Effect of Alloying Elements on Thermal Diffusivity of Gray Cast Iron Used in Automotive Brake Disks

The purpose of this work was to experimentally investigate the thermal diffusivity of four different gray cast iron alloys, regularly used to produce brake disks for automotive vehicles. Thermal diffusivity measurements were performed at temperatures ranging from room temperature to 600 A degrees C. The influence of the thermal conductivity on the thermomechanical fatigue life is also briefly presented. The measurements were sensitive to the influence of the carbon equivalent and alloying elements, such as molybdenum, copper and chromium. Molybdenum, unlike copper, lowered the thermal diffusivity of the gray cast iron, and alloy E (without molybdenum), besides presenting a relatively low carbon equivalent content and an increase in the values of the thermal diffusivity, presented the best performance during the thermomechanical fatigue. The molybdenum present in alloys B and C did not fulfill the expectations of providing the best thermomechanical fatigue behavior. Consequently, its elimination in the gray cast iron alloy for this application will result in a significant economy.

Tool wear aspects when applying high-speed tapping on grey cast iron

Tool wear is a very important subject affecting the economics of machining, especially in tapping, since it is one of the last operations to be performed within most operation sequences. In the present study, some aspects of tapping such as the mechanisms and types of wear were investigated in taps working at conventional and high-speed cutting (HSC). Additionally, different types of coatings and cooling /lubrication conditions were used. The tapping operation (M8 x 1.25) was performed in through holes with two cutting speeds (30 and 60 m/min) in grey cast iron GG25. Lubrication conditions tested were dry and with minimal quantity of lubricant. Tap materials were manufactured by powder metallurgy and coated with (TiAl)N and with TiCN. A go-non-go gauge criterion was used to assess tool life. The wear and surface aspects of the tools and workpiece were evaluated by scanning electron microscopy and energy dissipation spectroscopy. Torque signals were also measured during the tests. The main wear mechanism observed was adhesion, although some abrasion and diffusion may also have occurred, and the main type of wear was flank wear. The adhesion of workpiece material on the tool was the main and decisive factor ending tool life. Tool coatings proved to be an efficient way to minimize adhesion. Torque signals followed the same pattern as the flank wear and no significant change was observed when the cutting speed was increased.

Bond Strength of Multicomponent White Cast Iron Coatings Applied by HVOF Thermal Spray Process

Multicomponent white cast iron is a new alloy that belongs to system Fe-C-Cr-W-Mo-V, and because of its excellent wear resistance it is used in the manufacture of hot rolling mills rolls. To date, this alloy has been processed by casting, powder metallurgy, and spray forming. The high-velocity oxyfuel process is now also considered for the manufacture of components with this alloy. The effects of substrate, preheating temperature, and coating thickness on bond strength of coatings have been determined. Substrates of AISI 1020 steel and of cast iron with preheating of 150 A degrees C and at room temperature were used to apply coatings with 200 and 400 mu m nominal thickness. The bond strength of coatings was measured with the pull-off test method and the failure mode by scanning electron microscopic analysis. Coatings with thickness of 200 mu m and applied on substrates of AISI 1020 steel with preheating presented bond strength of 87 +/- A 4 MPa.

Ferromagnetic resonance for the quantification of superparamagnetic iron oxide nanoparticles in biological materials

The aim of the present work is the presentation of a quantification methodology for the control of the amount of superparamagnetic iron oxide nanoparticles (SPIONs) administered in biological materials by means of the ferromagnetic resonance technique (FMR) applied to studies both in vivo and in vitro. The in vivo study consisted in the analysis of the elimination and biodistribution kinetics of SPIONs after intravenous administration in Wistar rats. The results were corroborated by X-ray fluorescence. For the in vitro study, a quantitative analysis of the concentration of SPIONs bound to the specific AC133 monoclonal antibodies was carried out in order to detect the expression of the antigenic epitopes (CD133) in stem cells from human umbilical cord blood. In both studies FMR has proven to be an efficient technique for the SPIONs quantification per volume unit (in vivo) or per labeled cell (in vitro).

The metal content of bulge field stars from FLAMES-GIRAFFE spectra - I. Stellar parameters and iron abundances

Aims. We determine the iron distribution function (IDF) for bulge field stars, in three different fields along the Galactic minor axis and at latitudes b = -4 degrees, b = -6 degrees, and b = -12 degrees. A fourth field including NGC 6553 is also included in the discussion. Methods. About 800 bulge field K giants were observed with the GIRAFFE spectrograph of FLAMES@VLT at spectral resolution R similar to 20 000. Several of them were observed again with UVES at R similar to 45 000 to insure the accuracy of the measurements. The LTE abundance analysis yielded stellar parameters and iron abundances that allowed us to construct an IDF for the bulge that, for the first time, is based on high-resolution spectroscopy for each individual star. Results. The IDF derived here is centered on solar metallicity, and extends from [Fe/H] similar to -1.5 to [Fe/H] similar to + 0.5. The distribution is asymmetric, with a sharper cutoff on the high-metallicity side, and it is narrower than previously measured. A variation in the mean metallicity along the bulge minor axis is clearly between b = -4 degrees and b = -6 degrees ([Fe/H] decreasing similar to by 0.6 dex per kpc). The field at b = -12 degrees. is consistent with the presence of a gradient, but its quantification is complicated by the higher disk/bulge fraction in this field. Conclusions. Our findings support a scenario in which both infall and outflow were important during the bulge formation, and then suggest the presence of a radial gradient, which poses some challenges to the scenario in which the bulge would result solely from the vertical heating of the bar.

Contrasting photoelectrochemical behaviour of two isomeric supramolecular dyes based on meso-tetra(pyridyl)porphyrin incorporating four (mu(3)-oxo)- triruthenium(III) clusters

A saddle shaped tetracluster porphyrin species containing four [Ru(3)O(OAc)(6)(py)(2)](+) clusters coordinated to the N-pyridyl atoms of 5,10,15,20-tetra(3-pyridyl)porphyrin, H(2)(3-TCPyP), has been investigated in comparison with the planar tetra(4-pyridyl) porphyrin analogue H(2)(4-TCPyP). The steric effects from the bulky peripheral complexes play a critical role in the H(2)(3-TCPyP) species, determining a non-planar configuration around the porphyrin centre and precluding any significant pi-electronic coupling, in contrast with the less hindered H(2)(4-TCPyP) species. Both systems exhibit a photoelectrochemical response in the presence of nanocrystalline TiO(2) films, involving the porphyrin excitation around 450 nm. However, only in the H(2)(4-TCPyP) case do the cluster moieties also contribute to the photoinduced electron injection process at 670 nm, reflecting the relevance of the electronic coupling between the porphyrin centre and the peripheral complexes.

Response of Wolfiporia cocos to iron availability: alterations in growth, expression of cellular proteins, Fe3+-reducing activity and Fe3+-chelators production

Aims: The main objective of this study was to evaluate the behaviour of the brown-rot fungus Wolfiporia cocos under differential iron availability. Methods and Results: W. cocos was grown under three differential iron conditions. Growth, catecholate and hydroxamate production, and mycelial and extracellular Fe3+-reducing activities were determined. Iron starvation slowed fungal growth and accelerated pH decline. Some mycelial proteins of low molecular weight were repressed under iron restriction, whereas others of high molecular weight showed positive iron regulation. Mycelial ferrireductase activity decreased as culture aged, while Fe3+-reducing activity of low molecular reductants constantly increased. Hydroxamates production suffered only limited iron repression, whereas catecholates production showed to be more iron repressible. Conclusions: W. cocos seems to possess more than one type of iron acquisition mechanism; one involving secretion of organic acids and ferrireductases and/or extracellular reductants, and another relying on secretion of catecholates and hydroxamates chelators. Significance and Impact of the Study: This paper is the first to report the kinetic study of brown-rot fungus grown under differential iron availability, and the information provided here contributes to address more traditional problems in protecting wood from brown decay, and also makes a contribution in the general area of the physiology of brown-rot fungi.

Impact of transition oxides on growth stresses and texture of alumina scales formed during oxidation of iron aluminides

The internal stresses and crystallographic texture in alpha-Al(2)O(3) scales grown on iron aluminides at 1100 degrees C were determined in situ using synchrotron X-ray diffraction. In the first hour of oxidation, alpha-Al(2)O(3) was formed by direct nucleation and by conversion from transition oxides (either theta-Al(2)O(3) or a mixed Fe-Al oxide). A sharp texture develops connected with the direct nucleation of alpha-Al(2)O(3), in contrast to the weaker texture observed in alpha-Al(2)O(3) originated by previous transformations, which also yielded tensile stresses in early oxidation stages. (C) 2011 Acta Materialia Inc. Published by Elsevier Ltd. All rights reserved.

Tempering temperature effects on abrasive wear of mottled cast iron

The effects of different tempering temperatures (300-600 degrees C) on abrasive wear resistance of mottled cast iron were studied. Abrasive wear tests were carried out using the rubber-wheel test on quartz sand and the pin test on Al(2)O(3) abrasive cloths. The retained austenite content of the matrix was determined by X-ray diffraction. The wear surface of the specimens was examined by scanning electron microscopy for identifying the wear micromechanism. Bulk hardness and matrix hardness before and after the tests were measured. The results showed that in the two-body (pin-on-disc test) system, the main wear mechanism was microcutting and high matrix hardening was presented. The wear rates presented higher correlation with the retained austenite than with the bulk and matrix hardness. In the three-body system (sand-rubber wheel), the wear surfaces presented indentations due to abrasive rolling. The wear rates had better correlation with both the bulk and matrix hardness (before and after the wear test) than with the retained austenite content. There are two groups of results, high and low wear rates corresponding to each tribosystem, two-body abrasive wear and three-body abrasive wear, respectively. (C) 2009 Elsevier B.V. All rights reserved.

Particle size effect on abrasion resistance of mottled cast iron with different retained austenite contents

Effects of particle abrasive sizes on wear resistance of mottled cast iron with different retained austenite contents were studied. Abrasive wear tests using a pin test on alumina paper were carried out, using abrasive sizes between 16 mu m and 192 mu m. Retained austenite content of the matrix was determined by X-ray diffraction. The wear surface of samples and the alumina paper were examined by scanning electron microscopy for identifying the wear micromechanism. The results show that at lower abrasive sizes the mass loss was similar for the iron with different austenite contents. However, at higher abrasive sizes the samples with higher retained austenite content presented higher abrasion resistance. For lower abrasive sizes tested, samples with higher and lower retained austenite content both presented microcutting. On the other hand, the main wear micromechanism for the samples with higher retained austenite content and higher abrasive sizes was microploughing. The samples with lower retained austenite content presented microcutting and wedge formation at higher abrasive sizes. Higher abrasive size induced more microcutting in samples with lower retained austenite. The iron with lower retained austenite content presented wider grooves for the different abrasive sizes measured. SEM on the abrasive paper used on samples with higher retained austenite showed continuous and discontinuous microchips and the samples with lower retained austenite showed discontinuous microchips at 66 and 141 mu m. This research demonstrates the relation between abrasive size, wear resistance, groove width and wear micromechanism for mottled cast iron with different retained austenite contents. (C) 2009 Elsevier B.V. All rights reserved.

Abrasive wear study of white cast iron with different solidification rates

The abrasive wear resistance of white cast iron was studied. The iron was solidified using two solidification rates of 1.5 and 15 degrees C/s. Mass loss was evaluated with tests of the type pin on abrasive disc using alumina of different sizes. Two matrices were tested: one predominantly austenitic and the other predominantly martensitic, containing M(3)C carbides. Samples with cooling rate of 15 degrees C/s showed higher hardness and more refined microstructure compared with those solidified at 1.5 degrees C/s. During the test, the movement of successive abrasives gave rise to the strain hardening of the austenite phase, leading to the attainment of similar levels of surface hardness, which explains why the wear rate showed no difference compared to the austenite samples with different solidification rates. For the austenitic matrix the wear rate seems to depend on the hardness of the worn surface and not on the hardness of the material without deformation. The austenitic samples showed cracking and fracture of M(3)C carbides. For the predominantly martensitic matrix, the wear rate was higher at the solidification rate of 1.5 degrees C/s, for grain size of 66 and 93 mu m. Higher abrasive sizes were found to produce greater penetration and strain hardening of austenitic matrices. However, martensitic iron produces more microcutting, increasing the wear rate of the material. The analysis of the worn surface by scanning electron microscopy indicated abrasive wear mechanisms such as: microcutting, microfatigue and microploughing. Yet, for the iron of austenitic matrix, the microploughing mechanism was more severe. (C) 2009 Elsevier B.V. All rights reserved.

Load effect in abrasive wear mechanism of cast iron with graphite and cementite

In this study four irons were casted with different chromium and vanadium contents: 2.66% Cr, 5.01% Cr, 2.51% V and 5.19% V. Their microstructure is composed of: ledeburite, graphite and M(3)C carbides (cementite). Pin-abrasion tests were carried out using fixed alumina abrasive grains at different loads: 1, 2, 4.6 and 10 N. The wear surface and the abrasive paper were examined by scanning electron microscopy for identifying the wear micromechanism. The results reveal that the mass loss increased with the load increase, and the effect of the percentage of chromium on mass loss is inverted when the load is increased from 4.6 to 10 N; for 4.6 N the mass loss decreased when the chromium percentage was increased from 2.66% to 5.01%. Nevertheless, for 10 N the mass loss increased when the chromium percentage was increased. The worn surfaces of the materials tested at 1 N show microcutting caused by the abrasive tip that produces continuous microchips. The worn surfaces and the abrasive paper tested at 10 N show continuous microchips and brittle debris. The results show that high pressures produce a brittle wear mechanism and low pressures produce a more ductile wear micromechanism, for this, the applied pressure defines the dependence between the wear resistance and wear micromechanism. (C) 2009 Elsevier B.V. All rights reserved.

Influence of parameters of the HVOF thermal spray process on the properties of multicomponent white cast iron coatings

High velocity oxi-fuel (HVOF) thermal spray process has been used in order to deposit a new alloy known as multicomponent white cast iron. The coatings were characterized in terms of macrostructure, phase composition, porosity and hardness. Coating characteristics and properties were found to be dependent on the particles size range, spray distance, gases flow rate and oxygen to propane ratio. For set of parameters utilized in this job a narrow particle size range between 20 and 45 gm with a spray distance of 200 mm and oxygen to propane ratio of 4.6 are the preferred coating parameters. Coating porosity of 0.9% and hardness of 766 HV were obtained under these conditions. (c) 2007 Elsevier B.V. All rights reserved.

Reduction of Chromium from Al(2)O(3)-CaO-SiO(2)-CrOx Slags by Carbon Dissolved in Liquid Iron

The goal of this work is to investigate the reduction of chromium from a quaternary slag by carbon dissolved in liquid steel. Laboratory scale experiments were conducted to study the reduction of chromium oxides in the slag by carbon dissolved in the melt. These experiments were made under different conditions of slag basicity and amount of added carbon. Thermodynamic calculations based on Double Sublattice model were applied using the commercial software Thermo-Calc, with the IRSID database. The results obtained showed good correlation with practical and calculated results, making it possible to predict equilibrium conditions of the system and to determine the activities of chromium oxides in the slag.

Reaction rate and product morphology in carbon composite iron ore pellets with and without Portland cement

The aim of this work is to study the reaction rate and the morphology of intermediate reaction products during iron ore reduction when iron ore and carbonaceous materials are agglomerated together with or without Portland cement. The reaction was performed at high temperatures, and used small size samples in order to minimise heat transfer constraints. Coke breeze and pure graphite were the carbonaceous materials employed. Portland cement was applied as a binder, and pellet diameters were in the range 5.6-6.5 mm. The experimental technique involved the measurement of the pellet weight loss, as well as the interruption of the reaction at different stages, in order to submit the partially reduced pellet to scanning electron microscopy. The experimental temperature was in the range 1423-1623 K, and the total reaction time varied from 240 to 1200 s. It was observed that above 1523 K the formation of liquid slag occurred inside the pellets, which partially dissolved iron oxides. The apparent activation energies obtained were 255 kJ mol(-1) for coke breeze containing pellets, and 230 kJ mol(-1) for those pellets containing graphite. It was possible to avoid heat transfer control of the reaction rate up to 1523 K by employing small composite pellets.