Effects of tungsten carbide thermal spray coating by HP/HVOF and hard chromium electroplating on AISI 4340 high strength steel

In cases of decorative and functional applications, chromium results in protection against wear and corrosion combined with chemical resistance and good lubricity. However, pressure to identify alternatives or to improve conventional chromium electroplating mechanical characteristics has increased in recent years, related to the reduction in the fatigue strength of the base material and to environmental requirements. The high efficiency and fluoride-free hard chromium electroplating is an improvement to the conventional process, considering chemical and physical final properties. One of the most interesting, environmentally safer and cleaner alternatives for the replacement of hard chrome plating is tungsten carbide thermal spray coating, applied by the high velocity oxy-fuel (HVOF) process. The aim of this study was to analyse the effects of the tungsten carbide thermal spray coating applied by the HP/HVOF process and of the high efficiency and fluoride-free hard chromium electroplating (in the present paper called 'accelerated'), in comparison to the conventional hard chromium electroplating on the AISI 4340 high strength steel behaviour in fatigue, corrosion, and abrasive wear tests. The results showed that the coatings were damaging to the AISI 4340 steel behaviour when submitted to fatigue testing, with the tungsten carbide thermal spray coatings showing the better performance. Experimental data from abrasive wear tests were conclusive, indicating better results from the WC coating. Regarding corrosion by salt spray test, both coatings were completely corroded after 72 h exposure. Scanning electron microscopy technique (SEM) and optical microscopy were used to observe crack origin sites, thickness and adhesion in all the coatings and microcrack density in hard chromium electroplatings, to aid in the results analysis. © 2001 Elsevier Science B.V. All rights reserved.

An investigation of electrolytic surface damages and electroplated crhomium effects on fatigue behavior of high strength steel

Fatigue crack initiation occurs at the surface, although sub surface nucleation has also been reported. Localized imperfections like inclusions close to surface and surface small pits can result in crack sources. Coatings are not always beneficial by fatigue point of view too. Mechanical properties of the covering material can change considerably the fatigue behavior of base metal due to residual surface stresses, to micro cracks or to hydrogen embrittlement. This paper is concerned with analysis of electrolytic etch on the fatigue resistance of a 35NCD16 high strength steel in a mechanical condition of (1760 - 1960) MPa, and analysis of electroplated hard chromium effects on the fatigue resistance in a strength condition of 989 MPa. Hardness impression was used as a reference parameter in case of electrolytic etch. In both cases, experimental data showed that fatigue strength of 35NCD16 steel was considerably reduced. Copyright © 2001 Society of Automotive Engineers, Inc.

Analysis of diametrical wear of grinding wheel and roundness errors in the machining of steel VC 131

Due to the high industrial competitiveness, the rigorous laws of environmental protection, the necessary reduction of costs, the mechanical industry sees itself forced to worry more and more with the refinement of your processes and products. In this context, can be mentioned the need to eliminate the roundness errors that appear after the grinding process. This work has the objective of verifying if optimized nozzles for the application of cutting fluid in the grinding process can minimize the formation of the roundness errors and the diametrical wear of grinding wheel in the machining of the steel VC 131 with 60 HRc, when compared to the conventional nozzles. These nozzles were analyzed using two types of grinding wheels and two different cutting fluids. Was verified that the nozzle of 3mm of diameter, integral oil and the CBN grinding wheel, were the best options to obtain smaller roundness errors and the lowest diametrical wears of grinding wheels.

Effect of 0.4% stannous fluoride gel on Streptococci mutans in relation to elastomeric rings and steel ligatures in orthodontic patients

Background: Patients with fixed orthodontic appliances often experience an absolute increase in the number of Streptococci mutans colony-forming units (cfu). The aim of this investigation was to study the development of biofilm and S. mutans cfu in connection with stainless steel ligatures and elastomeric rings in orthodontic patients treated with and without 0.4% stannous fluoride gel (SFG). Material: Forty-seven patients were divided into 2 groups: those treated with 0.4% SFG for 4 minutes (experimental) and those without 0.4% SFG (control). In each patient, elastomeric rings were used for ligation on 1 side of the dental arch midline, and stainless steel ligatures were used on the opposite side. Saliva samples were collected before and after appliance placement. At 15 and 30 days after appliance placement, biofilm samples from the stainless steel ligatures and the elastomeric rings were collected and subjected to microbiologic procedures and scanning electron microscopy (SEM) analysis. Results: The numbers of S. mutans cfu in the saliva and biofilm were not statistically different between the teeth fitted with elastomeric rings and stainless steel ligatures, or between the experimental and control groups. SEM analysis showed biofilm formation on both ligature ties. Conclusions: Topical application of 0.4% SFG in orthodontic patients with elastomeric rings or stainless steel ligatures does not cause a significant decrease in S. mutans cfu in the saliva and biofilm. Copyright © 2005 by the American Association of Orthodontists.

Study on the behavior of the Minimum quantity lubricant - MQL technique under different lubricating and cooling conditions when grinding ABNT 4340 steel

The behavior of the minimum quantity lubricant (MQL) technique was analyzed under different lubricating and cooling conditions when grinding ABNT 4340 steel. The comparative analysis of the residual stress values showed that residual compressive stresses were obtained under all the lubrication/cooling conditions and types of abrasive tools employed. The highest residual compressive stress obtained with the aluminum oxide grinding wheel with MQL under the condition of V= 30m/s for air and V= 40ml/h for lubricant was -376MPa against the -160MPa attained with conventional cooling, representing a 135% increase in residual compressive stress. The results show that method and quantity of lubricant and cooling are factors that influence the grinding process.

Effect of thermal treatments on tensile strength of commercially cast pure titanium and Ti-6Al-4V alloys

Heating titanium structures is assumed to relieve tensions induced by the casting process as well as possibly optimizing some mechanical properties. The aim of this investigation was to evaluate the effect of thermal treatments on tensile strength of commercially pure titanium (CP Ti) and Ti-6Al-4V alloy. Thirty dumbbell rods, with diameters of 3.0 mm at the central segment and lengths of 42 mm, were cast for each metal using the Rematitan System. CP Ti and Ti-6Al-4V specimens were randomly divided into three groups of ten: a control group that received no thermal treatment and two test groups. One (T1) was heated at 750°C for 2 h and the other (T2) was annealed at 955°C for 1 h and aged at 620°C for 2 h. Tensile strength was measured with a universal testing machine (MTS model 810). Tensile strength means and standard deviations were statistically compared using a Kruskal-Wallis test at a α = 0.05 significance level. No statistically significant differences in tensile strength were observed among CP Ti groups. For the Ti-6Al-4V alloy, the control and T1 groups revealed statistically higher tensile strengths when compared to the T2 group, with no significant difference between the control and T1 groups. © 2005 Springer Science + Business Media, Inc.

Photo-oxidation of polyphenylenevinylene chains in Langmuir-Blodgett and cast films

Poly(p-phenylene vinylene) (PPV) derivatives are well known for their applications in polymer light emitting diodes (PLEDs). These derivatives are highly susceptible to photooxidation though, which is mainly caused by the scission of the vinyl double bond on the polymer backbone. In this work, we show that Langmuir-Blodgett (LB) films are less degraded than cast films of a PPV derivative (OC1OC6-PPV). Both films had similar thickness (∼50 nm) to allow for a more realistic comparison. Photodegradation experiments were carried out by illuminating the films with white light from a halogen lamp (50W, 12 V), placed at a fixed dstance from the sample. The decay was monitored by UV-Vis and FTIR spectroscopies. The results showed that cast films are completely degraded in ca. 300 min, while LB took longer times, ca. 1000 min, i.e. 3 times the values for the cast films. The degradation process occurs in at least two stages, the rates of which were calculated assuming that the reaction follows a first order kinetics. The characteristic times for the first stage were 3.6×10-2 and 1.3×10-3 min-1 for cast and LB films, respectively. For the second stage the characteristic times were 5.6×10-2 and 5.0×10 -3 min-1. The differences can be attributed to the more compact morphology in the LB than in the cast films. With a compact morphology the diffusion of oxygen in the LB film is hampered and this causes a delay in the degradation process.

Steel bars identification in reinforced concrete structures by using ANN and magnetic fields

This work proposes a methodology for non destructive testing (NDT) of reinforced concrete structures, using superficial magnetic fields and artificial neural networks, in order to identify the size and position of steel bars, embedded into the concrete. For the purposes of this paper, magnetic induction curves were obtained by using a finite element program. Perceptron Multilayered (PML) ANNs, with Levemberg-Marquardt training algorithm were used. The results presented very good agreement with the expect ones, encouraging the development of real systems based upon the proposed methodology.

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.

Vickers hardness of cast commercially pure titanium and Ti-6Al-4V alloy submitted to heat treatments

The purpose of this study was to evaluate the effect of heat treatments on the Vickers hardness of commercially pure titanium and Ti-6Al-4V cast alloys. Six-millimeter-diameter cylindrical specimens were cast in a Rematitan System. Commercially pure titanium and Ti-6Al-4V alloy specimens were randomly assigned to 3 groups (n=10) that received the following heat treatments: control (no heat treatment); treatment 1 (T1): heating at 750°C for 2 h; and treatment 2 (T2): annealing at 955°C for 1 h and aging at 620°C for 2 h. After heat treatments, the specimens were embedded in acrylic resin and their surface was ground and polished and hardness was measured. Vickers hardness means (VHN) and standard deviations were analyzed statistically by Kruskal-Wallis test at 5% significance level. For commercially pure titanium, Vickers hardness means of group T2 (259.90 VHN) was significantly higher than those of the other groups (control - 200.26 VHN and T1 - 202.23 VHN), which presented similar hardness means to each other (p>0.05). For Ti-6Al-4V alloy, statistically significant differences were observed among the three groups: T2 (369.08 VHN), T1 (351.94 VHN) and control (340.51 VHN) (p<0.05). The results demonstrated different hardness of CP Ti and Ti-6Al-4V when different heat treatments were used. For CP Ti, VHN means of T2 group was remarkably higher than those of control and T1 group, which showed similar VHN means to each other. For Ti-6Al-4V alloy, however, VHN means recorded for each group may be presented as follows: T2>T1>control.

An overview of the microstructures present in high-speed steel - Carbides crystallography

The aim of the work was to prepare an overview about the microstructures present in high-speed steel, focused on the crystallography of the carbides. High-speed steels are currently obtained by casting, powder metallurgy and more recently spray forming. High-speed steels have a high hardness resulting from a microstructure, which consists of a steel matrix (martensite and ferrite), in which embedded carbides of different crystal structure, chemical composition, morphology and size, exist. These carbides are commonly named MxC, where M represents one or more metallic atoms. These carbides can be identified by X-ray diffraction considering M as a unique metallic atom. In this work, it is discussed, in basis of the first principles of physics crystallography, the validation of this identification when it is considered that other atoms in the structure are substitutional. Further, it is discussed some requirements for data acquisition that allows the Rietveld refinement to be applied on carbide crystallography and phase amount determination.

Effect of cast rectifiers on the marginal fit of UCLA abutments

Objectives: This study assessed the effect of cast rectifiers on the marginal misfit of cast UCLA abutments compared to premachined UCLA abutments. The influence of casting and porcelain baking on the marginal misfit of these components was also investigated. Methods: Two groups were analyzed: test group - 10 cast UCLA abutments, finished with cast rectifier and submitted to ceramic application; control group - 10 premachined UCLA abutments, cast with noble metal alloy and submitted to ceramic application. Vertical misfit measurements were performed under light microscopy. In the test group, measurements were performed before and after the use of cast rectifiers, and after ceramic application. In the control group, measurements were performed before and after casting, and after ceramic application. Data were submitted to statistical analysis by ANOVA and Tukey's test (α= 5%). Results: The use of cast rectifiers significantly reduced the marginal misfit of cast UCLA abutments (from 25.68μm to 14.83μm; p<0.05). After ceramic application, the rectified cylinders presented misfit values (16.18μm) similar to those of premachined components (14.3 μm). Casting of the premachined UCLA abutments altered the marginal misfit of these components (from 9.63 μm to 14.6 μm; p<0.05). There were no significant changes after porcelain baking, in both groups. Conclusion: The use of cast rectifiers reduced the vertical misfit of cast UCLA abutments. Even with carefully performed laboratory steps, changes at the implant interface of premachined UCLA abutments occurred. Ceramic application did not alter the marginal misfit values of UCLA abutments.

Microstructure evolution during warm deformation of low carbon steel with dispersed cementite

The microstructure evolution and mechanical behavior during large strain of a 0.16%C-Mn steel has been investigated by warm torsion tests. These experiments were carried out at 685°C at equivalent strain rate of 0.1 s . The initial microstructure composed of a martensite matrix with uniformly dispersed fine cementite particles was attained by quenching and tempering. The microstructure evolution during tempering and straining was performed through interrupted tests. As the material was reheated to testing temperature, well-defined cell structure was created and subgrains within lath martensite were observed by TEM; strong recovery took place, decreasing the dislocation density. After 1 hour at the test temperature and without straining, EBSD technique showed the formation of new grains. The flow stress curves measured had a peculiar shape: rapid work hardening to a hump, followed by an extensive flow-softening region. 65% of the boundaries observed in the sample strained to ε = 1.0 were high angle grain boundaries. After straining to ε = 5.0, average ferrite grain size close to 1.5 μm was found, suggesting that dynamic recrystallization took place. Also, two sets of cementite particles were observed: large particles aligned with straining direction and smaller particles more uniformly dispersed. The fragmentation or grain subdivision that occurred during reheating and tempering time was essential for the formation of ultrafine grained microstructure.