Abrasion and corrosion resistance of new Ni-based coating deposited by HVOF thermal spray process

Coatings based on NiCrAlC intermetallic based alloy were applied on AISI 316L stainless steel substrates using a high velocity oxygen fuel torch. The influence of the spray parameters on friction and abrasive wear resistance were investigated using an instrumented rubber wheel abrasion test, able to measure the friction forces. The corrosion behaviour of the coatings were studied with electrochemical techniques and compared with the corrosion resistance of the substrate material. Specimens prepared using lower O(2)/C(3)H(8) ratios showed smaller porosity values. The abrasion wear rate of the NiCrAlC coatings was much smaller than that described in the literature for bulk as cast materials with similar composition and one order of magnitude higher than bulk cast and heat treated (aged) NiCrAlC alloy. All coatings showed higher corrosion resistance than the AISI 316L substrate in HCl (5%) aqueous solution at 40 degrees C.

Effect of cerium (IV) ions on the anticorrosion properties of siloxane-poly(methyl methacrylate) based film applied on tin coated steel

This work investigates the influence of the addition of cerium (IV) ions on the anticorrosion properties of organic-inorganic hybrid coatings applied to passivated tin coated steel. In order to evaluate the specific effect of cerium (IV) addition on nanostructural features of the organic and inorganic phases of the hybrid coating, the hydrolytic polycondensation of silicon alkoxide and the radical polymerization of the methyl methacrylate (MMA) function were induced separately. The corrosion resistance of the coatings was evaluated by means of linear polarization, Tafel type curves and electrochemical impedance measurements. The impedance results obtained for the hybrid coatings were discussed based on an electrical equivalent circuit used to fit the experimental data. The electrochemical results clearly showed the improvement of the protective properties of the organic-inorganic hybrid coating mainly when the cerium (IV) was added to the organic phase solution precursor, which seemed to be due to the formation of a more uniform and densely reticulated siloxane-PMMA film. (C) 2010 Elsevier Ltd. All rights reserved.

The effect of metal transfer modes and shielding gas composition on the emission of ultraafine particles in MAG steel welding

The present study aims to characterize ultrafine particles emitted during gas metal arc welding of mild steel and stainless steel, using different shielding gas mixtures, and to evaluate the effect of metal transfer modes, controlled by both processing parameters and shielding gas composition, on the quantity and morphology of the ultrafine particles. It was found that the amount of emitted ultrafine particles (measured by particle number and alveolar deposited surface area) are clearly dependent from the main welding parameters, namely the current intensity and the heat input of the Welding process. The emission of airborne ultrafine particles increases with the current intensity as fume formation rate does. When comparing the shielding gas mixtures, higher emissions were observed for more oxidizing mixtures, that is, with higher CO2 content, which means that these mixtures originate higher concentrations of ultrafine particles (as measured by number of particles. by cubic centimeter of air) and higher values of alveolar deposited surface area of particles, thus resulting in a more hazardous condition regarding welders exposure.

Electrochemical and analytical investigation of passive films formed on stainless steels in alkaline media

Passive films were grown in potentiodynamic mode, by cyclic voltammetry on AISI 316 and AISI 304 stainless steels. The composition of these films was investigated by X-ray photoelectron spectroscopy (XPS). The electrochemical behaviour and the chemical composition of the passive films formed by cyclic voltammetry were compared to those of films grown under natural conditions (by immersion at open circuit potential, OCP) in alkaline solutions simulating concrete. The study included the effect of pH of the electrolyte and the effect of the presence of chloride ions. The XPS results revealed important changes in the passive film composition, which becomes enriched in chromium and depleted in magnetite as the pH decreases. On the other hand, the presence of chlorides promotes a more oxidised passive layer. The XPS results also showed relevant differences on the composition of the oxide layers for the films formed under cyclic voltammetry and/or under OCP.

Estudo da corrosão em diferentes tipos de aço

Mestrado em Engenharia Química - Ramo Optimização Energética na Indústria Química

Establishing the main Guidelines for Cast Steel to Produce Truck Parts

Este trabalho foi realizado na Scania CV AB e teve como principal objectivo estabelecer uma diretriz sobre a possível utilização de aços vazados. Existe uma grande necessidade na realização deste trabalho, de forma a apoiar os engenheiros de projecto no seu processo de selecção dos materiais mais adequados, para produzir componentes mais leves e de elevado desempenho. Esta diretriz apresenta informação relacionada com propriedades mecânicas, processos de fundição, vazabilidade, tipologia de defeitos, tratamentos térmicos, soldabilidade e tratamentos superficiais dos aços vazados. Este trabalho foi limitado, na seleção de materiais para componentes do camião, a aços vazados que poderiam ser aplicados em dois componentes específicos: um componente estrutural da carroçaria sujeito a esforços de fadiga e a um colector de gases de combustão, sujeito a fluência, oxidação, fadiga por corrosão, fadiga-térmica e fadiga-mecânica. Foi realizado um benchmark focado nestes dois componentes de forma a saber que materiais são utilizados de momento por outras empresas concorrentes. Foi realizada ainda uma análise sobre possíveis materiais que possam ser aplicados em cada componente referido. Foi conduzida uma caracterização no estado bruto de fundição de um aço inoxidável vazado usado para produzir um protótipo do colector de gases. Esta caracterização consistiu numa análise microestrutural e medição de macro e microdurezas. Além da caracterização inicial, foram aplicados um conjunto de tratamentos térmicos, de forma a estudar a possibilidade de eliminar os carbonetos presentes inicialmente nas fronteiras de grão. As principais conclusões deste trabalho são que o aço vazado apresenta potencial para ser uma escolha válida em diversas aplicações, devido a um leque alargado de propriedades apresentadas tipicamente por este material. Relativamente a aplicações estruturais, o aço vazado é vantajoso comparativamente ao ferro fundido, quando são requeridos, por exemplo, soldabilidade e elevada resistência, combinada com elevada tenacidade à fractura. Para componentes sujeitos a elevadas temperaturas de serviço, o aço inoxidável vazado é vantajoso quando usado a temperaturas superiores a 750°C, apesar do seu elevado custo. O tratamento térmico composto por um recozimento de solubilização seguido de envelhecimento, elimina quase na totalidade os carbonetos presentes nas fronteiras de grão e verifica-se um aumento de dureza através de uma precipitação de carbonetos finamente dispersos na matriz, que poderão também aumentar a resistência à fluência.

Desenvolvimento e caracterização tribológica de hidrogéis poliméricos de PVA reforçados com fosfato tricálcico para aplicação como cartilagem articular para implantes articulares

Dissertação de mestrado integrado em Engenharia de Materiais

Antibacterial properties of multifunctional coatings Ag-ZrCN for biomedical devices: a novel approach

PhD in Sciences Specialty in Physics

Metallien laserporaus

Lasertarkkuusporauksella on tämän hetken teollisuudessa useita sovelluksia, kuten esimerkiksi mustesuihkukirjoittimet, dieselmoottoreiden polttoainesuuttimet, lääketieteen instrumentit, turbiinien lapojen jäähdytysreiät ja stensiilit. Tässä työssä on tutkittu laserporauksen mahdollisuuksia 99,9 % kupariin sekä EN 1.4301 ruostumattomaan teräkseen (vastaava AISI 304). Ainepaksuuksia oli käytettävissä kolmea: 0,1 mm, 0,5 mm ja 1,0 mm. Vertailun vuoksi valittiin tutkimukseen mukaan ainepaksuudeltaan 1,0 mm EN 1.4432 haponkestävää terästä (vastaava AISI 316L). Tutkimuksessa käytettiin kolmea eritehoista 1,064 µm aallonpituuden Nd:YAG – laseria ja yhtä CO2 – laseria. Poratut reiät kuvattiin elektronimikroskoopilla ja jokaisesta reiästä mitattiin halkaisija, ympyrämäisyys ja kartiokkuus. Lisäksi reiän laatua arvioitaessa tarkasteltiin purseen määrää reikien ympärillä. Tutkimus osoitti, että eri materiaaleihin voidaan porata, laserin säteen laadusta ja aallonpituudesta riippuen, hyvin erikokoisia reikiä. Kartiokkuuteen havaittiin voitavan vaikuttaa polttopisteen paikkaa siirtämällä.

Laserhitsausparametrien vaikutus ruostumattomien terästen hitsin mikrorakenteeseen

Työn teoriaosassa käsitellään ruostumattomia teräksiä ja terästen metallurgiaan vaikuttavia tekijöitä yleisesti, sekä terästen hitsattavuutta. Hitsauksesta teoriassa käydään läpi laser- ja kaasukaarihitsausta ja hitsin metallurgiaan vaikuttavia tekijöitä. Kokeellisessa osassa paneudutaan kahdeksan eri ruostumattoman teräksen hitsien metallurgiaan ja metallurgiassa tapahtuviin muutoksiin hitsausparametrien mukaan. Koemateriaaleina on neljä austeniittista ruostumatonta terästä, 201, 301LN, 316L ja 254 SMO, kaksi austeniittis-ferriittistä ruostumatonta terästä, 2101 LDX ja 2205, sekä kaksi ferriittistä ruostumatonta terästä, 430 ja 1.4003. Hitsien mikrorakenteen tutkimisessa käytettiin sekä valomikroskooppia sekä joissain tapauksissa pyyhkäisyelektronimikroskooppia. Lisäksi työn kokeellisessa osassa paneuduttiin hitsien metallografisiin syövytystekniikoihin. Kokeiden perusteella voidaan sanoa, että hitsin metallurgia riippuu hitsauksen aikaisesta lämpösyklistä ja hitsausparametreilla voidaan vaikuttaa tämän lämpösyklin muotoon. Austeniittis-ferriittisillä teräksillä hitsauksen aikaisesta lämpösyklistä riippuu pitkälti hitsin austeniitti-ferriitti-suhde. Ferriittisillä teräksillä lämpösyklin muoto vaikuttaa hitsiin muodostuvan martensiitin kovuuteen ja määrään sekä rakenteen hienojakoisuuteen. Austeniittisilla teräksillä lämpösyklinmuodon vaikutus riippuu pitkälti teräksen seostusasteesta ja seosaineista. Austeniittisilla teräksillä kokeissa havaittuja muutoksia, parametrien muutosten mukaan oli muun muassa suotautumisen voimakkuuden

Performance of high power fibre laser cutting of thick-section steel and mediumsection aluminium

Cutting of thick section stainless steel and mild steel, and medium section aluminium using the high power ytterbium fibre laser has been experimentally investigated in this study. Theoretical models of the laser power requirement for cutting of a metal workpiece and the melt removal rate were also developed. The calculated laser power requirement was correlated to the laser power used for the cutting of 10 mm stainless steel workpiece and 15 mm mild steel workpiece using the ytterbium fibre laser and the CO2 laser. Nitrogen assist gas was used for cutting of stainless steel and oxygen was used for mild steel cutting. It was found that the incident laser power required for cutting at a given cutting speed was lower for fibre laser cutting than for CO2 laser cutting indicating a higher absorptivity of the fibre laser beam by the workpiece and higher melting efficiency for the fibre laser beam than for the CO2 laser beam. The difficulty in achieving an efficient melt removal during high speed cutting of the 15 mmmild steel workpiece with oxygen assist gas using the ytterbium fibre laser can be attributed to the high melting efficiency of the ytterbium fibre laser. The calculated melt flow velocity and melt film thickness correlated well with the location of the boundary layer separation point on the 10 mm stainless steel cut edges. An increase in the melt film thickness caused by deceleration of the melt particles in the boundary layer by the viscous shear forces results in the flow separation. The melt flow velocity increases with an increase in assist gas pressure and cut kerf width resulting in a reduction in the melt film thickness and the boundary layer separation point moves closer to the bottom cut edge. The cut edge quality was examined by visual inspection of the cut samples and measurement of the cut kerf width, boundary layer separation point, cut edge squareness (perpendicularity) deviation, and cut edge surface roughness as output quality factors. Different regions of cut edge quality in 10 mm stainless steel and 4 mm aluminium workpieces were defined for different combinations of cutting speed and laserpower.Optimization of processing parameters for a high cut edge quality in 10 mmstainless steel was demonstrated

The laser weldability of lean duplex stainless steels

Ruostumattomien terästen hinta on kasvanut maailman laajuisen kysynnän kasvun seurauksena. Samoin on käynyt myös ruostumattomien terästen valmistukseen käytettävien seosaineiden hinnalle. Terästen valmistajat ovatkin kehittäneet lean duplex teräksiä vastatakseen hintatietoisten markkinoiden kysyntään. Näissä lean duplex teräksissä kalliita seosaineita kuten nikkeliä ja molybdeenia on korvattu typellä ja mangaanilla. Houkutteleviksi vaihtoehdoiksi perinteisille ruostumattomille teräksille lean duplex laadut tekee myös niiden hyvät lujuus- ja korroosio-ominaisuudet. Kirjallisuus osio esittelee lasereiden toimintaperiaatteen. Myös avaimenreikähitsauksen periaate on esitetty. Ruostumattomien terästen yleisimmät seosaineet ovat esitelty, kuten myös syy niiden seostamiseen. Ruostumattomat duplex-teräkset on esitelty samoin kuin lean duplex teräkset. Kokeellisen osion koehitsit hitsattiin osin samalla tuotantolinjalla lopputuotteen kanssa ja osin laboratoriossa. Koemateriaaleina olivat lean duplex teräkset 1.4162 ja 1.4362 joiden materiaalipaksuudet olivat 1.2 mm ja 1.5 mm. Hitsatuille lamelleille tehtiin painetestaus. Makroskopiaa ja valomikroskopiaa käytettiin koehitsien arvioinnissa kuten myös ristivetokoetta. Kiinnostavimmista hitseistä määritettiin myös faasisuhde. Lean duplex teräs 1.4362 havaittiin sopivammaksi laaduksi tämän kaltaisessa sovelluksessa, mutta myös laatu 1.4162 täyttää sovelluksen hitsille asetetut vaatimukset, tosin huomattavasti pienemmässä parametri ikkunassa. Valittu menetelmä faasisuhteen määrittämiseen osoittautui epätarkaksi, joten faasisuhteen osalta tämän tutkimuksen tulokset ovat vain suuntaa-antavia.

Defining of the material models for stainless steels to be used in FE modeling

The aim of this work is to study the results of tensile tests for austenitic stainless steel type 304 and make accurate FE-models according to the results of the tests. Tensile tests were made at Central Research Institute of Structural Material, Prometey at Saint Petersburg and Mariyenburg in Russia. The test specimens for the tensile tests were produced at Lappeenranta University of Technology in a Laboratory of Steel Structures. In total 4 different tests were made, two with base material specimens and two with transverse butt weld specimens. Each kind of a specimen was tested at room temperature and at low temperature. By comparing the results of room and low temperature tests of similar test specimen we get to study the results of work hardening that affect the austenitic steels at below room temperature. The produced specimens are to be modeled accurately and then imported for nonlinear FEM- analyzing. Using the data gained from the tensile tests the aim is to get the models work like the specimens did during the tests. By using the analyzed results of the FE-models the aim is to calculate and get the stress-strain curves that correspond to the results acquired from the tensile tests.

Defining the keyhole modes – the effects on the weld geometry and the molten pool behaviour in high power laser welding of stainless steels

Keyhole welding, meaning that the laser beam forms a vapour cavity inside the steel, is one of the two types of laser welding processes and currently it is used in few industrial applications. Modern high power solid state lasers are becoming more used generally, but not all process fundamentals and phenomena of the process are well known and understanding of these helps to improve quality of final products. This study concentrates on the process fundamentals and the behaviour of the keyhole welding process by the means of real time high speed x-ray videography. One of the problem areas in laser welding has been mixing of the filler wire into the weld; the phenomena are explained and also one possible solution for this problem is presented in this study. The argument of this thesis is that the keyhole laser welding process has three keyhole modes that behave differently. These modes are trap, cylinder and kaleidoscope. Two of these have sub-modes, in which the keyhole behaves similarly but the molten pool changes behaviour and geometry of the resulting weld is different. X-ray videography was used to visualize the actual keyhole side view profile during the welding process. Several methods were applied to analyse and compile high speed x-ray video data to achieve a clearer image of the keyhole side view. Averaging was used to measure the keyhole side view outline, which was used to reconstruct a 3D-model of the actual keyhole. This 3D-model was taken as basis for calculation of the vapour volume inside of the keyhole for each laser parameter combination and joint geometry. Four different joint geometries were tested, partial penetration bead on plate and I-butt joint and full penetration bead on plate and I-butt joint. The comparison was performed with selected pairs and also compared all combinations together.

Investigation of AISI 1040 steel corrosion H(2)S solution containing chloride ions by digital image processing coupled with in electrochemical techniques

This paper presents a study of AISI 1040 steel corrosion in aqueous electrolyte of acetic acid buffer containing 3.1 and 31 x 10(-3) mol dm(-3) of Na(2)S in both the presence and absence of 3.5 wt.% NaCl. This investigation of steel corrosion was carried out using potential polarization, and open-circuit and in situ optical microscopy. The morphological analysis and classification of types of surface corrosion damage by digital image processing reveals grain boundary corrosion and shows a non-uniform sulfide film growth, which occurs preferentially over pearlitic grains through successive formation and dissolution of the film. (C) 2011 Elsevier Ltd. All rights reserved.