Sviluppo e caratterizzazione microstrutturale e meccanica di leghe innovative di magnesio

Le attività di ricerca svolte nel corso del dottorato di ricerca, sono state focalizzate principalmente sullo studio dell’evoluzione microstrutturale, delle proprietà meccaniche e tribologiche di una particolare lega da fonderia, EV31A, con alte percentuali di terre rare (Nd e Gd > 4% in peso). Le analisi microstrutturali sono state eseguite tramite microscopia ottica (OM), elettronica in scansione (SEM) ed elettronica in trasmissione (TEM), mentre le proprietà meccaniche sono state determinate attraverso prove di trazione e prove di fatica a flessione rotante. Al fine di incrementare le proprietà tribologiche delle leghe di magnesio è stata valutata l’efficacia del trattamento PEO sia sulla lega EV31A, sia sulle più comuni leghe AZ80 e AZ91D, effettuando test tribologici in modalità pattino su cilindro (Block on Ring). Infine è stato condotto uno studio sull’efficacia del trattamento di fusione superficiale laser (LSM), analizzandone gli effetti sia sull’evoluzione microstrutturale, sia sulle proprietà meccaniche e sulla resistenza a corrosione. Le attività svolte nel corso del dottorato di ricerca sono state svolte presso il Dipartimento di Ingegneria Industriale DIN della Scuola di Ingegneria e Architettura dell’Università di Bologna sotto la supervisione della Prof. ssa Lorella Ceschini.

Ottimizzazione di materiali e trattamenti per componenti critici destinati a motociclette da competizione

L’attività svolta durante il dottorato è stata incentrata su due tematiche riguardanti: (i) la modifica della composizione chimica delle classiche leghe di alluminio da fonderia per incrementarne la resistenza e stabilità termica; (ii) lo studio del comportamento a fatica di acciai innovativi alto-resistenziali, allo scopo di valutarne il loro utilizzo per la produzione di alberi motore e distribuzione in sostituzione dei tradizionali acciai utilizzati dopo bonifica e trattamento superficiale di nitrurazione. La messa a punto di una lega di alluminio da fonderia con elevata resistenza in temperatura ha richiesto, oltre all’individuazione della composizione chimica, l’ottimizzazione del trattamento termico e una completa caratterizzazione meccanica statica a fatica sia a temperatura ambiente sia a 200°C. L’attività ha permesso di sviluppare una lega, ottenuta aggiungendo 1,3% in peso di rame alla classica lega A357 (Al-Si-Mg), cha ha mostrato avere proprietà meccaniche superiori a quelle delle tradizionali leghe Al-Si-Mg-Cu quali la A354 e C355 sia a temperatura ambiente che a 200 °C dopo lunga esposizione in temperatura. Per quanto riguarda gli acciai innovativi, dopo una preliminare analisi di mercato per individuare quali acciai potessero essere oggetto di studio, è stato valutato come migliorarne le prestazioni a fatica, anche in presenza d’intaglio, attraverso la scelta del trattamento termico più opportuno e del processo di pallinatura. I risultati delle caratterizzazioni microstrutturale e meccanica svolte hanno permesso di individuare due acciai (nomi commerciali K890 e ASP2017) ottenuti per metallurgia delle polveri, ad oggi utilizzati solo per la produzione di stampi e/o utensili, in grado di sostituire gli acciai con cui vengono oggi realizzati i componenti, senza la necessità di eseguire il trattamento di nitrurazione

Joints and innovative components for automotive applications

The research activities described in this thesis were focused on two main topics: the study of shaft-hub joint performance, with particular regard to interference-fitted and adhesively bonded connection, and the fatigue characterization of additively processed metal alloys. The research on interference-fitted shaft-hub joints dealt with some studies in the field of fretting fatigue. Rotating bending fatigue tests were performed on different materials by not conventional specimens to determine the fatigue properties of interference-fitted joints and to investigate the fretting fatigue phenomenon, which led to novel and original results. In adhesively bonded and interference-fitted shaft-hub connections (called hybrid joints) the synergic effect of anaerobic adhesive and interference has the capability of improving the joint strength. However, the adhesive contribution depends on several factors. Therefore, its behavior was investigated for different coupling pressure, coupling procedure, operating temperature and joint design. The study on additively manufactured metal alloy deals with rotating banding fatigue tests. AlSi10Mg and Maraging Stainless Steel CX were involved in the campaign for their wide applicability in Automotive. Build direction, heat and surface treatments were considered as input parameters. Fatigue results were interpreted by statistical method and microscopy analyses in order to determine the effectiveness and the beneficial or detrimental effects of the considered factors. Fracture mode and microstructure were investigated by fractographic and micrographic analyses

Fretting fatigue in overhead conductors: Rig design and failure analysis of a Grosbeak aluminium cable steel reinforced conductor

The performance optimisation of overhead conductors depends on the systematic investigation of the fretting fatigue mechanisms in the conductor/clamping system. As a consequence, a fretting fatigue rig was designed and a limited range of fatigue tests was carried out at the middle high cycle fatigue regime in order to access an exploratory S-N curve for a Grosbeak conductor, which was mounted on a mono-articulated aluminium clamping system. Subsequent to these preliminary fatigue tests, the components of the conductor/clamping system, such as ACSR conductor, upper and lower clamps, bolt and nuts, were subjected to a failure analysis procedure in order to investigate the metallurgical free variables interfering on the fatigue test results, aiming at the optimisation of the testing reproducibility. The results indicated that the rupture of the planar fracture surfaces observed in the external At strands of the conductor tested under lower bending amplitude (0.9 mm) occurred by fatigue cracking (I mm deep), followed by shear overload. The V-type fracture surfaces observed in some At strands of the conductor tested under higher bending amplitude (1.3 mm) were also produced by fatigue cracking (approximately 400 mu m deep), followed by shear overload. Shear overload fracture (45 degrees fracture surface) was also observed on the remaining At wires of the conductor tested under higher bending amplitude (1.3 mm). Additionally, the upper and lower Al-cast clamps presented microstructure-sensitive cracking, which was folowed by particle detachment and formation of abrasive debris on the clamp/conductor tribo-interface, promoting even further the fretting mechanism. The detrimental formation of abrasive debris might be inhibited by the selection of a more suitable class of as-cast At alloy for the production of clamps. Finally, the bolt/nut system showed intense degradation of the carbon steel nut (fabricated in ferritic-pearlitic carbon steel, featuring machined threads with 190 HV), with intense plastic deformation and loss of material. Proper selection of both the bolt and nut materials and the finishing processing might prevent the loss in the clamping pressure during the fretting testing. It is important to control the specification of these components (clamps, bolt and nuts) prior to the start of large scale fretting fatigue testing of the overhead conductors in order to increase the reproducibility of this assessment. (c) 2008 Elsevier Ltd. All rights reserved.

The synergism between high superficial roughness and corrosive atmosphere in the fatigue behavior of the SAE 1045 steel

The fatigue behavior of the SAE 1045 steel in four different conditions is reported in this paper. Four treatments were tested: polished surface, corrosive atmosphere (sugar cane juice), low quality roughness (typical equivalent surface of the shaft cane mill) and the combined condition of the two last treatments involved. Fatigue tests were performed in rotating bending conditions and the values of fatigue strength for the different situations from tests were obtained. The diminution in fatigue strength for the synergy condition of rough surface and corrosive atmosphere was of 8.7%, result statistically representative with less than 0.01% of uncertainty.

Determinação da tenacidade à fratura de adesivos estruturais em modo misto pelo ensaio Single-Leg Bending

A utilização de juntas adesivas em aplicações industriais tem vindo a aumentar, em detrimento dos métodos tradicionais tais como a soldadura, brasagem e ligações aparafusadas e rebitadas. Este facto deve-se às vantagens que estas oferecem, como o facto de serem mais leves, comportarem-se bem sob cargas cíclicas ou de fadiga, a ligação de materiais diferentes e menores concentrações de tensões. Para aumentar a confiança no projeto de estruturas adesivas, é importante conseguir prever com precisão a sua resistência mecânica e respetivas propriedades de fratura (taxa crítica de libertação de energia de deformação à tração, GIC, e corte, GIIC). Estas propriedades estão diretamente relacionadas com a Mecânica da Fratura e são estimadas através de uma análise energética. Para este efeito, distinguem-se três tipos de modelos: modelos que necessitam da medição do comprimento de fenda durante a propagação do dano, modelos que utilizam um comprimento de fenda equivalente e métodos baseados no integral J. Como na maioria dos casos as solicitações ocorrem em modo misto (combinação de tração com corte), é de grande importância a perceção da fratura nesta condições, nomeadamente das taxas de libertação de energia relativamente a diferentes critérios ou envelopes de fratura. Esta comparação permite, por exemplo, averiguar qual o melhor critério energético de rotura a utilizar em modelos numéricos baseados em Modelos de Dano Coesivo. Neste trabalho é realizado um estudo experimental utilizando o ensaio Single-Leg Bending (SLB) em provetes colados com três tipos de adesivos, de forma a estudar e comparar as suas propriedades de fratura. Para tal, são aplicados alguns modelos de redução da taxa de libertação de energia de deformação à tração, GI, e corte, GII, enquadrados nos modelos que necessitam da medição do comprimento de fenda e nos modelos que utilizam um comprimento de fenda equivalente. Numa fase posterior, procedeu-se à análise e comparação dos resultados adquiridos durante a fase experimental de GI e GII de cada adesivo. A discussão de resultados foi também feita através da análise dos valores obtidos em diversos envelopes de fratura, no sentido de averiguar qual o critério de rotura mais adequado a considerar para cada adesivo. Foi obtida uma concordância bastante boa entre métodos de determinação de GI e GII, com exceção do adesivo mais dúctil, para o qual o método baseado no comprimento de fenda equivalente apresentou resultados ligeiramente superiores.

Effect of loading type on the fatigue strength of symmetric and asymmetric welded joints made of ultra high strength steel

In this study, finite element analyses and experimental tests are carried out in order to investigate the effect of loading type and symmetry on the fatigue strength of three different non-load carrying welded joints. The current codes and recommendations do not give explicit instructions how to consider degree of bending in loading and the effect of symmetry in the fatigue assessment of welded joints. The fatigue assessment is done by using effective notch stress method and linear elastic fracture mechanics. Transverse attachment and cover plate joints are analyzed by using 2D plane strain element models in FEMAP/NxNastran and Franc2D software and longitudinal gusset case is analyzed by using solid element models in Abaqus and Abaqus/XFEM software. By means of the evaluated effective notch stress range and stress intensity factor range, the nominal fatigue strength is assessed. Experimental tests consist of the fatigue tests of transverse attachment joints with total amount of 12 specimens. In the tests, the effect of both loading type and symmetry on the fatigue strength is studied. Finite element analyses showed that the fatigue strength of asymmetric joint is higher in tensile loading and the fatigue strength of symmetric joint is higher in bending loading in terms of nominal and hot spot stress methods. Linear elastic fracture mechanics indicated that bending reduces stress intensity factors when the crack size is relatively large since the normal stress decreases at the crack tip due to the stress gradient. Under tensile loading, experimental tests corresponded with finite element analyzes. Still, the fatigue tested joints subjected to bending showed the bending increased the fatigue strength of non-load carrying welded joints and the fatigue test results did not fully agree with the fatigue assessment. According to the results, it can be concluded that in tensile loading, the symmetry of joint distinctly affects on the fatigue strength. The fatigue life assessment of bending loaded joints is challenging since it depends on whether the crack initiation or propagation is predominant.

Effects of electroplated zinc-nickel alloy coatings on the fatigue strength of AISI 4340 high-strength steel

Recovered substrates have been extensively used in the aerospace field. Cadmium electroplating has been widely applied to promote protective coatings in aeronautical components, resulting in excellent corrosion protection combined with a good performance in cyclic loading. Ecological considerations allied to the increasing demands for corrosion resistance have resulted in the search for possible alternatives. Zinc-nickel (Zn-Ni) alloys have received considerable interest recently, because these coatings show advantages such as a good resistance to white and red rust, high plating rates, and acceptance in the market. In this study, the effect of electroplated Zn-Ni coatings on AISI 4340 high-strength steel was analyzed for rotating bending fatigue strength, corrosion, and adhesion resistance. The compressive residual stress field was measured by x-ray diffraction prior to fatigue tests. Optical microscopy documented coating thickness, adhesion characteristics, and coverage extent for nearly all substrates. Fractured fatigue specimens were investigated using scanning electron microscopy (SEM). Three different Zn-Ni coating thicknesses were tested, and comparisons with the rotating bending fatigue data from electroplated Cd specimens were performed. Experimental results differentiated the effects of the various coatings on the AISI 4340 steel behaviour when submitted to fatigue testing and the influence of coating thickness on the fatigue strength.

Considerations on corrosion and weld repair effects on the fatigue strength of a steel structure critical to the flight-safety

The aim of this study is to analyze the effects of corrosion and successive tungsten inert gas (TIC) welding repairs on the reverse bending fatigue strength of AISI 4130 steel used in components critical to the flight-safety. The tests were performed on hot-rolled steel plate specimens, 1.10 mm and 1.60 mm thick, by means of a SCHENK PWS equipment, with load ratio R = -1, constant amplitude, 30 Hz frequency and room temperature. It was observed that the reverse bending fatigue strength of AISI 4130 steel decreases due to the corrosion and the TIC welding and re-welding processes. (C) 2010 Elsevier Ltd. All rights reserved.

Fatigue life studies in carbon dual-phase steels

An investigation has been conducted to examine the morphological influence on fatigue life of low carbon steel with dual phase microstructure. The results showed that dual-phase microstructure, composed by ferrite and martensite had superior symmetrical bending fatigue strength when compared with ferrite-pearlite steel. Through those tests, evidences of different mechanisms were verified (such as ferrite cyclic hardening, slip band formation and beginning of crack nucleation and propagation). Based on the fatigue tests results, various mechanisms stages were discussed associated with different microstructure morphology. Copyright (C) 1996 Published by Elsevier B.V. Limited.

Effects of electroplated zinc-nickel alloy coatings on the fatigue strength of AISI 4340 high strength steel

It is well known that fatigue behaviour is an important parameter to be considered in mechanical components subjected to constant and variable amplitude loadings. In combination with corrosion phenomenon, fatigue effects were responsible for proximally 64% of fails that occur in metallic parts of aeronautical accidents in the last 30 years. Recovered substrates have been extensively used in the aerospace field. Cadmium electroplating has been widely applied to promote protective coatings in aeronautical components, resulting in excellent corrosion protection combined with a good performance in cyclic loading. Ecological considerations allied to the increasing demands for corrosion resistance, resulted in the search for possible alternatives. Zinc-nickel alloys received considerable interest recently, since these coatings showed some advantages such as a good resistance to white and red rust, high plating rates and acceptation in the market. In this study the effects of zinc-nickel coatings electroplated on AISI 4340 high strength steel were analysed on rotating bending and axial fatigue strength, corrosion and adhesion resistance. Compressive residual stress field was measured by a X-ray tensometry prior to fatigue tests. Optical microscopy images showed coating thicknesses, adhesion and the existence of an uniform coverage of nearly all substrates. The fractured fatigue specimens were investigated using a scanning electron microscope. Three different zinc-nickel coating thicknesses were tested and comparison with rotating bending fatigue data from specimens cadmium electroplated and heat treated at 190°C for 3, 8 and 24 hours to avoid the diffusion of hydrogen in the substrate, was performed. Experimental results showed effect of coatings on the AISI 4340 steel behaviour when submitted to fatigue testing and the existence of coating thickness influence on the fatigue strength.

Thixocasting of an A356 alloy: Fluidity, porosity distribution and thermomechanical fatigue behavior

An extensive set of experiments was performed on a semi-solid A356 alloy in order to assess its flow behavior, mechanical properties, microstructural evolution and porosity level. Three different microstructural conditioning techniques (raw material preparation) were employed: deformation recrystallization, magnetohydrodynamic stirring and low temperature pouring. Measurement of microstructural parameters such as Al-alpha particle size, shape factor, contiguity and entrapped liquid showed a relative equivalency among the various conditioning techniques. It was found that the strongest influence on semi-solid slurry fluidity is exerted by the mould temperature. Tensile properties and porosity levels were measured on a demonstration part produced with different slurry ingate velocities. Results showed similar strength levels among all thixocast samples, a strong correlation between elongation and pore volume fraction and porosity levels much lower than the typical figure for permanent mould or die cast Al-Si alloys. Finally, thermomechanical fatigue tests results were much more favorable to the semi-solid material when compared with the conventionally cast alloy, a result attributed to lower porosity, spheroidal shape of the Al-alpha phase, and refined Si eutectic particles. alpha 2007 Elsevier B.V. All rights reserved.

A critical view on biaxial and short-beam uniaxial flexural strength tests applied to resin composites using Weibull, fractographic and finite element analyses

Objective. To evaluate the biaxial and short-beam uniaxial strength tests applied to resin composites based upon their Weibull parameters, fractographic features and stress distribution. Methods. Disk- (15 mm x 1 mm) and beam-shaped specimens (10 mm x 2 mm x 1 mm) of three commercial composites (Concept/Vigodent, CA; Heliomolar/Ivoclar-Vivadent, HE; Z250/3M ESPE, FZ) were prepared. After 48h dry storage at 37 degrees C, disks and beams were submitted to piston-on-three-balls (BI) and three-point bending (UNI) tests, respectively. Data were analyzed by Weibull statistics. Fractured surfaces were observed under stereomicroscope and scanning electron microscope. Maximum principal stress (sigma(1)) distribution was determined by finite element analysis (FEA). Maximum sigma(1-BI) and sigma(1-UNI) were compared to FZ strengths calculated by applying the average failure loads to the analytical equations (sigma(a-BI) and sigma(a-UNI)). Results. For BI, characteristic strengths were: 169.9a (FZ), 122.4b (CA) and 104.8c (HE), and for UNI were: 160.3a (FZ), 98.2b (CA) and 91.6b (HE). Weibull moduli ( m) were similar within the same test. CA and HE presented statistically higher m for BI. Surface pores ( BI) and edge flaws ( UNI) were the most frequent fracture origins. sigma(1-BI) was 14% lower than sigma(a-BI.) sigma(1-UNI) was 43% higher than sigma(a-UNI). Significance. Compared to the short-beam uniaxial test, the biaxial test detected more differences among composites and displayed less data scattering for two of the tested materials. Also, biaxial strength was closer to the material`s strength estimated by FEA. (C) 2009 Academy of Dental Materials. Published by Elsevier Ltd. All rights reserved.

Fatigue and damage accumulation of veneer porcelain pressed on Y-TZP

Objectives: This study compared the reliability and fracture patterns of zirconia cores veneered with pressable porcelain submitted to either axial or off-axis sliding contact fatigue. Methods: Forty-two Y-TZP plates (12 mm x 12 mm x 0.5 mm) veneered with pressable porcelain (12 mm x 12 mm x 1.2 mm) and adhesively luted to water aged composite resin blocks (12 mm x 12 mm x 4 mm) were stored in water at least 7 days prior to testing. Profiles for step-stress fatigue (ratio 3:2:1) were determined from single load to fracture tests (n = 3). Fatigue loading was delivered on specimen either on axial (n = 18) or off-axis 30 degrees angulation (n = 18) to simulate posterior tooth cusp inclination creating a 0.7 mm slide. Single load and fatigue tests utilized a 6.25 mm diameter WC indenter. Specimens were inspected by means of polarized-light microscope and SEM. Use level probability Weibull curves were plotted with 2-sided 90% confidence bounds (CB) and reliability for missions of 50,000 cycles at 200 N (90% CB) were calculated. Results: The calculated Weibull Beta was 3.34 and 2.47 for axial and off-axis groups, respectively, indicating that fatigue accelerated failure in both loading modes. The reliability data for a mission of 50,000 cycles at 200 N load with 90% CB indicates no difference between loading groups. Deep penetrating cone cracks reaching the core-veneer interface were observed in both groups. Partial cones due to the sliding component were observed along with the cone cracking for the off-axis group. No Y-TZP core fractures were observed. Conclusions: Reliability was not significantly different between axial and off-axis mouth-motion fatigued pressed over Y-TZP cores, but incorporation of sliding resulted in more aggressive damage on the veneer. (C) 2009 Elsevier Ltd. All rights reserved.

Caracterização mecânica de misturas betuminosas a aplicar em infra-estruturas de transportes

A maioria das infra-estruturas de transportes, nomeadamente os pavimentos rodoviários e aeroportuários, são constituídas por misturas betuminosas, o que permite um bom desempenho e uma adequada durabilidade, nas condições usuais de serviço. As misturas betuminosas são ainda amplamente utilizadas na construção de zonas de estacionamento de veículos, tendo-se verificado recentemente a sua aplicação também em infra-estruturas ferroviárias. Face à necessidade de melhorar o desempenho das vias-férreas, permitindo uma concepção mais durável de linhas de alta velocidade e uma redução dos custos da sua manutenção, tem-se vindo a desenvolver diversos estudos para promover a utilização de novos materiais, principalmente através da incorporação de misturas betuminosas. O presente trabalho tem como objectivo a caracterização do comportamento mecânico de misturas betuminosas a aplicar em infra-estruturas de transportes. Como metodologia para o estudo do comportamento mecânico das misturas betuminosas foram realizados em laboratório ensaios de cargas repetidas, nomeadamente, ensaios de flexão em quatro pontos para determinação da rigidez e da resistência à fadiga e ensaios de compressão triaxiais cíclicos para avaliação do comportamento à deformação permanente. A resistência à fadiga das misturas betuminosas em estudo foi avaliada através do ensaio de flexão em quatro pontos, com extensão controlada, e aplicação de um carregamento sinusoidal com diferentes frequências, de acordo com o procedimento de ensaio da norma europeia EN 12697-24 (2004 + A1: 2007). A resistência à deformação permanente das misturas betuminosas foi analisada através de ensaios de compressão triaxiais cíclicos, submetendo-as a uma tensão de confinamento estática pela aplicação parcial de vácuo e a uma pressão axial cíclica sob a forma rectangular, de acordo com a norma europeia EN 12697-25 (2004). O conhecimento destas propriedades mecânicas assume particular importância ao nível da formulação das misturas betuminosas, do dimensionamento de uma estrutura ou do estabelecimento de uma adequada solução para uma obra de reabilitação duma infra-estrutura de transportes. Para este estudo foi utilizado um modelo físico construído numa fossa no LNEC, com o propósito de serem testadas três substruturas ferroviárias não convencionais, utilizando sub-balastro betuminoso. A selecção das substruturas foi efectuada após uma análise de várias secções de estruturas já testadas e aplicadas noutros países, de forma a proporcionar comparações fiáveis entre elas. Os resultados obtidos mostraram que a mistura betuminosa AC20 base 50/70 (MB) aplicada na camada de sub-balastro é adequada para ser aplicada nas infra-estruturas de transportes pois apresenta um bom desempenho à fadiga e à deformação permanente. Através dos ensaios efectuados foi ainda possível entender a importante influência das características volumétricas, principalmente da porosidade para o bom comportamento da mistura betuminosa.