alloys. These alloys have to demonstrate a specific surface finishing to be used in aircraft's fuselage. This kind of industry is one of the segments which is still rising in Brazil, and they are looking viable alternatives in the manufacturing processes of materials, due the need to produce more and more parts and equipment, with costs increasingly reduced. The purpose of this project is the development of a ceramic with differentiated properties. The ceramics were developed using a pre-sintering at 1200 °C, with posterior sintering at 1600°C, and subjected to dry turning process on aluminum alloy 6005. The characterizations showed that ceramics presented with toughness on the center of 1700 MPa and on the surface of 1950 MPa, density 98,5 ±0,14. g/cm³. Ceramics were grinded and faceted, according to ISO standard 1832, and subjected to turning tests in a ROMI lathe brand, model GL240M, using cutting speeds of 500, 800 and 1000 m/min with different feed rates. The machining results showed low occurrence of flank wear to all cutting speeds, and better surface finishing average values of Ra = 0,4935 μm and Rt = 8,112 μm. In general, it could be seen that the tool presents important potential to machining 6005 alloy, and that the use of correct parameters can decrease and/or eliminate subsequent processes, providing important reductions in costs related to the machining processes

Análise e comparação de orelhamento na liga AA3104 após laminação a quente

Aluminum has been widely used in the forming and manufacture of beverage cans, specific aluminum alloy AA3104, which manufacturers are increasingly demanding as to mechanical properties, quality and reducing waste. This work describes the analysis and comparison of the behavior of earing AA3104 aluminum alloy samples of final thicknesses of 1.80 and 2.10 mm. Were obtained after a hot rolling process, a total population of 86 samples for the two different thicknesses, of which 23 samples of 1.80 mm and 2.10 mm 63 samples. After removal of samples, there was a mechanical test inlay, then characterizing the earing in them. The results earing to the thicknesses of 1.80 and 2.10 mm were analyzed and compared statistically to give 7.1% and 7.4% on average, respectively, correlated with the hot rolling process variables, showing that they are statistically equal and that the process variables do not affect the end result desired, ranging from 7.0 to 7,5%

Sviluppo di sperimentazioni per la produzione di getti in lega di alluminio a caratteristiche difettologiche e microstrutturali controllate, per la validazione di modelli di previsione delle porosità

Nei processi di progettazione e produzione tramite tecnologie di colata di componenti in alluminio ad elevate prestazioni, risulta fondamentale poter prevedere la presenza e la quantità di difetti correlabili a design non corretti e a determinate condizioni di processo. Fra le difettologie più comuni di un getto in alluminio, le porosità con dimensioni di decine o centinaia di m, note come microporosità, hanno un impatto estremamente negativo sulle caratteristiche meccaniche, sia statiche che a fatica. In questo lavoro, dopo un’adeguata analisi bibliografica, sono state progettate e messe a punto attrezzature e procedure sperimentali che permettessero la produzione di materiale a difettologia e microstruttura differenziata, a partire da condizioni di processo note ed accuratamente misurabili, che riproducessero la variabilità delle stesse nell’ambito della reale produzione di componenti fusi. Tutte le attività di progettazione delle sperimentazioni, sono state coadiuvate dall’ausilio di software di simulazione del processo fusorio che hanno a loro volta beneficiato di tarature e validazioni sperimentali ad hoc. L’apparato sperimentale ha dimostrato la propria efficacia nella produzione di materiale a microstruttura e difettologia differenziata, in maniera robusta e ripetibile. Utilizzando i risultati sperimentali ottenuti, si è svolta la validazione di un modello numerico di previsione delle porosità da ritiro e gas, ritenuto ad oggi allo stato dell’arte e già implementato in alcuni codici commerciali di simulazione del processo fusorio. I risultati numerici e sperimentali, una volta comparati, hanno evidenziato una buona accuratezza del modello numerico nella previsione delle difettologie sia in termini di ordini di grandezza che di gradienti della porosità nei getti realizzati.

Desarrollo de nuevos tratamientos térmicos para aleaciones avanzadas de interés aeroespacial

La corrosión bajo tensiones (SCC) es un problema de gran importancia en las aleaciones de aluminio de máxima resistencia (serie Al-Zn-Mg-Cu). La utilización de tratamientos térmicos sobremadurados, en particular el T73, ha conseguido prácticamente eliminar la susceptibilidad a corrosión bajo tensiones en dichas aleaciones pero a costa de reducir su resistencia mecánica. Desde entonces se ha tratado de optimizar simultáneamente ambos comportamientos, encontrándose para ello diversos inconvenientes entre los que destacan: la dificultad de medir experimentalmente el crecimiento de grieta por SCC, y el desconocimiento de las causas y el mecanismo por el cual se produce la SCC. Los objetivos de esta Tesis son mejorar el sistema de medición de grietas y profundizar en el conocimiento de la SCC, con el fin de obtener tratamientos térmicos que aúnen un óptimo comportamiento tanto en SCC como mecánico en las aleaciones de aluminio de máxima resistencia utilizadas en aeronáutica. Para conseguir los objetivos anteriormente descritos se han realizado unos cuarenta tratamientos térmicos diferentes, de los cuales la gran mayoría son nuevos, para profundizar en el conocimiento de la influencia de la microestructura (fundamentalmente, de los precipitados coherentes) en el comportamiento de las aleaciones Al-Zn-Mg-Cu, y estudiar la viabilidad de nuevos tratamientos apoyados en el conocimiento adquirido. Con el fin de obtener unos resultados aplicables a productos o semiproductos de aplicación aeronáutica, los tratamientos térmicos se han realizado a trozos grandes de una plancha de 30 mm de espesor de la aleación de aluminio 7475, muy utilizada en las estructuras aeronáuticas. Asimismo con el objeto de conseguir una mayor fiabilidad de los resultados obtenidos se han utilizado, normalmente, tres probetas de cada tratamiento para los diferentes ensayos realizados. Para la caracterización de dichos tratamientos se han utilizado diversas técnicas: medida de dureza y conductividad eléctrica, ensayos de tracción, calorimetría diferencial de barrido (DSC), metalografía, fractografía, microscopia electrónica de transmisión (MET) y de barrido (MEB), y ensayos de crecimiento de grieta en probeta DCB, que a su vez han permitido hacer una estimación del comportamiento en tenacidad del material. Las principales conclusiones del estudio realizado se pueden resumir en las siguientes: Se han diseñado y desarrollado nuevos métodos de medición de grieta basados en el empleo de la técnica de ultrasonidos, que permiten medir el crecimiento de grieta por corrosión bajo tensiones con la precisión y fiabilidad necesarias para valorar adecuadamente la susceptibilidad a corrosión bajo tensiones. La mejora de medida de la posición del frente de grieta ha dado lugar, entre otras cosas, a la definición de un nuevo ensayo a iniciación en probetas preagrietadas. Asimismo, se ha deducido una nueva ecuación que permite calcular el factor de intensidad de tensiones existente en punta de grieta en probetas DCB teniendo en cuenta la influencia de la desviación del plano de crecimiento de la grieta del plano medio de la probeta. Este aspecto ha sido determinante para poder explicar los resultados experimentales obtenidos ya que el crecimiento de la grieta por un plano paralelo al plano medio de la probeta DCB pero alejado de él reduce notablemente el factor de intensidades de tensiones que actúa en punta de grieta y modifica las condiciones reales del ensayo. Por otro lado, se han identificado los diferentes constituyentes de la microestructura de precipitación de todos los tratamientos térmicos estudiados y, en especial, se ha conseguido constatar (mediante MET y DSC) la existencia de zonas de Guinier-Preston del tipo GP(II) en la microestructura de numerosos tratamientos térmicos (no descrita en la bibliografía para las aleaciones del tipo de la estudiada) lo que ha permitido establecer una nueva interpretación de la evolución de la microestructura en los diferentes tratamientos. Al hilo de lo anterior, se han definido nuevas secuencias de precipitación para este tipo de aleaciones, que han permitido entender mejor la constitución de la microestructura y su relación con las propiedades en los diferentes tratamientos térmicos estudiados. De igual manera, se ha explicado el papel de los diferentes microconstituyentes en diversas propiedades mecánicas (propiedades a tracción, dureza y tenacidad KIa); en particular, el estudio realizado de la relación de la microestructura con la tenacidad KIa es inédito. Por otra parte, se ha correlacionado el comportamiento en corrosión bajo tensiones, tanto en la etapa de incubación de grieta como en la de propagación, con las características medidas de los diferentes constituyentes microestructurales de los tratamientos térmicos ensayados, tanto de interior como de límite de grano, habiéndose obtenido que la microestructura de interior de grano tiene una mayor influencia en el comportamiento en corrosión bajo tensiones que la de límite de grano. De forma especial, se ha establecido la importancia capital, y muy negativa, de la presencia en la microestructura de zonas de Guinier-Preston en el crecimiento de la grieta por corrosión bajo tensiones. Finalmente, como consecuencia de todo lo anterior, se ha propuesto un nuevo mecanismo por el que se produce la corrosión bajo tensiones en este tipo de aleaciones de aluminio, y que de forma muy resumida se puede concretar lo siguiente: la acumulación de hidrógeno (formado, básicamente, por un proceso corrosivo de disolución anódica) delante de la zonas GP (en especial, de las zonas GP(I)) próximas a la zona libre de precipitados que se desarrolla alrededor del límite de grano provoca enfragilización local y causa el rápido crecimiento de grieta característico de algunos tratamientos térmicos de este tipo de aleaciones. ABSTRACT The stress corrosion cracking (SCC) is a major problem in the aluminum alloys of high resistance (series Al-Zn-Mg-Cu). The use of overaged heat treatments, particularly T73 has achieved virtually eliminate the susceptibility to stress corrosion cracking in such alloys but at the expense of reducing its mechanical strength. Since then we have tried to simultaneously optimize both behaviors, several drawbacks found for it among them: the difficulty of measuring experimentally the SCC crack growth, and ignorance of the causes and the mechanism by which SCC occurs. The objectives of this thesis are to improve the measurement system of cracks and deeper understanding of the SCC, in order to obtain heat treatments that combine optimum performance in both SCC and maximum mechanical strength in aluminum alloys used in aerospace To achieve the above objectives have been made about forty different heat treatments, of which the vast majority are new, to deepen the understanding of the influence of microstructure (mainly of coherent precipitates) in the behavior of the alloys Al -Zn-Mg-Cu, and study the feasibility of new treatments supported by the knowledge gained. To obtain results for products or semi-finished aircraft application, heat treatments were performed at a large pieces plate 30 mm thick aluminum alloy 7475, widely used in aeronautical structures. Also in order to achieve greater reliability of the results obtained have been used, normally, three specimens of each treatment for various tests. For the characterization of these treatments have been used several techniques: measurement of hardness and electrical conductivity, tensile testing, differential scanning calorimetry (DSC), metallography, fractography, transmission (TEM) and scanning (SEM) electron microscopy, and crack growth tests on DCB specimen, which in turn have allowed to estimate the behavior of the material in fracture toughness. The main conclusions of the study can be summarized as follows: We have designed and developed new methods for measuring crack based on the use of the ultrasound technique, for measuring the growth of stress corrosion cracks with the accuracy and reliability needed to adequately assess the susceptibility to stress corrosion. Improved position measurement of the crack front has resulted, among other things, the definition of a new initiation essay in pre cracked specimens. Also, it has been inferred a new equation to calculate the stress intensity factor in crack tip existing in DCB specimens considering the influence of the deviation of the plane of the crack growth of the medium plane of the specimen. This has been crucial to explain the experimental results obtained since the crack growth by a plane parallel to the medium plane of the DCB specimen but away from it greatly reduces the stress intensity factor acting on the crack tip and modifies the actual conditions of the essay. Furthermore, we have identified the various constituents of the precipitation microstructure of all heat treatments studied and, in particular note has been achieved (by TEM and DSC) the existence of the type GP (II) of Guinier-Preston zones in the microstructure of several heat treatments (not described in the literature for alloys of the type studied) making it possible to establish a new interpretation of the evolution of the microstructure in the different treatments. In line with the above, we have defined new precipitation sequences for these alloys, which have allowed a better understanding of the formation of the microstructure in relation to the properties of different heat treatments studied. Similarly, explained the role of different microconstituents in various mechanical properties (tensile properties, hardness and toughness KIa), in particular, the study of the relationship between the tenacity KIa microstructure is unpublished. Moreover, has been correlated to the stress corrosion behavior, both in the incubation step as the crack propagation, with the measured characteristics of the various microstructural constituents heat treatments tested, both interior and boundary grain, having obtained the internal microstructure of grain has a greater influence on the stress corrosion cracking behavior in the grain boundary. In a special way, has established the importance, and very negative, the presence in the microstructure of Guinier-Preston zones in crack growth by stress corrosion. Finally, following the above, we have proposed a new mechanism by which stress corrosion cracking occurs in this type of aluminum alloy, and, very briefly, one can specify the following: the accumulation of hydrogen (formed basically by a corrosive process of anodic dissolution) in front of the GP zones (especially the GP (I) zones) near the precipitates free zone that develops around grain boundary causes local embrittlement which characterizes rapid crack growth of some heat treatments such alloys.

Strength-ductility behaviour of Al-Si-Cu-Mg casting alloys in T6 temper

A comparative study of the mechanical properties of 20 experimental alloys has been carried out. The effect of different contents of Si, Cu, Mg, Fe and Mn, as well as solidification rate, has been assessed using a strength-ductility chart and a quality index-strength chart developed for the alloys. The charts show that the strength generally increases and the ductility decreases with an increasing content of Cu and Mg. Increased Fe (at Fe/Mn ratio 0.5) dramatically lowers the ductility and strength of low Si alloys. Increased Si content generally increases the strength and the ductility. The increase in ductility with increased Si is particularly significant when the Fe content is high. The charts are used to show that the cracking of second phase particles imposes a limit to the maximum achievable strength by limiting the ductility of strong alloys. The (Cu + Mg) content (at.%), which determines the precipitation strengthening and the volume fraction of Cu-rich and Mg-rich intermetallics, can be used to select the alloys for given strength and ductility, provided the Fe content stays below the Si-dependent critical level for the formation of pre-eutectic alpha-phase particles or beta-phase plates.

Migration of crystals during the filling of semi-solid castings

In cold-chamber high-pressure die castings (HPDC), the microstructure consists of coarse externally solidified crystals (ESCs) that are commonly observed in the central region of cross sections. In the present work, controlled laboratory scale casting experiments have been conducted with particular emphasis on the flow and solidification conditions. An A356 aluminum alloy was used to produce castings by pouring semi-solid metal through a steel die. Microstructures similar to those encountered in HPDC have been produced and the resulting microstructure is found to depend on the melt and die temperature: (1) the fraction of ESCs determines the extent of migration to the central region; (2) a maximum packing determines the area fraction of ESCs in the center; and (3) the die temperature affects the position of the ESCs-a higher die temperature can induce a displaced ESC distribution. It is found that the n-figration of crystals to the central region requires a flow, which is constrained at all melt/die interfaces. Furthermore, potential lift mechanisms are discussed. An assessment of the Saffman lift force on individual particles shows it has no significant effect on the migration of ESCs.

Recommendations and guidelines for the performance of accurate heat transfer measurements in rapid forming processes

The published requirements for accurate measurement of heat transfer at the interface between two bodies have been reviewed. A strategy for reliable measurement has been established, based on the depth of the temperature sensors in the medium, on the inverse method parameters and on the time response of the sensors. Sources of both deterministic and stochastic errors have been investigated and a method to evaluate them has been proposed, with the help of a normalisation technique. The key normalisation variables are the duration of the heat input and the maximum heat flux density. An example of application of this technique in the field of high pressure die casting is demonstrated. The normalisation study, coupled with previous determination of the heat input duration, makes it possible to determine the optimum location for the sensors, along with an acceptable sampling rate and the thermocouples critical response-time (as well as eventual filter characteristics). Results from the gauge are used to assess the suitability of the initial design choices. In particular the unavoidable response time of the thermocouples is estimated by comparison with the normalised simulation. (c) 2006 Elsevier Ltd. All rights reserved.