Estudo da viabilidade técnica para obtenção de superfície duplex em aço inoxidável martensítico AISI 410 através do processo de deposição a plasma por gaiola catódica

The technique of plasma nitriding by the cathode cage mainly stands out for its ability to produce uniform layers, even on parts with complex geometries. In this study, it was investigated the efficiency of this technique for obtaining duplex surface, when used, simultaneously, to nitriding treatment and thin film deposition at temperatures below 500°C. For this, were used samples of AISI 41 0 Martensitic Stainless Steel and performed plasma treatment, combining nitriding and deposition of thin films of Ti and/or TiN in a plasma atmosphere containing N2-H2. It was used a cathodic cage of titanium pure grade II, cylindrical with 70 mm diameter and 34 mm height. Samples were treated at temperature 420ºC for 2 and 12 hours in different working pressures. Optical Microscopy (OM), Scanning Electron Microscopy (SEM) with micro-analysis by Energy Dispersive Spectroscopy (EDS), X-Ray Diffraction (XRD), Atomic Force Microscopy (AFM) and analysis of Vickers Microhardness were used to investigate coating properties such as homogeneity and surface topography, chemical composition, layer thickness, crystalline phase, roughness and surface microhardness. The results showed there is a direct proportionality between the presence of H2 in plasma atmosphere and the quantity of titanium in surface chemical composition. It was also observed that the plasma treatment at lowpressure is more effective in formation of TiN thin film

Initiation and early crack growth in VHCF of stainless steels : Experimental and theoretical analysis

Mechanical fatigue is a failure phenomenon that occurs due to repeated application of mechanical loads. Very High Cycle Fatigue (VHCF) is considered as the domain of fatigue life greater than 10 million load cycles. Increasing numbers of structural components have service life in the VHCF regime, for instance in automotive and high speed train transportation, gas turbine disks, and components of paper production machinery. Safe and reliable operation of these components depends on the knowledge of their VHCF properties. In this thesis both experimental tools and theoretical modelling were utilized to develop better understanding of the VHCF phenomena. In the experimental part, ultrasonic fatigue testing at 20 kHz of cold rolled and hot rolled stainless steel grades was conducted and fatigue strengths in the VHCF regime were obtained. The mechanisms for fatigue crack initiation and short crack growth were investigated using electron microscopes. For the cold rolled stainless steels crack initiation and early growth occurred through the formation of the Fine Granular Area (FGA) observed on the fracture surface and in TEM observations of cross-sections. The crack growth in the FGA seems to control more than 90% of the total fatigue life. For the hot rolled duplex stainless steels fatigue crack initiation occurred due to accumulation of plastic fatigue damage at the external surface, and early crack growth proceeded through a crystallographic growth mechanism. Theoretical modelling of complex cracks involving kinks and branches in an elastic half-plane under static loading was carried out by using the Distributed Dislocation Dipole Technique (DDDT). The technique was implemented for 2D crack problems. Both fully open and partially closed crack cases were analyzed. The main aim of the development of the DDDT was to compute the stress intensity factors. Accuracy of 2% in the computations was attainable compared to the solutions obtained by the Finite Element Method.

Estudo do mecanismo de corrosão por pites em água do mar de aços inoxidáveis supermartensíticos microligados com Nb e Ti

Os aços inoxidáveis supermartensíticos (SMSS) são usados em ambientes agressivos devido à sua boa soldabilidade, boas propriedades mecânicas em temperaturas elevadas e superior resistência à corrosão sob tensão. Aplicações na exploração de petróleo demandam superior combinação de propriedades e os aços inoxidáveis duplex e superduplex têm sido aplicados nessa área, a despeito de seus custos elevados. Os SMSS consistem numa alternativa técnica e econômica ao uso daqueles aços. Nesse trabalho, adições de Nb e Ti foram realizadas com o intuito de minimizar o efeito de sensitização, promover o refino de grãos e foram estudados os aspectos microestruturais e a resistência à corrosão por pites em água do mar. A formação e a evolução dos pites foram acompanhadas por ensaios de corrosão, microscopia óptica e eletrônica, focalizando suas morfologias. O aço com Ti apresentou o melhor desempenho quanto à corrosão, com o maior potencial de corrosão e menor potencial de pite entre os aços em estudo. O aço com Nb, apesar de apresentar potencial de corrosão superior ao do aço sem adição, teve um potencial de pite inferior ao do mesmo.

X-ray diffraction characterisation of expanded austenite and ferrite in plasma nitrided stainless steels

The S phase, known as expanded austenite, is formed on the surfaces of austenitic stainless steels that are nitrided under low temperature plasma. A similar phase was observed for nitrided ferritic stainless steels and was designed as expanded ferrite or ferritic S phase. The authors treated samples of austenitic AISI 304L and AISI 316L and ferritic AISI 409 stainless steels by plasma nitriding at different temperatures and then studied the structural, morphological, chemical and corrosion characteristics of the modified layers by X-ray diffraction, scanning electron microscopy/energy dispersive spectroscopy and electrochemical tests. For both austenitic AISI 304L and AISI 316L stainless steels, the results showed that a hard S phase layer was formed on the surfaces, promoting an anodic polarisation curve displacement to higher current density values that depend on the plasma nitriding temperature. A layer having a high amount of nitrogen was formed on the ferritic AISI 409 stainless steel. X-ray diffraction measurements indicated high strain states for the modified layers formed on the three stainless steels, being more pronounced for the ferritic S phase.

Wear mechanisms and microstructure of pulsed plasma nitrided AISI H13 tool steel

AISI H13 tool steel discs were pulsed plasma minded during different times at a constant temperature of 400 degrees C Wear tests were performed in order to study the acting wear mechanisms The samples were characterized by X-ray diffraction, scanning electron microscopy and hardness measurements The results showed that longer nitriding times reduce the wear volumes. The friction coefficient was 0.20 +/- 0 05 for all tested conditions and depends strongly on the presence of debris After wear tests, the wear tracks were characterized by optical and scanning electron microscopy and the wear mechanisms were observed to change from low cycle fatigue or plastic shakedown to long cycle fatigue These mechanisms were correlated to the microstructure and hardness of the nitrided layer (C) 2010 Elsevier B V All rights reserved

ASTM A923-Practice A application to identify intermetallic phases in a UNS S32750 superduplex welded joint

Duplex and superduplex stainless steels present superior mechanical and corrosion properties when compared to usual stainless steels. This superiority is based on chemical composition when in a balanced microstructure (approximately 50% of ferrite). During welding, changes may occur in both, the chemical composition and volume fraction of phases in the material, which may generate the presence of intermetallic phases and, as a consequence, modify the mechanical and corrosion properties of this group of stainless steels. The objective of this work is to apply ASTM A923- Practice A to verify the presence of intermetallic phases in welded joints of UNS 32750 su-perduplex stainless steel. Tubes of UNS 32750, with external diameters of 18 and 44 mm and a thickness of 1.5 mm, were welded using orbital GTAW, with filler metal 25Cr-10Ni-4Mo and a diameter of 0.8 mm. The metal-based and welded joints were characterized by optical and scanning electron microscopy. The results showed that there was no precipitation of the intermetallic phase, such as sigma phase, detected by ASTM A923, but the HAZ of the two tubes studied presented small regions with chromium nitrides, which can also change the properties of welded joins.

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.

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.

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

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.