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.

The significance and determination by image analysis of microcrack density in hard chromium plating

It is well known that the microcrack density is a fundamental parameter in hard chromium electroplating. The chemical and mechanical properties of this coating are widely dependent on its microcrack density. In this paper a simple image analysis procedure to determine microcrack density is presented in order to demonstrate it as a fundamental tool to estimate the fatigue, corrosion and wear behavior, as well as the residual stress field of a coated component. For this purpose, the image analysis procedure was carried out on two kinds of hard chromium plating - one called accelerated (high velocity of deposition and fluoride-free) and the other conventional (with fluoride). The coatings were applied on samples of AISI 4340 aeronautical steel, which is widely used in aircraft landing gear components. To characterize the practical significance of this study, the microcrack density results were related to the fatigue, wear and corrosion behavior from previous study and to the residual stress field in the coatings.

Influence of voids in the hybrid layer based on self-etching adhesive systems: a 3-D FE analysis

The presence of porosities at the dentin/adhesive interface has been observed with the use of new generation dentin bonding systems. These porosities tend to contradict the concept that etching and hybridization processes occur equally and simultaneously. Therefore, the aim of this study was to evaluate the micromechanical behavior of the hybrid layer (HL) with voids based on a self-etching adhesive system using 3-D finite element (FE) analysis. Three FE models (Mr) were built: Mr, dentin specimen (41x41x82 μm) with a regular and perfect (i.e. pore-free) HL based on a self-etching adhesive system, restored with composite resin; Mp, similar to M, but containing 25% (v/v) voids in the HL; Mpp, similar to Mr, but containing 50% (v/v) voids in the HL. A tensile load (0.03N) was applied on top of the composite resin. The stress field was obtained by using Ansys Workbench 10.0. The nodes of the base of the specimen were constrained in the x, y and z axes. The maximum principal stress (σmax) was obtained for all structures at the dentin/adhesive interface. The Mpp showed the highest peak of σmax in the HL (32.2 MPa), followed by Mp (30 MPa) and Mr (28.4 MPa). The stress concentration in the peritubular dentin was high in all models (120 MPa). All other structures positioned far from voids showed similar increase of stress. Voids incorporated into the HL raised the σmax in this region by 13.5%. This behavior might be responsible for lower bond strengths of self-etching and single-bottle adhesives, as reported in the literature.

Micromechanics of dentin/adhesive interface in function of dentin depth: 3d finite element analysis

Objectives: The aim of this study was to analyze the stress distribution on dentin/adhesive interface (d/a) through a 3-D finite element analysis (FEA) varying the number and diameter of the dentin tubules orifice according to dentin depth, keeping hybrid layer (HL) thickness and TAǴs length constant. Materials and Methods: 3 models were built through the SolidWorks software: SD - specimen simulating superficial dentin (41 x 41 x 82 μm), with a 3 μm thick HL, a 17 μm length Tag, and 8 tubules with a 0.9 μm diameter restored with composite resin. MD - similar to M1 with 12 tubules with a 1.2 μm diameter, simulating medium dentin. DD - similar to M1 with 16 tubules with a 2.5 μm diameter, simulating deep dentin. Other two models were built in order to keep the diameter constant in 2.5 μm: MS - similar to SD with 8 tubules; and MM - similar to MD with 12 tubules. The boundary condition was applied to the base surface of each specimen. Tensile load (0.03N) was performed on the composite resin top surface. Stress field (maximum principal stress in tension - σMAX) was performed using Ansys Wokbench 10.0. Results: The peak of σMAX (MPa) were similar between SD (110) and MD (106), and higher for DD (134). The stress distribution pathway was similar for all models, starting from peritubular dentin to adhesive layer, intertubular dentin and hybrid layer. The peak of σMAX (MPa) for those structures was, respectively: 134 (DD), 56.9 (SD), 45.5 (DD), and 36.7 (MD). Conclusions: The number of dentin tubules had no influence in the σMAX at the dentin/adhesive interface. Peritubular and intertubular dentin showed higher stress with the bigger dentin tubules orifice condition. The σMAX in the hybrid layer and adhesive layer were going down from superficial dentin to deeper dentin. In a failure scenario, the hybrid layer in contact with peritubular dentin and adhesive layer is the first region for breaking the adhesion. © 2011 Nova Science Publishers, Inc.

Evolução do rifteamento e paleogeografia da margem Atlântica Equatorial do Brasil: Triássico ao Holoceno

The Equatorial Atlantic Margin evolved from three rift systems recorded by a complex set of sedimentary basins developed since Upper Triassic to the Lower Cretaceous (Albian). The first rift system formed Foz do Amazonas Basin in Upper Triassic; the second phase formed Marajó Basin in Berriasian, a new rift in Foz do Amazonas Basin in Valanginian and Bragança-Viseu, Ilha Nova, São Luís e Barreirinhas basins in Aptian; the third phase formed Barreirinhas and Pará- Maranhão basins and a new rifting in the Foz do Amazonas Basin between the Aptian and Albian and evolved to continental break up. The main paleostress field during rift evolution was NE-SW and after the continental break up took the E-W direction, from the development of transform zones in the oceanic crust. From Miocene, South America was subjected to intraplate tectonics, which resulted in formation of E-W transcurrent faults that generated transtensive and transpressive segments that formed sedimentary basins and hills, resulting in changes in the drainage network. In Quaternary the landscape was modified by the last ice age that changed the sea level; the coastal drainage network was drowning resulting in the formation of the current line coast.

Comparative analysis of strut-and-tie models using Smooth Evolutionary Structural Optimization

The strut-and-tie models are widely used in certain types of structural elements in reinforced concrete and in regions with complexity of the stress state, called regions D, where the distribution of deformations in the cross section is not linear. This paper introduces a numerical technique to determine the strut-and-tie models using a variant of the classical Evolutionary Structural Optimization, which is called Smooth Evolutionary Structural Optimization. The basic idea of this technique is to identify the numerical flow of stresses generated in the structure, setting out in more technical and rational members of strut-and-tie, and to quantify their value for future structural design. This paper presents an index performance based on the evolutionary topology optimization method for automatically generating optimal strut-and-tie models in reinforced concrete structures with stress constraints. In the proposed approach, the element with the lowest Von Mises stress is calculated for element removal, while a performance index is used to monitor the evolutionary optimization process. Thus, a comparative analysis of the strut-and-tie models for beams is proposed with the presentation of examples from the literature that demonstrates the efficiency of this formulation. © 2013 Elsevier Ltd.

Efeito do fresamento com alta velocidade de corte na integridade superficial de aços ferríticos com grãos ultrafinos

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Comportamento mecânico do aço AISI 4340 revestido com WC-CrCNi; WC-10Ni; Ni-20Cr; Ni-Cr-B-Si-Fe; Cr3C2-NiCr pelo processo HVOF

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Um estudo da estabilidade mecânica de poços a partir de perfis geofísicos em formações pouco consolidadas

A análise da estabilidade mecânica de um poço pode ser feita a partir do cálculo de parâmetros elásticos da formação utilizando a densidade do meio e as velocidades de propagação das ondas compressional e cisalhante na formação rochosa, os quais podem ser obtidos de perfis geofísicos do poço. Em formações sedimentares pouco consolidadas as ferramentas de perfilagem sônica convencionais (monopolares) não conseguem registrar com acuidade a velocidade da onda cisalhante pois a primeira chegada dessa onda é camuflada pela chegada de outras ondas que podem ser mais rápidas que a onda cisalhante num poço perfurado neste tipo de formação. Medidas das velocidades sônicas são feitas em laboratório em amostras da formação, sob condições semelhantes às condições in situ, servindo como ajuste das velocidades registradas no poço pela ferramenta de perfilagem sônica. Para a análise de estabilidade da formação, perfis auxiliares são necessários como o perfil de porosidade, saturação de fluidos e perfis de composição mineralógica da formação rochosa. Exige-se ainda dados de testes de avaliação da formação e de condições do reservatório, mas que são comuns em poços de petróleo, como o teste de formação e os testes de pressurização do poço, tais como o teste de micro-fraturamento hidráulico ou o teste de absorção. A avaliação das tensões principais efetivas que atuam distante do poço, e que não são afetadas pela sua presença, é feita através da associação de um modelo de deformação elástica apropriado e o resultado do teste de pressurização disponível para o poço em estudo. Utilizando resultados clássicos da teoria da elasticidade geral pode-se calcular o campo de tensões modificado na vizinhança da parede do poço devido ao efeito da própria presença do poço ali perfurado e da diferença de pressão existente entre o interior do poço e a formação rochosa. A determinação das propriedades mecânicas da formação a partir das velocidades sônicas e a avaliação do campo de tensões assumindo um modelo elástico de deformação, supõem o meio rochoso no qual as ondas se propagam como elástico, homogêneo e isotrópico. Esta suposição representa a principal aproximação assumida pela metodologia descrita neste trabalho. De posse das propriedades mecânicas da formação e do campo de tensões que age na vizinhança do poço resta definir o critério segundo o qual a rocha sofre instabilidade mecânica quando submetida aquele campo de tensões. Isto permite determinar se, nas condições avaliadas do poço e da formação, haverá quebra da parede do poço por excesso de tensão e, se houver, qual a sua extensão. Assim o problema é como analisar o comportamento mecânico de um poço em uma formação pouco consolidada a partir de perfis geofísicos os quais podem ter problemas no registro das propriedades físicas do meio em formações deste tipo. A metodologia proposta é aplicada a dois intervalos de profundidade pertencentes a dois poços onde arenitos e folhelhos se intercalam e nos quais todos os dados necessários estão disponíveis. Os resultados obtidos mostram que, exceto quando outros mecanismos de quebra da parede do poço agem na formação, a metodologia proposta consegue com sucesso detectar zonas de ocorrência de instabilidade mecânica do poço provocadas por um campo de tensões que excede a resistência mecânica da formação.

Influence of shot peening on the fatigue strength of Custom 465 stainless steel for aeronautic application

This project was originated from the national aircraft industry requirements to reduce the use of coated materials with electroplated chromium or cadmium that produce waste, which is harmful to health or the environment. The selected material is a Custom 465 stainless steel used in the aeronautical field due to its high mechanical strength. Considering the load sustained by the wheel axis of the landing gear, the Custom 465 is tested in axial fatigue. The objective is to compare the behavior of the Custom 465 with plated AISI 4340 steel coated with cadmium. X-ray diffraction method was used to determine the residual stress field induced by shot peening.

FATIGUE IN CUSTOM 465 STAINLESS STEEL FOR AERONAUTIC APPLICATION

This project was originated from the national aircraft industry requirements to reduce the use of coated materials with electroplated chromium or cadmium that produce waste, which is harmful to health or the environment. The selected material is a Custom 465 stainless steel used in the aeronautical field due to its high mechanical strength. Considering the load sustained by the wheel axis of the landing gear, the Custom 465 was tested in axial fatigue. The objective is to compare the behavior of the Custom 465 stainless steel with plated AISI 4340 steel coated with cadmium. Fractographic analysis was conducted using scanning electron microscopy. X-ray diffraction method was used to determine the residual stress field induced by shot peening.

Fast detection of the magnetic easy axis on steel sheet using the continuous rotational Barkhausen method

The magnetic behaviour of most commercial ferromagnetic steels is usually anisotropic presenting a magnetic easy axis. Changes in the direction of this axis can be related to mechanical changes and anomalies that occur in the fabrication process. The present work describes a method that uses a device with permanent magnets to create a precise rotational magnetic field. The device measures continuous Magnetic Barkhausen Noise signals related to the angle of magnetization, in order to determine the direction of the macroscopic magnetic easy axis. It also offers the possibility of obtaining real time parameters that quantify the magnetic anisotropy of the sample. (C) 2011 Elsevier Ltd. All rights reserved.

Effect of sample pre-cracking method and notch geometry in plane strain fracture toughness tests as applied to a PMMA resin

The influence of test method factors (notch shape, square or angular, and pre-cracking method, by tapping onto or pressing a razor blade) on the results obtained in plane strain fracture toughness test according to standard ASTM D5045 using SENB specimens made of a commercial PMMA resin were investigated. Results were analyzed quantitatively by comparing the obtained K-IC values and qualitatively by observing their effect on the Moire fringes observed using photoelasticity, showing that, at 95% significance level, the K-IC values are affected by the pre-cracking method, with the most conservative value being obtained when natural pre-cracks were introduced by tapping onto a razor blade (K-IC = 1.15 +/- 0.11 MPa.m(0.5)). This correlates with a perturbation in the stress field close to the pre-crack tip observed in the photoelasticity test sample when it was introduced by pressing the razor blade. Surprisingly, notch geometry only slightly affects the results. (C) 2012 Elsevier Ltd. All rights reserved.

Experimental and numerical analysis of dry contact in the pin on disc test

The reduction of friction and wear in systems presenting metal-to-metal contacts, as in several mechanical components, represents a traditional challenge in tribology. In this context, this work presents a computational study based on the linear Archard's wear law and finite element modeling (FEM), in order to analyze unlubricated sliding wear observed in typical pin on disc tests. Such modeling was developed using finite element software Abaqus® with 3-D deformable geometries and elastic–plastic material behavior for the contact surfaces. Archard's wear model was implemented into a FORTRAN user subroutine (UMESHMOTION) in order to describe sliding wear. Modeling of debris and oxide formation mechanisms was taken into account by the use of a global wear coefficient obtained from experimental measurements. Such implementation considers an incremental computation for surface wear based on the nodal displacements by means of adaptive mesh tools that rearrange local nodal positions. In this way, the worn track was obtained and new surface profile is integrated for mass loss assessments. This work also presents experimental pin on disc tests with AISI 4140 pins on rotating AISI H13 discs with normal loads of 10, 35, 70 and 140 N, which represent, respectively, mild, transition and severe wear regimes, at sliding speed of 0.1 m/s. Numerical and experimental results were compared in terms of wear rate and friction coefficient. Furthermore, in the numerical simulation the stress field distribution and changes in the surface profile across the worn track of the disc were analyzed. The applied numerical formulation has shown to be more appropriate to predict mild wear regime than severe regime, especially due to the shorter running-in period observed in lower loads that characterizes this kind of regime.

Detailed study of the seismotectonic setting in the Lucanian Apennines and surrounding areas (Southern Italy)

In this research work I analyzed the instrumental seismicity of Southern Italy in the area including the Lucanian Apennines and Bradano foredeep, making use of the most recent seismological database available so far. I examined the seismicity occurred during the period between 2001 and 2006, considering 514 events with magnitudes M ≥ 2.0. In the first part of the work, P- and S-wave arrival times, recorded by the Italian National Seismic Network (RSNC) operated by the Istituto Nazionale di Geofisica e Vulcanologia (INGV), were re-picked along with those of the SAPTEX temporary array (2001–2004). For some events located in the Upper Val d'Agri, I also used data from the Eni-Agip oil company seismic network. I computed the VP/VS ratio obtaining a value of 1.83 and I carried out an analysis for the one-dimensional (1D) velocity model that approximates the seismic structure of the study area. After this preliminary analysis, making use of the records obtained in the SeSCAL experiment, I incremented the database by handpicking new arrival times. My final dataset consists of 15,666 P- and 9228 S-arrival times associated to 1047 earthquakes with magnitude ML ≥ 1.5. I computed 162 fault-plane solutions and composite focal mechanisms for closely located events. I investigated stress field orientation inverting focal mechanism belonging to the Lucanian Apennine and the Pollino Range, both areas characterized by more concentrated background seismicity. Moreover, I applied the double difference technique (DD) to improve the earthquake locations. Considering these results and different datasets available in the literature, I carried out a detailed analysis of single sub-areas and of a swarm (November 2008) recorded by SeSCAL array. The relocated seismicity appears more concentrated within the upper crust and it is mostly clustered along the Lucanian Apennine chain. In particular, two well-defined clusters were located in the Potentino and in the Abriola-Pietrapertosa sector (central Lucanian region). Their hypocentral depths are slightly deeper than those observed beneath the chain. I suggest that these two seismic features are representative of the transition from the inner portion of the chain with NE-SW extension to the external margin characterized by dextral strike-slip kinematics. In the easternmost part of the study area, below the Bradano foredeep and the Apulia foreland, the seismicity is generally deeper and more scattered and is associated to the Murge uplift and to the small structures present in the area. I also observed a small structure NE-SW oriented in the Abriola-Pietrapertosa area (activated with a swarm in November 2008) that could be considered to act as a barrier to the propagation of a potential rupture of an active NW-SE striking faults system. Focal mechanisms computed in this study are in large part normal and strike-slip solutions and their tensional axes (T-axes) have a generalized NE-SW orientation. Thanks to denser coverage of seismic stations and the detailed analysis, this study is a further contribution to the comprehension of the seismogenesis and state of stress of the Southern Apennines region, giving important contributions to seismotectonic zoning and seismic hazard assessment.