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.

Análise e simulação do processo de dobragem de um tubo elíptico utilizando um aço avançado de elevada resistência

Dissertação de mestrado integrado em Engenharia Mecânica

Kylmämuokatun austeniittisen ruostumattoman teräsputkipalkin hitsaus

Diplomityön tavoitteena on selvittää kylmälujitetusta austeniittisesta ruostumattomasta teräksestä valmistettavan putkipalkin pituussuunnassa hitsaamalla tapahtuvaa valmistusta. Työssä tarkastellaan eri hitsausprosessien lämmöntuonnin ja putkipalkin kylmämuovaamalla tapahtuvan valmistuksen ja hitsin jälkikäsittelynvaikutuksia putkipalkin pituushitsin mekaanisiin ominaisuuksiin. Teoriaosassa on perehdytty austeniittisen ruostumattoman teräksen hitsaukseen, kylmämuokkaamalla lujitetun teräksen käyttäytymiseen hitsauksessa, monipoltinkaari-, TIG-suurtaajuuspulssi- ja kaariavusteiseen laserhitsaukseen. Kokeellisessa osassaon suoritettu koehitsauksia edellä mainituilla menetelmillä kylmälujitetulle austeniittiselle ruostumattomalle teräkselle ja suoritettu saatujen koehitsien mekaanisien ominaisuuksien arviointia. Saatujen koetulosten perusteella ontodettu, että huolimatta hitsauksen lämmöntuonnin kylmämuokatun teräksen lujuusarvoja alentavasta vaikutuksesta on mahdollista valmistaa hitsin osalta perusaineen lujuusluokituksen täyttäviä putkipalkkeja. Tämä johtuu putkipalkin kylmämuovaamalla tapahtuvan valmistuksen ja hitsin jälkikäsittelyn hitsauksessa pehmentyneen vyöhykkeen lujuusarvoja takaisin perusaineen tasolle palauttavasta vaikutuksesta.

Materials selection for superheater tubes in municipal solid waste incineration plants

Corrosion reduces the lifetime of municipal solid waste incineration (MSWI) superheater tubes more than any other cause. It can be minimized by the careful selection of those materials that are most resistant to corrosion under operating conditions. Since thousands of different materials are already known and many more are developed every year, here the selection methodology developed by Prof. Ashby of the University of Cambridge was used to evaluate the performance of different materials to be used as MSWI superheater tubes. The proposed materials can operate at steam pressures and temperatures over 40 bars and 400ºC, respectively. Two case studies are presented: one makes a balanced selection between mechanical properties and cost per thermal unit; and the other focuses on increasing tube lifetime. The balanced selection showed that AISI 410 martensitic stainless steel (wrought, hard tempered) is the best candidate with a good combination of corrosion resistance, a relatively low price (0.83-0.92 e/kg) and a good thermal conductivity (23-27 W/m K). Meanwhile, Nitronic 50/XM-19 stainless steel is the most promising candidate for longterm selection, as it presents high corrosion resistance with a relatively low price (4.86-5.14 e/kg) compared to Ni-alloys.

Uma célula eletroquímica de fluxo para modificação permanente de tubo de grafite empregado em absorção atômica

A flow cell assembled on the original geometry of a graphite tube to achieve permanent chemical modifier is proposed. The graphite tube operates as the working electrode. A stainless steel tube, positioned downstream from the working electrode, was used as the auxiliary electrode. The potential value applied on the graphite electrode was measured against a micro reference electrode (Ag/AgCl) inserted into the auxiliary electrode. Palladium solutions in acetate buffer (100 mmol L-1, pH = 4.8), flowing at 0.5 mL min-1 for 60 min was used to perform the electrochemical modification. A mercury solution (1 ng) was used to evaluate the performance of the permanent palladium modifier.

Construção e caracterização de um detector eletroquímico para análises em fluxo

The present work describes a low-cost electrochemical "wall-jet" detector for flow analysis. The electrolytic solution enters into the cell through a tube of stainless steel (200 to 300 µm i.d), reaching to the center of the working electrode perpendicularly and then being mixed to the remaining solution in the cell, which flows under atmospheric pressure into a waste reservoir. The proposed electrochemical detector can be used with any type of working electrode, from commercial to home-made, such as glassy carbon and metallic electrodes (modified or unmodified), which enlarge the applications of the electrochemical detector.

Desenvolvimento e avaliação de um porta-amostra de baixo custo para caracterização elétrica de materiais cerâmicos

Conventional sample holder cells used to the electric characterization of ceramics at high temperature consists of an alumina tube and platinum wires and plates using a complex design. The high cost materials used in the conventional sampler holder cell were replaced by stainless steel and conventional ceramics. The sample holder was validated by characterizing yttria-stabilized-zirconia in a temperature range of 25 to 700 ºC. The results do not present variations, discontinuity or unusual noise in the electric signals. Several samples were characterized without maintenance, which demonstrates that the sample holder is electric and mechanic adequate to be used to electrical characterization of ceramics up to 700 ºC.

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.

Ohutseinämäisten putkien hitsauksen robotisointi

Tämän diplomityön tavoitteena on ollut selvittää, kuinka robotisoitua hitsausta on mahdollista hyödyntää teollisuuskaiteiden valmistuksessa. Tutkimusmenetelminä käytettiin kirjallisuusselvitystä, hitsauskokeita ja makrohietutkimuksia. Työssä keskityttiin robottihitsauksen menetelmiin ja työstä on rajattu pois kaikki kustannuslaskelmat sekä alumiinin hitsaus. Hitsattavat materiaalit olivat rakenneteräs ja ruostumaton teräs. Rakenneteräsputken koko oli 42,4 x 2,6 mm ja ruostumattoman putken koko 42,4 x 2,0 mm. Käytetyt liitosmuodot olivat T-liitoksia, joista suorassa T-liitoksessa putkien välinen kulma oli 90 astetta ja vinossa T-liitoksessa noin 45 astetta. Tehdyn selvitystyön ja hitsauskokeiden perusteella voidaan sanoa, että kaiteissa käytettävien materiaalipaksuuksien ja liitosmuotojen hitsaaminen robotilla on mahdollista. Hitsauksen lopputulos riippuu hitsausasennosta ja paras tulos saavutetaan, kun kappaletta pyöritetään hitsauksen aikana siten, että hitsaus tapahtuu koko ajan jalkoasennossa.

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.

Influence of surface texture on the galling characteristics of lean duplex and austenitic stainless steels

Two simulative test methods were used to study galling in sheet forming of two types of stainlesssteel sheet: austenitic (EN 1.4301) and lean duplex LDX 2101 (EN 1.4162) in different surface conditions. Thepin-on-disc test was used to analyse the galling resistance of different combinations of sheet materials and lubricants. The strip reduction test, a severe sheet forming tribology test was used to simulate the conditionsduring ironing. This investigation shows that the risk of galling is highly dependent on the surface texture of theduplex steel. Trials were also performed in an industrial tool used for high volume production of pumpcomponents, to compare forming of LDX 2101 and austenitic stainless steel with equal thickness. The forming forces, the geometry and the strains in the sheet material were compared for the same component.It was found that LDX steels can be formed to high strain levels in tools normally applied for forming ofaustenitic steels, but tool adaptations are needed to comply with the higher strength and springback of thematerial.

Construção, caracterização e aplicação de eletrodos para descarga por arco de cátodo oco

The system built to characterize electrodes and, consequently, deposited fine films are constituted by a hollow cathode that works to discharges and low pressures (approximately 10-3 to 5 mbar), a source DC (0 to 1200 V), a cylindrical camera of closed borossilicato for flanges of stainless steel with an association of vacuum bombs mechanical and spread. In the upper flange it is connected the system of hollow cathode, which possesses an entrance of gas and two entrances for its refrigeration, the same is electrically isolated of the rest of the equipment and it is polarized negatively. In front of the system of hollow cathode there is a movable sample in stainless steel with possibility of moving in the horizontal and vertical. In the vertical, the sample can vary its distance between 0 and 70 mm and, in the horizontal, can leave completely from the front of the hollow cathode. The sample and also the cathode hollow are equipped with cromel-alumel termopares with simultaneous reading of the temperatures during the time of treatment. In this work copper electrodes, bronze, titanium, iron, stainless steel, powder of titanium, powder of titanium and silício, glass and ceramic were used. The electrodes were investigated relating their geometry change and behavior of the plasma of the cavity of hollow cathode and channel of the gas. As the cavity of hollow cathode, the analyzed aspects were the diameter and depth. With the channel of the gas, we verified the diameter. In the two situations, we investigated parameters as flow of the gas, pressure, current and applied tension in the electrode, temperature, loss of mass of the electrode with relationship at the time of use. The flow of gas investigated in the electrodes it was fastened in a work strip from 15 to 6 sccm, the constant pressure of work was among 2.7 to 8 x 10-2 mbar. The applied current was among a strip of work from 0,8 to 0,4 A, and their respective tensions were in a strip from 400 to 220 V. Fixing the value of the current, it was possible to lift the curve of the behavior of the tension with the time of use. That curves esteem in that time of use of the electrode to its efficiency is maximum. The temperatures of the electrodes were in the dependence of that curves showing a maximum temperature when the tension was maximum, yet the measured temperatures in the samples showed to be sensitive the variation of the temperature in the electrodes. An accompaniment of the loss of mass of the electrode relating to its time of use showed that the electrodes that appeared the spherical cavities lost more mass in comparison with the electrodes in that didn't appear. That phenomenon is only seen for pressures of 10-2 mbar, in these conditions a plasma column is formed inside of the channel of the gas and in certain points it is concentrated in form of spheres. Those spherical cavities develop inside of the channel of the gas spreading during the whole extension of the channel of the gas. The used electrodes were cut after they could not be more used, however among those electrodes, films that were deposited in alternate times and the electrodes that were used to deposit films in same times, those films were deposited in the glass substrata, alumina, stainless steel 420, stainless steel 316, silício and steel M2. As the eletros used to deposit films in alternate time as the ones that they were used to deposit in same times, the behavior of the thickness of the film obeyed the curve of the tension with relationship the time of use of the electrode, that is, when the tension was maximum, the thickness of the film was also maximum and when the tension was minimum, the thickness was minimum and in the case where the value of the tension was constant, the thickness of the film tends to be constant. The fine films that were produced they had applications with nano stick, bio-compatibility, cellular growth, inhibition of bacterias, cut tool, metallic leagues, brasagem, pineapple fiber and ornamental. In those films it was investigated the thickness, the adherence and the uniformity characterized by sweeping electronic microscopy. Another technique developed to assist the production and characterization of the films produced in that work was the caloteste. It uses a sphere and abrasive to mark the sample with a cap impression, with that cap form it is possible to calculate the thickness of the film. Through the time of life of the cathode, it was possible to evaluate the rate of waste of its material for the different work conditions. Values of waste rate up to 3,2 x 10-6 g/s were verified. For a distance of the substratum of 11 mm, the deposited film was limited to a circular area of 22 mm diameter mm for high pressures and a circular area of 75 mm for pressure strip. The obtained films presented thickness around 2,1 µm, showing that the discharge of arch of hollow cathode in argon obeys a curve characteristic of the tension with the time of life of the eletrodo. The deposition rate obtained in this system it is of approximately 0,18 µm/min