Utilização de técnicas do planejamento de experimentos na otimização de um processo de torneamento da superliga NIMONIC 80A

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Torneamento de liga de níquel Pyromet 31V (N07032) com ferramentas de metal duro

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Utilização de metaheurísticas combinada a diferentes métodos de aglutinação para a otimização de um processo de torneamento com múltiplas respostas

Pós-graduação em Engenharia Mecânica - FEG

Influência de tratamentos termo-mecânicos na estrutura e microestrutura da liga Ti-10%pNi obtida por fusão a arco

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

Structure, microstructure, and selected mechanical properties of Ti-Zr-Mo alloys for biomedical applications

New titanium alloys for biomedical applications have been developed primarily with the addition of Nb, Ta, Mo, and Zr, because those elements stabilize the β phase and they don’t cause cytotoxicity in the organism. The objective of this paper is to analyze the effect of molybdenum on the structure, microstructure, and selected mechanical properties of Ti-15Zr-xMo (x = 5, 10, 15, and 20 wt%) alloys. The samples were produced in an arc-melting furnace with inert argon atmosphere, and they were hot-rolled and homogenized. The samples were characterized using chemical, structural, and microstructural analysis. The mechanical analysis was made using Vickers microhardness and Young’s modulus measurements. The compositions of the alloys were sensitive to the molybdenum concentration, indicating the presence of α’+α”+β phases in the Ti-15Zr-5Mo alloy, α”+β in the Ti-15Zr-10Mo alloy, and β phase in the Ti-15Zr-15Mo and Ti-15Zr-20Mo alloys. The mechanical properties showed favorable values for biomedical application in the alloys presenting high hardness and low Young’s modulus compared with CP-Ti.

Preparation and characterization of Zircaloy 4-Tantalum alloys for application in corrosive media

Two Zircaloy 4-Ta alloys (14 and 55 wt.% Ta) were produced by arc-melting. The alloys were hot-rolled at 900 degrees C and heat-treated under argon atmosphere for 100 h at 700 degrees C. The alloys were analyzed by scanning electron microscopy and X-ray diffractometry. The microstructure of both rolled and heat-treated alloys is constituted of (beta Zr,Ta)-II Ta-rich precipitates dispersed in a (alpha Zr) matrix. Corrosion tests performed in boiling concentrated H2SO4 solutions showed that the Zircaloy 4-Ta alloys are more corrosion resistant than Zircaloy 4 and that the corrosion resistance increases with increasing Ta content. (c) 2012 Elsevier Ltd. All rights reserved.

Realidad estratégica de la sostenibilidad de los recursos naturales: La explotación del hierro

Es en el campo de los recursos naturales y su aplicación a la industria, el entorno donde se desarrolla esta Tesis. El objetivo de la misma es demostrar cómo la minería del hierro puede resultar una actividad sostenible, logrando continuar de esta manera la estrecha relación de siempre entre las necesidades del hombre y la pervivencia de los recursos naturales. Es en la minería del hierro donde hace mayor énfasis este trabajo, dando lugar a un nuevo Indicador Sostenible que intenta evaluar las explotaciones de mineral de hierro desde una visión sostenible, empleando el consumo energético y las emisiones de CO2 como principales herramientas. Como se observa en el día a día, el tema de la sostenibilidad es de plena actualidad, lográndose en este trabajo implicar, tanto a la eficiencia energética, como al control de emisiones de gases efecto invernadero; ambas herramientas cobran más importancia cada día que pasa. La Tesis se desarrolla en 5 capítulos, aparte de su bibliografía correspondiente. En el primer capítulo se introduce el sentido de la sostenibilidad, desde sus inicios conceptuales, hasta sus actuales clasificaciones y definiciones empleadas; todo ello desde el punto de vista de los recursos naturales, y más habitualmente desde la minería. Resulta llamativo el contraste de opiniones, en lo que se ha dado a llamar la paradoja de la minería sostenible, quedando tras su lectura, la posición de la minería en una situación, si no ventajosa, si de equilibrio en importancia entre las necesidades a cubrir y el agotamiento de recursos. El segundo capítulo nos muestra el entorno donde se va a conducir la Tesis. El marco que engloba este trabajo se extiende desde la extracción del mineral de hierro (minería), su tratamiento y concentración (mineralurgia), su venta a los hornos altos (mercados) hasta su posterior fabricación en acero terminado (siderurgia). En este capítulo se presentan los principales actores que entrarán en el sector de la minería del hierro (productores y fabricantes) incluyendo una serie de datos estadísticos de gran interés para el desarrollo de la Tesis. El tercer capítulo se refiere al proceso completo que precisa la actividad sobre la que se va a evaluar la sostenibilidad. Es donde se definen, paso a paso, y obteniendo todos los datos de consumos energéticos y emisiones de CO2, las diferentes etapas por las que pasa el mineral de hierro, hasta encontrarse laminado en la acería. Es aquí donde se analizan los diversos tipos de yacimientos de hierro dispersos por el mundo y el mineral extraído, de manera que las propiedades aprendidas se puedan emplear más adelante en un indicador, y que así diferencie la sostenibilidad en función de los orígenes motivo de las necesidades energéticas para su transformación. El capítulo 4 consta de dos bloques: el uso de las herramientas de medida de la sostenibilidad, a día de hoy en el mundo industrial, y de una manera pormenorizada, el consumo energético y sus emisiones medioambientales como herramienta de gestión ambiental para la minería del hierro. Esta herramienta resultará básica para el cálculo del indicador buscado para la medida de la sostenibilidad. El capítulo 5 constituye el núcleo de la tesis, y supone el desarrollo del indicador, la metodología de uso y las conclusiones obtenidas. A través de varios ejemplos se logra entender la aplicación del indicador, dando lugar a una clasificación sostenible sencilla y práctica, situando en orden las diferentes explotaciones en función de un nivel de sostenibilidad determinado. Este último capítulo da origen al Indicador Sostenible Energético buscado, mostrándose en todo su esplendor y descubriendo cómo la relación ponderada entre el consumo energético y sus emisiones de CO2 permite, a través de una valoración, mostrar todos los parámetros de relevancia para el mineral de hierro y su posterior transformación en acero. Esa cifra obtenida por el indicador, clasificará la explotación teniendo en cuenta, el tipo de yacimiento, características del mineral (especie mineralógica, tipo de mineral, ley del mineral en hierro, tipo de ganga, características físicas como dureza o tamaño de grano, susceptibilidad magnética, etc.), situación geográfica, infraestructuras, etc. Sin profundizar en la siderurgia, por lo menos sí incluir los principales parámetros (relacionados siempre desde el mineral) que pudieran tener influencia en la disminución de energía requerida (y sus emisiones de CO2 relacionadas): la reducibilidad, el contenido en hierro, y mencionar la influencia del SiO2. Se completa la Tesis con las referencias bibliográficas y documentales, así como con una bibliografía general. ABSTRACT This Thesis is set in a context of natural resources and applied science. The aim of this document is to prove that iron mining is a sustainable activity, so the ancient relationship between men and natural resources will continue. Iron mining is the main subject of this work, so a new sustainable indicator is created in order to evaluate the iron mining from a sustainable point of view. The main tools applied are energy consumption and CO2 emissions. In this research document two relevant issues are involved: energy efficiency and GHGs control; both tools gain significance by the day. This thesis develops along 5 chapters and its bibliography. The first chapter refers to the concept of sustainability, from the beginning to the current definitions and classifications; all this information is focused from the natural resources point of view, especially mining. The contrast of opinion is remarkable, which has been called the “paradox of sustainable mining”; however this chapter concludes that taking into account the less bright side of the mining its activity maintains an important balance between necessities to cover, available resources and environment. The second chapter sets out where this Thesis has been conducted. The frame of this work lies between iron mining, ore processing, the market and the latter steel fabrication (steelmaking). This chapter shows the iron mining key stakeholders, supported with statistical data. The third chapter refers to the whole process definition. From the iron mineral to the rolled steel, all data related with energy consumption and CO2 emissions are considered step by step. Different iron deposits widespread all over the world are analyzed now, as well as the exploited iron mineral in order to apply the lessons learned to create a new sustainability tool. Then, our sustainability studies will consider the influence of this in the energy necessities when iron is transformed. Chapter four is divided in the currently applied sustainability measurement tools, and focusing on energy consumption and CO2 emissions linked to the iron mining process. This tool is essential to calculate the required indicator that reflects the sustainability. Chapter five is the Thesis’ core: it is where the new sustainable indicator is developed, the methodology stated and the final conclusions obtained. Through several examples the indicator application is explained, and a practical and simple sustainable classification will show the ranking of every exploitation. This last chapter develops the sustainable tool and discovers how the weighted relation between energy consumption and CO2 emissions allows understanding all the relevant parameters in the iron mineral transformation. The number calculated will be used to classify the mineral exploitation, taking into account the deposit typology, mineral characteristics (mineralogy, type of mineral, iron percentage, physical properties as hardness or grain size, magnetic susceptibility, etc.), geographic situation, infrastructures, etc. Although steelmaking is not studied in depth, main parameters (from the mineral side) which can operate in the energy decrease (and CO2 emissions in parallel) are referred to: reducibility, iron content and SiO2 influence. The bibliography used is included at the end of this paper.

Estudo da substituição da fluorita por alumina ou sodalita e de cal por resíduo de mármore em escórias sintéticas dessulfurantes.

A siderurgia vem sofrendo transformações que buscam inovação e matérias-primas alternativas. Dentro deste contexto, o uso de resíduos industriais para a formação de escórias sintéticas é tido como alternativa na busca de novos materiais e rotas de reaproveitamento de resíduos. Portanto, este trabalho teve como objetivo estudar o uso de escórias sintéticas na etapa de dessulfuração do ferro-gusa, aço e ferro fundido. Assim como, propor a utilização da sodalita e da alumina em substituição à fluorita e o resíduo de mármore em substituição à cal convencional. Inicialmente, o resíduo foi caracterizado utilizando as seguintes técnicas: análise química, análise granulométrica, área de superfície específica, difração de raios-X, microscopia eletrônica de varredura (MEV) e análise de espectroscopia por energia dispersiva (EDS). Os resultados da caracterização mostraram que aproximadamente 90% das partículas do resíduo de mármore estão abaixo de 100m e sua área superficial foi de 0,24m²/g. Através da difração de raios-X foi observado que o resíduo é composto por CaCO3, MgCO3 e SiO2. Na sequência, foram feitas simulações com o software Thermo-Calc para obter dados termodinâmicos das fases presentes nas misturas e compará-los com os resultados experimentais. Além disso, também foram calculados dados de capacidade de sulfeto (Cs), partição de enxofre (Ls) e basicidade ótica () das misturas iniciais. Posteriormente, foram realizados os ensaios experimentais em escala laboratorial para ferro-gusa, ferro fundido e aço, respectivamente nas temperaturas de 1400°C, 1550°C e 1600°C. Nos ensaios de dessulfuração do aço e do ferro-gusa, utilizou-se um rotor de alumina com o objetivo de favorecer a agitação no metal e aumentar a remoção de enxofre. Na etapa de dessulfuração do ferro-gusa, constatou-se que a fase sólida de CaO é a responsável pela remoção de enxofre e que a presença das fases silicato tricálcio e aluminato tricálcio (3CaO.SiO2 e 3CaO.Al2O3) limitam a reação, sendo maiores suas concentrações nas escórias que utilizaram o resíduo de mármore e sodalita, devido a presença de SiO2 e Al2O3 nestas matérias-primas. Já para o aço e o ferro fundido, que foram estudados com escórias à base de CaO e Al2O3, observou-se que o aumento da fase líquida favoreceu a dessulfuração. Verificou-se que a dessulfuração no ferro fundido foi por escória de topo e no aço por um processo misto, onde a fase líquida e fase sólida participaram da dessulfuração.

Consumable electrode arc-melting of cold-compacted thorium powder /

The consumable electrode arc melting of cold-compacted thorium powder has been developed to produce dense, clean and soft ingots which can be hot rolled without cracking. By using a water-cooled copper crucible, contamination has been prevented and resultant ingots cleaner than the original powder have been produced.

Validation of processing maps for 304L stainless steel using hot forging, rolling and extrusion

The development of a microstructure in 304L stainless steel during industrial hot-forming operations, including press forging (mean strain rate of 0.15 s(-1)), rolling/extrusion (2-5 s(-1)), and hammer forging (100 s(-1)) at different temperatures in the range 600-1200 degrees C, was studied with a view to validating the predictions of the processing map. The results have shown that excellent correlation exists between the regimes exhibited by the map and the product microstructures. 304L stainless steel exhibits instability bands when hammer forged at temperatures below 1100 degrees C, rolled/extruded below 1000 degrees C, or press forged below 800 degrees C. All of these conditions must be avoided in mechanical processing of the material. On the other hand, ideally, the material may be rolled, extruded, or press forged at 1200 degrees C to obtain a defect-free microstructure.

Industrial validation of processing maps of 316L stainless steel using hot forging, rolling, and extrusion

The development of microstructure in 316L stainless steel during industrial hot forming operations including press forging (strain rate of 0 . 15 s(-1)), rolling/extrusion (strain rate of 2-8 . 8 s(-1)), and hammer forging (strain rate of 100 s(-1)) at different temperatures in the range 600-1200 degrees C was studied with a view to validating the predictions of the processing map. The results showed that good col relation existed between the regimes indicated in the map and the product microstructures. The 316L stainless steel exhibited unstable flow in the form of flow localisation when hammer forged at temperatures above 900 degrees C, rolled below 1000 degrees C, or press forged below 900 degrees C. All these conditions must therefore be avoided in mechanical processing of the material. Conversely, in order to obtain defect free microstructures, ideally the material should be rolled at temperatures above 1100 degrees C, press forged at temperatures above 1000 degrees C, or hammer forged in the temperature range 600-900 degrees C. (C) 1996 The Institute of Materials.

Validation of processing maps for a 15Cr-15Ni-2.2Mo-0.3Ti austenitic stainless steel using hot forging and rolling tests

The processing maps are being developed for use in optimising hot workability and controlling the microstructure of the product. The present investigation deals with the examination to assess the prediction of the processing maps for a 15Cr-15Ni-2.2Mo-0.3Ti austenitic stainless steel using forging and rolling tests at different temperatures in the range of 600-1200 degreesC. The tensile properties of these deformed products were evaluated at room temperature. The influence of the processing conditions, i.e. strain rate and temperature on the tensile properties of the deformed product were analysed to identify the optimum processing parameters. The results have shown good agreement between the regimes exhibited by the map and the properties of the rolled or forged product. The optimum parameters for processing of this steel were identified as rolling or press forging at temperatures above 1050 degreesC to obtain optimum product properties. (C) 2002 Elsevier Science B.V. All rights reserved.

Orientation dependence of the deformation microstructure in a Fe-30Ni-Nb model austenitic steel subjected to hot uniaxial compression

The present work was aimed at a detailed investigation of the orientation dependence of the microstructure characteristics in a Fe-30Ni-Nb austenitic model steel subjected to hot uniaxial compression at 1198 K (925 °C) at a strain rate of 1 s−1 to several strain levels up to 1.0. The quantification of the substructure evolution as a function of strain was performed for the stable 〈011〉 oriented grains. Other grain orientations were also investigated in detail at a strain of 0.2. The 〈110〉 oriented grains contained self-screening arrays of “microbands” (MBs) aligned with high Schmid factor {111} slip planes. The MB crystallographic alignment was largely maintained up to a strain of 1.0, which suggests that the corresponding boundaries kept continuously rearranging themselves during straining and did not follow the sample shape change. The mean MB spacing decreased and misorientation angle increased with strain towards saturation, indicating the operation of the “repolygonization” dynamic recovery mechanism. The non-〈011〉 oriented grains displayed a strong tendency to split during deformation into deformation bands having alternating orientations and being mutually rotated by large angles. The bands were separated by transition regions comprising arrays of closely spaced, extended sub-boundaries collectively accommodating large misorientations across very small distances.

Influence of electroslag refining on the hot ductility of AISI 4340 steel in torsion

Electroslag refining is a useful remelting process by which clean steels can be produced for sophisticated applications. In this investigation, AISI 4340 steel has been electroslag refined and the improvement in its hot ductility has been assessed using hot torsion tests; electroslag refining has improved the hot ductility considerably. The temperature at which peak ductility is obtained has also increased — from 1473 K in the unrefined steel to 1573 K in ESR steel. Results indicate that it should be possible to subject the ESR ingot to much higher strains per unit operation during industrial hot working processes such as forging, which would result in a considerable saving of power. The improvement in hot ductility in ESR steel has been attributed primarily to the removal of non-metallic inclusions and the reduction in sulphur content. From the apparent activation energy estimated from the hot torsion data, the dynamic recrystallization process is identified as the mechanism controlling the rate of hot deformation.

Effect of Prestrain on Fracture Toughness of Rolled Mild Steel with Significant Inclusion Content

The basic method of JIc calculation using a single specimen is discussed. Dokouipil's approach for evaluating the JIc value is extended further and the effect of prestrain on rolled mild steel with significant inclusions is studied using this modified approach. Although this method does not give an accurate value of JIc, it is quite effective for a comparative study. While the fracture toughness of annealed and 7% prestrained materials are about the same, the fracture toughness of 3% prestrained material is significantly lower.