Tribology in Metal Working

This thesis focuses on the tribological performance of tool surfaces in two steel working operations, namely wire drawing and hot rolling. In all forming operations dimensions and surface finish of the products are of utmost importance. Forming basically includes three parts – forming conditions excluded – that may be changed; work material, tool and (possibly) lubricant. In the interface between work material and tool, the conditions are very aggressive with – generally or locally – high temperatures and pressures. The surfaces will be worn in various ways and this will change the conditions in the process. Consequently, the surface finish as well as the dimensions of the formed product may change and in the end, the product will not fulfil the requirements of the customer. Therefore, research and development in regard to wear, and consequently tribology, of the forming tools is of great interest. The investigations of wire drawing dies focus on coating adhesion/cohesion, surface characteristics and material transfer onto the coated steel both in laboratory scale as well as in the wire drawing process. Results show that it in wire drawing is possible to enhance the tribological performance of drawing dies by using a lubricant together with a steel substrate coated by a polished, dual-layer coating containing both hard and friction-lowering layers. The investigations of hot rolling work rolls focus on microstructure and hardness as well as cracking- and surface characteristics in both laboratory scale and in the hot strip mill. Results show that an ideal hot work roll material should be made up of a matrix with high hardness and a large amount of complex, hard carbides evenly distributed in the microstructure. The surface failure mechanisms of work rolls are very complex involving plastic deformation, abrasive wear, adhesive wear, mechanical and thermal induced cracking, material transfer and oxidation. This knowledge may be used to develop new tools with higher wear resistance giving better performance, lower costs and lower environmental impact.

Dynamic whole system testing of combined renewable heating systems : the current state of the art

Objective: For the evaluation of the energetic performance of combined renewable heating systems that supply space heat and domestic hot water for single family houses, dynamic behaviour, component interactions, and control of the system play a crucial role and should be included in test methods. Methods: New dynamic whole system test methods were developed based on “hardware in the loop” concepts. Three similar approaches are described and their differences are discussed. The methods were applied for testing solar thermal systems in combination with fossil fuel boilers (heating oil and natural gas), biomass boilers, and/or heat pumps. Results: All three methods were able to show the performance of combined heating systems under transient operating conditions. The methods often detected unexpected behaviour of the tested system that cannot be detected based on steady state performance tests that are usually applied to single components. Conclusion: Further work will be needed to harmonize the different test methods in order to reach comparable results between the different laboratories. Practice implications: A harmonized approach for whole system tests may lead to new test standards and improve the accuracy of performance prediction as well as reduce the need for field tests.

Microstructural, Mechanical and Tribological Characterisation of CVD and PVD Coatings for Metal Cutting Applications

The present thesis focuses on characterisation of microstructure and the resulting mechanical and tribological properties of CVD and PVD coatings used in metal cutting applications. These thin and hard coatings are designed to improve the tribological performance of cutting tools which in metal cutting operations may result in improved cutting performance, lower energy consumption, lower production costs and lower impact on the environment.  In order to increase the understanding of the tribological behaviour of the coating systems a number of friction and wear tests have been performed and evaluated by post-test microscopy and surface analysis. Much of the work has focused on coating cohesive and adhesive strength, surface fatigue resistance, abrasive wear resistance and friction and wear behaviour under sliding contact and metal cutting conditions. The results show that the CVD deposition of accurate crystallographic phases, e.g. α-Al2O3 rather than κ-Al2O3, textures and multilayer structures can increase the wear resistance of Al2O3. However, the characteristics of the interfaces, e.g. topography as well as interfacial porosity, have a strong impact on coating adhesion and consequently on the resulting properties.  Through the deposition of well designed bonding and template layer structures the above problems may be eliminated. Also, the presence of macro-particles in PVD coatings may have a significant impact on the interfacial adhesive strength, increasing the tendency to coating spalling and lowering the surface fatigue resistance, as well as increasing the friction in sliding contacts. Finally, the CVD-Al2O3 coating topography influences the contact conditions in sliding as well as in metal cutting. In summary, the work illuminates the importance of understanding the relationships between deposition process parameters, composition and microstructure, resulting properties and tribological performance of CVD and PVD coatings and how this knowledge can be used to develop the coating materials of tomorrow.

Primitive art as it relates to contemporary design

For the most part, my project has been of an individually rewarding nature due to an extensive amount of reading and studio work. My paper functions as the major means of communication of my own experiences and findings. It is an attempt to share with others the ideas which I have found particularly stimulating and worthwhile during the course of the year. In other words, the written portion does not intend to summarize all of the phases of primitive art which I have studied during the past year; rather, it is indicative of the type of pursuit with which I became involved. It is neither a historical survey nor a specific and thorough study of one area of primitive art. Instead, my paper is a series of essays focusing upon primitive art in general, and upon some of the aspects of primitive art with which I became concerned in particular.

Graduate of the Sheet Metal Department, Thomas Carlough

A 1946 graduate of the Sheet Metal Department, Thomas Carlough is pictured at work at the Triangle Sheet Metal Works, Inc. Original caption reads, "Thomas Carlough - Sheet Metal 1946. The Sheet Metal Draftsman lays out the duct work etc, for the ventilation and Air Conditioning of buildings." Black and white photograph with caption adhered to reverse.

Graduate of the Sheet Metal Department, John Loonie

John Loonie, a graduate of the Sheet Metal Department of the New York Trade School, is pictured welding at work in the Triangle Sheet Metal Works Inc. Original caption reads, "John Loonie - Sheet Metal 1955, one of the Sheet Metal workers employed at the Triangle Sheet Metal Works, qualified to weld." Black and white photograph with caption adhered to reverse.

Early and post transition metal complexes as a single of combined components in the ethylene and isoprene polynerization

In this work is reported, in a first step, the effect of different experimental parameters and their relation with polymer properties using the homogeneous binary catalyst system composed by Ni(α-diimine)Cl2 (α-diimine = 1,4-bis(2,6-diisopropylphenyl)- acenaphthenediimine) and {TpMs*}V(Ntbu)Cl2 (TpMs* = hydridobis(3-mesitylpyrazol-1- yl)(5-mesitylpyrazol-1-yl)) activated with MAO. This complexes combination produces, in a single reactor, polyethylene blends with different and controlled properties dependent on the polymerization temperature, solvent and Nickel molar fraction (xNi). In second, the control of linear low density polyethylene (LLDPE) production was possible, using a combination of catalyst precursors {TpMs}NiCl (TpMs = hydridotris(3- mesitylpyrazol-1-yl)) and Cp2ZrCl2, activated with MAO/TMA, as Tandem catalytic system. The catalytic activities as well as the polymer properties are dependent on xNi. Polyethylene with different Mw and controlled branches is produced only with ethylene monomer. Last, the application group 3 metals catalysts based, M(allyl)2Cl(MgCl2)2.4THF (M = Nd, La and Y), in isoprene polymerization with different cocatalysts systems and experimental parameters is reported. High yields and polyisoprene with good and controlled properties were produced. The metal center, cocatalysts and the experimental parameters are determinant for the polymers properties and their control. High conversions in cis-1,4- or trans-1,4-polyisoprene were obtained and the polymer microstructure depending of cocatalyst and metal type. Combinations of Y and La precursors were effective systems for the cis/transpolyisoprene blends production, and the control of cis-trans-1,4-microstructures by Yttrium molar fraction (xY) variation was possible.

Um estudo empírico sobre a construção da identidade social do consumidor de toy art

O objetivo deste trabalho é compreender como os consumidores de Toy Art utilizam o seu bem para constituir a sua identidade social, além de explorar este relacionamento de consumo, investigando os fatores que desencadeiam o processo de extensão de si no Toy Art. A sustentação teórica deste trabalho se deu pelo aprofundamento dos temas já levantados anteriormente por Campbell & Barbosa (2006) e McCracken (2003), em seus estudos sobre cultura e consumo; Schouten & McAlexander (1995) em sua pesquisa sobre subculturas de consumo; Hall (2005), que expôs suas teorias sobre a formação da identidade no mundo moderno; Douglas & Isherwood (2004), que estudaram os rituais de consumo; Belk (1988), com suas pesquisas sobre a extensão do self. Este estudo é de caráter exploratório, e foi conduzido com entrevistas em profundidade com o intuito de deixar emergir os sentimentos e emoções dos respondentes, para uma melhor orientação na direção das análises dos dados obtidos. Os dados foram coletados junto a 14 consumidores de Toys, de ambos os sexos, com idades entre 19 e 38 anos, residentes nos estados de Belo Horizonte, Paraná, Rio de Janeiro, Rio Grande do Sul, São Paulo e o Distrito Federal, durante os meses de julho e agosto de 2009. Para atingir os objetivos propostos, o método de pesquisa adotado foi qualitativo, com priorização do sujeito e da subjetividade, utilizando-se uma forma interpretativa para a análise dos dados. Os resultados demonstraram que os consumidores de Toy Art utilizam o seu bem para constituir sua identidade social e como uma forma de diferenciação e expressão. A extensão de si se dá exatamente durante essa busca pelo incomum, por um bem que o distinga dos demais. Conclui-se o trabalho, fazendo-se recomendações gerenciais com o intuito de beneficiar e desenvolver a indústria deste segmento.

A transmissibilidade da obrigação de prestar alimentos no direito brasileiro: aplicabilidade do art. 1.700 do código civil

O presente trabalho tem como objetivo analisar a regra da transmissão da obrigação alimentar aos herdeiros, esclarecendo alguns pontos teóricos, que ainda hoje causam perplexidades aos operadores de direito, bem como encontrar uma maneira de aplicar o art. 1.700 do Código Civil de 2002. Para tanto, serão analisados os aspectos constitucionais do Direito de Família e das Sucessões e seus conceitos básicos.

Curial exegese do art. 14, caput, da lei 9.307/96: hermenêutica lege ferenda ou real vontade do legislador?

Considerando toda a evolução da ciência processual, não há mais qualquer dúvida acerca da importância de se garantir juízes imparciais para o exercício da atividade jurisdicional. Em sede de arbitragem, a preocupação não poderia ser diferente. Dado que o árbitro exerce igualmente as prerrogativas concedidas pela jurisdição, sendo árbitro de fato e de direito, a necessidade de que sejam pessoas munidas de inquestionável imparcialidade e independência em relação às partes é ainda maior, dado que a confiança é o principal requisito para a função de tal munus. Desta forma, o trabalho pretende compreender se pode o princípio da autonomia da vontade das partes relativizar a proibição estabelecida em lei, que impede a atuação de árbitros quando incidentes nas hipóteses de impedimento e suspeição.

The art of being together: a social constructionist perspective on dialogic methods in the organizational context

The purpose of this project is to understand, under a social constructionist approach, what are the meanings that external facilitators and organizational members (sponsors) working with dialogic methods place on themselves and their work. Dialogic methods, with the objective of engaging groups in flows of conversations to envisage and co-create their own future, are growing fast within organizations as a means to achieve collective change. Sharing constructionist ideas about the possibility of multiple realities and language as constitutive of such realities, dialogue has turned into a promising way for transformation, especially in a macro context of constant change and increasing complexity, where traditional structures, relationships and forms of work are questioned. Research on the topic has mostly focused on specific methods or applications, with few attempts to study it in a broader sense. Also, despite the fact that dialogic methods work on the assumption that realities are socially constructed, few studies approach the topic from a social constructionist perspective, as a research methodology per se. Thus, while most existing research aims at explaining whether or how particular methods meet particular results, my intention is to explore the meanings sustaining these new forms of organizational practice. Data was collected through semi-structured interviews with 25 people working with dialogic methods: 11 facilitators and 14 sponsors, from 8 different organizations in Brazil. Firstly, the research findings indicate several contextual elements that seem to sustain the choices for dialogic methods. Within this context, there does not seem to be a clear or specific demand for dialogic methods, but a set of different motivations, objectives and focuses, bringing about several contrasts in the way participants name, describe and explain their experiences with such methods, including tensions on power relations, knowledge creation, identity and communication. Secondly, some central ideas or images were identified within such contrasts, pointing at both directions: dialogic methods as opportunities for the creation of new organizational realities (with images of a ‘door’ or a ‘flow’, for instance, which suggest that dialogic methods may open up the access to other perspectives and the creation of new realities); and dialogic methods as new instrumental mechanisms that seem to reproduce the traditional and non-dialogical forms of work and relationship. The individualistic tradition and its tendency for rational schematism - pointed out by social constructionist scholars as strong traditions in our Western Culture - could be observed in some participants’ accounts with the image of dialogic methods as a ‘gym’, for instance, in which dialogical – and idealized –‘abilities’ could be taught and trained, turning dialogue into a tool, rather than a means for transformation. As a conclusion, I discuss what the implications of such taken-for-granted assumptions may be, and offer some insights into dialogue (and dialogic methods) as ‘the art of being together’.

Simulação computacional de medidas estereológicas em estruturas de metal duro (WC-Co)

This work focuses on the creation and applications of a dynamic simulation software in order to study the hard metal structure (WC-Co). The technological ground used to increase the GPU hardware capacity was Geforce 9600 GT along with the PhysX chip created to make games more realistic. The software simulates the three-dimensional carbide structure to the shape of a cubic box where tungsten carbide (WC) are modeled as triangular prisms and truncated triangular prisms. The program was proven effective regarding checking testes, ranging from calculations of parameter measures such as the capacity to increase the number of particles simulated dynamically. It was possible to make an investigation of both the mean parameters and distributions stereological parameters used to characterize the carbide structure through cutting plans. Grounded on the cutting plans concerning the analyzed structures, we have investigated the linear intercepts, the intercepts to the area, and the perimeter section of the intercepted grains as well as the binder phase to the structure by calculating the mean value and distribution of the free path. As literature shows almost consensually that the distribution of the linear intercepts is lognormal, this suggests that the grain distribution is also lognormal. Thus, a routine was developed regarding the program which made possible a more detailed research on this issue. We have observed that it is possible, under certain values for the parameters which define the shape and size of the Prismatic grain to find out the distribution to the linear intercepts that approach the lognormal shape. Regarding a number of developed simulations, we have observed that the distribution curves of the linear and area intercepts as well as the perimeter section are consistent with studies on static computer simulation to these parameters.

Metalização mecânica de ZrO2 com Ti para brasagem ZrO2/Aço com ligas de adição sem metal ativo

Metal/ceramic interfaces using zirconia have dominated the industrial applications in the last decade, due to the high mechanical strength and fracture toughness of zirconia, especially at temperatures below 300 ºC. Also noteworthy is the good ionic conductivity in high temperatures of this component. In this work joining between ZrO2 Y-TZP and ZrO2 Mg-PSZ with austenitic stainless steel was studied. These joints were brazed at high-vacuum after mechanical metallization with Ti using filler alloys composed by Ag-Cu and Ag-Cu-Ni. The influence of the metallization, and the affinity between the different groups (ceramic / filler alloys) was evaluated, in order to achieve strong metal/ceramic joints. Evaluation of joints and interfaces, also the characterization of base materials was implemented using various techniques, such as: x-ray diffraction, leak test, three-point flexural test and scanning electron microscopy with chemical analysis. The microstructural analysis revealed physical and chemical bonds in the metal/ceramic interfaces, providing superior leak proof joints and stress cracking, in order to a good joint in all brazed samples. Precipitation zones and reaction layers with eutetic characteristics were observed between the steel and the filler metal

Fresamento com ar quente: uma proposta para minimizar a formação de trincas térmicas em ferramentas de metal duro

This work presents the results, analyses and conclusions about a study carried out with objective of minimizing the thermal cracks formation on cemented carbide inserts during face milling. The main focus of investigation was based on the observation that milling process is an interrupted machining process, which imposes cyclic thermal loads to the cutting tool, causing frequent stresses changes in its superficial and sub-superficial layers. These characteristics cause the formation of perpendicular cracks from cutting edge which aid the cutting tool wear, reducing its life. Several works on this subject emphasizing the thermal cyclic behavior imposed by the milling process as the main responsible for thermal cracks formation have been published. In these cases, the phenomenon appears as a consequence of the difference in temperature experienced by the cutting tool with each rotation of the cutter, usually defined as the difference between the temperatures in the cutting tool wedge at the end of the cutting and idle periods (T factor). Thus, a technique to minimize this cyclic behavior with objective of transforming the milling in an almost-continuous process in terms of temperature was proposed. In this case, a hot air stream was applied into the idle period, during the machining process. This procedure aimed to minimize the T factor. This technique was applied using three values of temperature from the hot air stream (100, 350 e 580 oC) with no cutting fluid (dry condition) and with cutting fluid mist (wet condition) using the hot air stream at 580oC. Besides, trials at room temperature were carried out. Afterwards the inserts were analyzed using a scanning electron microscope, where the quantity of thermal cracks generated in each condition, the wear and others damages was analyzed. In a general way, it was found that the heating of the idle period was positive for reducing the number of thermal cracks during face milling with cemented carbide inserts. Further, the cutting fluid mist application was effective in reducing the wear of the cutting tools.

Hygrothermal effects on damping behavior of metal/glass fiber/epoxy hybrid composites

Continuous fiber/metal laminates (FML) offer significant improvements over current available materials for aircraft structures due to their excellent fatigue endurance and low density. Glass fibers/epoxy laminae and aluminum foil (Glare) are commonly used to obtain these hybrid composites. The environmental factors can limit the applications of composites by deteriorating the mechanical properties during service. Usually, epoxy resins absorb moisture when exposed to humid environments and metals are prone to surface corrosion. Therefore, the combination of the two materials in Glare (polymeric composite and metal). can lead to differences that often turn out to be beneficial in terms of mechanical properties and resistance to environmental influences. In this work. The viscoelastic properties. such as storage modulus (E') and loss modulus (E'), were obtained for glass fiber/epoxy composite, aluminum 2024-T3 alloy and for a glass fiber/epoxy/aluminum laminate (Glare). It was found that the glass fiber/epoxy (G/E) composites decrease the E' modulus during hygrothermal conditioning up to saturation point (6 weeks). However, for Glare laminates the E' modulus remains unchanged (49GPa) during the cycle of hygrothermal conditioning. The outer aluminum sheets in the Glare laminate shield the G/E composite laminae from moisture absorption. which in turn prevent, in a certain extent, the material from hygrothermal degradation effects. (c) 2005 Elsevier B.V. All rights reserved.