Dissertations / Theses on the topic 'Cast-iron Steel'

Cast iron and steel alloys are commonly used for tooling and structural components in Al production, Al die-casting and the aluminizing industry due to their favourable properties including high strength, good formability and low cost. However, the iquid Al corrosion of these materials is one of the crucial concerns in maintaining the efficient production. Al is produced by the electrolytic smelting of alumina. Cast iron and/or cast steel pipes - commonly known as „tapping pipes‟ - are used to extract the liquid Al produced by smelting. Tapping pipes mainly degrade by material loss because liquid Al reacts with nearly all metals. Failure of tapping pipes is a significant contributor to the maintenance expenses; therefore, the primary aim of this research is to develop a material to enhance the life time of tapping pipes. Various test methods were developed in order to examine the effect of molten Al environment on cast iron and steel alloys. The corrosion resistance of these alloys was determined under different conditions of Al flow and temperature. The intermetallic compounds formed by exposing the ferrous to liquid Al were characterized using the Energy Dispersive X-ray Spectroscopy (EDS) and Electron Back Scatter Diffraction (EBSD) techniques. The formation, growth and nature of reaction products were revealed to establish a link to the liquid Al corrosion resistance. A relationship between the chemical composition and liquid Al corrosion resistance of cast irons could not established in the past. In the present work, the corrosion rate was found to depend upon the graphite morphology and fraction of each Fe-C phase of cast iron matrix, which can be controlled by selecting the chemical composition. Moreover, present research suggested the guidelines for producing a cast iron with enhanced liquid Al corrosion resistance. The presence of C-rich phases, graphite flakes and cementite was found to be effective in enhancing the liquid Al corrosion resistance of gray cast irons. Conversely, a higher Si content was found to enhance the susceptibility of cast irons to liquid Al corrosion. The corrosion mechanisms for ferrous alloys in liquid Al are not fully understood. Thus the subsequent analysis of the dissolution data was supported by investigating the reaction products formed between Al and substrate materials. In addition to commonly existent ε-Fe2Al5 and ζ-FeAl3 phases, the formation of Al4C3 and κ-Fe3AlC compounds was confirmed for the first time in the intermetallic layers of ferrous alloys. The Fe3Si phase in the intermetallic layers of high Si cast irons was found, which was believed to facilitate the high corrosion rates of high Si cast irons. Moreover, the mechanism by which C in Fe-substrates affects the liquid Al corrosion resistance can be better understood given the present work. Furthermore, the analysis presented here gives an understanding of the nature, growth and dissolution of intermetallic compounds in several cast iron alloys. Higher Si additions to cast irons played an important role in molten metal corrosion by accelerating the material loss and changing the nature of intermetallic layers. The results of this study clearly indicated that the dissolution and the growth of intermetallic compounds are interrelated and the dissolution and/or spallation of the intermetallic layers may be the primary mode of liquid Al corrosion of ferrous alloys.

This study focuses on joining pearlitic ductile cast iron with low carbon steel by welding and investigation of this joint in microstructural and mechanical viewpoints. For this purpose E355 steel and GJS600-3 cast iron were joined using metal active gas (MAG) welding process by G3Si1 filler wire. The joining process is shaped mainly by the problems related to the low weldability of cast. Preheating was applied to prevent formation of cooling cracks and effects of post weld heat treatments (PWHT) were surveyed. Micro examination and micro hardness tests were applied to characterize the general microstructure. Grain size measurements were done for E355. Hardness profiles, tension and impact toughness properties were designated via mechanical tests. Fatigue behavior was surveyed and general fracture characteristics were determined via scanning electron microscopy (SEM) examinations. According to study it was concluded that successful weld joint could be formed between the materials by suitable preheating. Formation of ledeburitic white cast iron and martensite in heat affected zone of cast piece was witnessed. It was possible to lower high hardness values of these phases gradually by increasing post weld heat treatment temperatures. The weld joint behaved superior to the base metals under tension and fatigue tests. In tension tests failure occurred at E355 base metal whereas fatigue loading resulted failure at GJS600-3. A great impact toughness variation was determined between two pieces. It is seen that heat treatments had minor effect on mechanical test results except hardness. The study was concluded that a useful fusion weld joint between these materials can be built.

Increasing awareness of environmental protection has made both governments and the industry aim for lowering carbon dioxide emissions. For the transport industry this means increasing engine efficiency, replacing fossil fuels with bio-based fuels or full electrification. For heavy-duty trucks, the first two options are currently the paths taken as short and mid-term solutions. These alternatives introduce new service conditions to the engines; namely higher combustion temperature and pressure, which will impose increased thermal and mechanical loads on the engine parts. In particular, the exhaust system parts must withstand constant thermal cycles in their normal operation. In heavy-duty trucks, exhaust systems are mostly manufactured from cast iron or cast steel. The usual materials, such as cast iron SiMo51 are reaching their maximum operating temperature, therefore new materials must come forward to fulfill new challenges. These materials oxidize at high temperatures forming different types of scales, which sometimes can act as protective barriers preventing their degradation. However, thermal cycles in the engine can impose new stresses and strains in these newly formed oxide scales, sometimes leading to spallation. A continuous spallation behavior in the exhaust systems is deleterious for the system, and the debris could also affect the downstream engine parts. This investigation focuses on the study of high temperature oxidation behavior of four iron-based candidate materials. Samples of two ductile cast irons and two austenitic stainless steels were exposed to thermal cycling in a simulated exhaust gas atmosphere at 850 °C, and to isothermal experiments at 850 °C and 900 °C in a stagnant air atmosphere. Additionally, the thermodynamics and kinetics were simulated using Thermo-Calc and Dictra software, respectively.  The results show that SiMo1000 grows a relatively thick iron-rich oxide layer with evidence of internal oxidation aided by the graphite shape exhibited by the alloy. The other cast iron Ni-Resist behaves better than SiMo1000, forming chromia and silica layers that prevent internal oxidation from occurring, although some spallation did occur in water containing atmospheres. 1.4832 behaved poorly compared to the other materials, entering into breakaway oxidation mode throughout all the exposures; therefore, it is not a material suited for high temperature service. HK30 was susceptible to water aided chromium evaporation but had a comparatively small mass change throughout the experiments; nonetheless, there was evidence of internal oxidation following interdendritic zones. Also casting defects were observed in these areas. Both might affect mechanical properties at high temperature.
Ökad miljömedvetenhet har gjort att både industri och politiker har satt upp mål för att sänka koldioxidutsläppen. För transportbranschen innebär detta till exempel ökad motoreffektivitet, att fossila bränslen ersätts med biobaserade bränslen eller full elektrifiering. För tunga lastbilar är de två första alternativen de som är aktuella på kort och medellång sikt. Dessa alternativ innebär nya förhållanden för motorn; nämligen högre förbränningstemperatur och -tryck, vilket kommer att öka termisk och mekanisk last på motorn. Detta är särskilt tydligt för avgassystemet, eftersom det utsätts för termisk cykling vid normal drift. Avgassystemet i en tung lastbil är oftast gjort i gjutjärn och ibland i gjutstål. Gjutjärnen, t ex segjärn SiMo51, börjar nu närma sig sin maximala driftstemperatur och nya material behöver introduceras. Vid höga temperaturer oxiderar dessa metalliska material och bildar olika typer av oxidskal. Beroende på sammansättningen på oxidskalet, kan det fungera som skydd för underliggande material. Termisk cykling kan ge spänningar i oxidskiktet som i sin tur kan ge flagning av skiktet. Om flagningen fortsätter kontinuerligt, förbrukas dels material, men flagorna kan också ge skador nedströms i avgassystemet. I detta arbete undersöks fyra järnbaserade kandidatmaterial avseende högtemperaturkorrosion. Prover av två gjutjärn och två austenitiska rostfria gjutstål exponerades dels isotermt vid 850 °C och 900 °C i stillastående luft, dels i experiment med termisk cykling i en simulerad flödande avgasatmosfär och varm temperatur 850 °C. Dessutom användes termodynamisk programvara (Thermo-Calc/DICTRA) för att simulera termodynamik och kinetik. Resultaten visar att SiMo1000 bildar ett relativt tjockt, järnrikt oxidskikt med viss inre oxidation som verkar följa grafitstråk i materialet. Det andra gjutjärnet, segjärnet Ni-Resist, beter sig bättre än SiMo1000 och bildar krom och kiseldioxidlager som förhindrar intern oxidation. Viss flagning observerades i den cykliska exponeringen. 1.4832 visade ett sämre beteende än de andra materialen och bildade inget skyddande oxidskikt, utan visade kontinuerlig massförlust i samtliga exponeringar. Detta material är därför inte lämpligt för de undersökta högtemperaturmiljöerna. HK30 visade låg massförlust i samtliga undersökningar med oxidation i interdendritiska områden. Även gjutfel som t ex porer observerades idessa områden. Båda kan påverka materialets mekaniska egenskaper vid dessa temperaturer.

Spheroidal graphite cast iron is a material widely used in the industry for the manufacturing of all kind of covers and protective casings thanks to its good combination of mechanical properties, processability and cost. When cast iron components are put into service in corrosive environments the most common approach to protect the components is painting them. The protective painting has been found to flake off with time when aggressive washing procedures, such as the ones used in the Food & Beverage industry, are applied several times. In this project, the coating of cast iron with a corrosion resistant AISI 316L stainless steel by Laser Metal Powder Deposition has been studied as an alternative protection against corrosion. Several samples with different combinations of substrate preparation, number of layers and surface conditions were produced and analysed by optical microscopy, scanning electron microscopy, energy dispersive X-ray spectroscopy, wash down tests and salt spray chamber corrosion tests. Main results show that the diffusion of carbon from the carbon-rich cast iron to the stainless steel coating, which would have a negative effect on the corrosion resistant properties, was significantly low as a result of the low penetration and dilution achieved during the laser metal powder deposition process. The deposited stainless steel coatings successfully protected the substrate during the corrosion tests and the integrity of the coatings is not expected to fail during the washing producers applied in the industry.

Företaget Svensk Kärnbränslehantering AB (SKB) håller på att utveckla en slutförvaringskapsel som kommer innehålla avfall från den svenska kärnkraften. Det är dock fortfarande en process under utveckling och därför undersöks olika typer av metoder och kapselmaterial för att kunna tillverka en hållbar och säker kapsel. Kapseln består av ett hölje av kopparrör med svetsad botten och lock och en insats med stållock. Insatsen är en cylindrisk konstruktion  av segjärn och innehåller en svetsad stålkassett för att skapa utrymmen till det använda kärnbränslet. Insatsen innehåller bland annat stålrör som under tillverkning får utstå en gjutprocess med segjärn och erhåller efter det icke homogena egenskaper. Målet med undersökningen är hur stor påverkan gjutningen har på stålets kemiska sammansättning samt mikrostrukturer. Det som orsakar de inhomogena egenskaperna är främst värmebehandlingen som driver diffusionen av kol från gjutjärnet till stålet, som då ger ett hårdare men sprödare material. Med hjälp av experiment och simuleringar upptäcks hur mycket kol som diffunderar in i stålet samt ändringar i den kemiska sammansättningen i de påverkade zonerna. Identifiering av fasomvandlingar, diffusion och ändringar i mikrostrukturer är stora faktorer som i sin tur ändrar de mekaniska egenskaperna i stålet.
The Swedish Nuclear Fuel and Waste Management Company (SKB) have developed a final storage canister that will contain waste from the Swedish nuclear power plants. However, it is still in a development phase and therefore different types of methods and canister materials are investigated to produce the most durable and safe canister. The canister is made of a copper tube with a welded bottom and lid with an insert. The insert is a cylindrical construction of nodular cast iron that contains a welded steel cassette, to make space for the spent fuel, and a steel lid. The steel tubes showed inhomogeneous properties after being exposed to a casting around them. The aim of this investigation is to clarify the impact of casting on the chemical composition of the steel as well as the microstructure. The cause to the inhomogeneous properties were the diffusion of carbon from the cast iron to the steel, which then produced a harder and more brittle material. Experiments and simulations were used to see the carbon diffusion into the steel as well as what happens with the chemical composition in the affected zones. Identification of phase changes, diffusion and microstructures contributed to changes of mechanical properties in the steel.

In this thesis, the structural and mechanical changes, which took place in flake graphite cast iron after electron beam surface melting and chrome-nickel surface alloying, were studied. Furthermore, the effect of set parameters on properties and depth of the melted and alloyed region is also analyzed. In the experimental part, the analyzed microstructures, micro-hardness and the distribution of elements after melting and alloying, were presented. Structural differences of material regions caused by melting were described based on microstructures. In the end of diploma thesis, the conclusions of using EB technology for surface melting and alloying were discussed.

Ziel der Arbeit war die Entwicklung des Elektronenstrahl-Mehrspot/Mehrprozess-Schweißens für Gusseisen/Gusseisen- und Gusseisen/Stahl-Verbindungen ohne Schweißzusatzstoffe. Im Vergleich zum Einbad-Schweißen entsteht beim Mehrbad-Schweißen eine porenarme Schweißnaht, gleichzeitig senkt sich die Schweißnahthärte geringfügig ab. Dabei kann die Kaltrissbildung in der Schweißnaht für arteigene Gusseisen-Verbindungen nicht unterdrückt werden. Für Mischverbindungen ist der Strahlversatz der bestimmende Schweißparameter beim Mehrbad-Schweißen. Über diesen kann sowohl die chemische Zusammensetzung der Schweißnaht eingestellt als auch ohne Vorwärmen eine kaltrissfreie Schweißnaht für Gusseisen/Stahl-Verbindungen erzeugt werden. Für die prozessintegrierte Wärmebehandlung der Fügezone wurde ein neues EB-Thermofeld entwickelt. Durch den Thermofeldeinsatz konnte die Aufhärtung in der Schmelz- und Wärmeeinflusszone signifikant reduziert werden und die mechanischen Eigenschaften der Schweißverbindungen wurden deutlich verbessert.

Este estudo apresenta uma abordagem para a avaliação do comportamento de um ferro fundido branco de alto cromo e um aço ferramenta AISI D2 submetido a ciclos térmicos. Para a realização do estudo foi desenvolvido um procedimento para ensaios de fadiga térmica submetidos a números de ciclos variados, usando para aquecimento um sistema indutivo e para resfriamento um tanque de água. Devido a complexidade dos fenômenos envolvidos, um modelo de elementos finitos foi elaborado para a solução do campo de temperaturas e tensões superficiais atuantes. O controle da tensão superficial atuante foi realizado por meio da mudança de geometria do corpo de prova, sendo esta geometria resultante de teste por simulação computacional. Os corpos de prova foram caracterizados quando a sua microdureza e fração volumétrica de carbonetos antes do ensaio e após ensaio foram caracterizados quanto a sua microdureza, número e profundidade das trincas. O regime de propagação durante os primeiros 50 ciclos foi controlado por mecanismo de fadiga de baixo ciclo, exibindo as maiores velocidade de propagação das trincas e o regime de propagação depois dos 50 ciclos foram controlados por mecanismos de fadiga de alto ciclo. A nucleação das trincas ocorreu predominantemente pela interface matriz/carboneto e pelo próprio carboneto, sendo a propagação das trincas predominantemente pela interconexão de carbonetos fraturados na superfície do material e predominantemente na interface matriz carboneto em camadas mais profundas do corpo de prova. Os resultados obtidos mostraram uma boa correlação entre o ensaio e o modelo numérico, permitindo uma maior confiabilidade para execução do modelo mecânico subsequente. Baseado nos resultados foi possível propor uma metodologia para a avaliação de ambos materiais submetidos a ciclos térmicos.
This study presents an approach to evaluate the behavior of high chromium white cast iron and AISI D2 tool steel submitted at thermal cycles. It was developed a procedure for a thermal fatigue test in different times of cycles were done, using induced heating and water cooling. Due to the complexity of the phenomena involved, a FEM study was performed for solving the temperatures and superficial stresses fields. The control of superficial stress was done by changing the geometry of the test specimens, what was defined by computational simulation. The test specimens were evaluated the microstructure, microhardness and carbides contends before the test. After the test were evaluated microhardness, amount and depth of thermal fatigue cracks. The propagation during the earlier cycles was defined by mechanics of low cycle instead of after 100 cycles that was defined by mechanics of high cycle fatigue. This mechanics was observed by crack velocity analyses in both periods. The nucleation of thermal fatigue cracks initiate mostly at the matrix/carbide interface or at the carbide itself, being the cracks propagation was mainly by the interconnection of fractured carbides at surface and mainly at the interface matrix/carbide in the inner layer of the specimens test. The results obtained showed an adherence between the test and the numerical model, allowed a greater reliability to the subsequent mechanical model. Based on the results was possible propose a methodology for evaluation of both materials subjected a thermal cycles.

As ligas de ferro fundido branco multicomponente são aços rápidos resistentes ao desgaste em temperaturas elevadas. Estes aços apresentam carbonetos eutéticos do tipo MC e M2C quando no estado bruto de fundição. Neste trabalho foi caracterizada a microestrutura dos produtos de decomposição após tratamentos térmicos do carboneto eutético metaestável M2C de uma liga de ferro fundido multicomponente com composição (em % peso): 2 wt% de C e 5 wt% de cada um dos elementos V, Cr, Mo e W, o restante é Fe. A liga de ferro fundido multicomponente foi tratada isotermicamente a 950°C e a 1.050°C por tempos crescentes em forno poço com sal fundido e em forno mufla inseridas em ampolas de sílica sob vácuo. Os tempos de tratamento foram: 10s, 100s, 600s, 1.800s, 1 hora, 2 horas e 15 horas. As técnicas de caracterização envolvidas foram: difração de raios X de carbonetos extraídos, metalografia através de ataques seletivos, microscopia eletrônicas de varredura (SEM), microscopia eletrônica de transmissão e varredura (STEM), espectrometria por energia dispersiva de raios X (EDS) e difração de elétrons por área selecionada (SAED). Os resultados sugerem que além dos carbonetos MC, M2C irregular e regularcomplexo e M7C3 descritos na literatura, observa-se a presença de um novo tipo de carboneto M2C metaestável rico em cromo na liga no estado bruto de fundição. Os carbonetos metaestáveis M2C se decompõem em carbonetos M6C, em carbonetos M7C3 e finalmente MC globular com o aumento da temperatura e/ou com tempos crescentes de tratamento térmico. O carboneto M7C3 após tratamento térmico de longa duração passa por um processo de esferoidização e depois engrossamento.
Multicomponent White Cast Iron are high temperature wear resistant ferrous alloys, presenting eutectic MC and M2C carbides in their as cast structure. In the present work the decomposition microstructures of the metastable M2C carbide after heat treatments was characterized in a model multicomponent white cast iron with composition (in weight): 2 wt% C and 5 wt% of each of the carbide forming alloying elements V, Cr, Mo and W, and with the balance Fe. The model multicomponent alloy was isothermally treated at 950°C and 1.050°C for increasing time periods using a salt bath pit furnace and a muffle furnace using samples encapsulated in silica glass ampoules under vacuum. Treatment times were: 10s, 100s, 600s, 1.800s, 1 hour, 2 hours and 15 hours. Characterization techniques used were: X Ray diffraction of extracted carbides, optical microscopy metallography with selective etching techniques, scanning electron microscopy (SEM), X ray energy dispersive spectroscopy (EDS), transmission and scanning electron microscopy (STEM) and selected area electrons diffraction (SAED). Besides the MC, irregular and regular-complex M2C and M7C3 described in the literature, it was found in the as cast alloy also a hitherto unknown chromium rich M2C carbide. The metastable M2C carbides decompose into M6C carbides, then M7C3 and finally globular MC with increasing temperatures and/or increasing times at heat treatment temperatures. After long times heat treatments the M7C3 carbides, spheroidize and coarsen.

Nos dias atuais, com o mercado altamente seletivo, com vários fabricantes e fornecedores de diversos tipos de produtos e serviços, a qualidade se tornou uma necessidade premente, na qual uma empresa que forneça bens e/ou serviços com baixa qualidade corre sérios riscos de ser descartada pelos mercados consumidores. Assim, a importância da qualidade é que se converteu em um requisito básico para uma empresa competir e se manter no mercado. As empresas veem a qualidade como uma ferramenta para a redução de custos e para a melhoria de sua imagem junto ao mercado consumidor. Neste contexto, de melhora da imagem junto ao mercado consumidor e de redução de custos, o presente trabalho foi realizado em uma importante e tradicional multinacional de grande porte que produz compressores herméticos para refrigeração, com o intuito de estudar a soldagem do mancal de ferro fundido à carcaça de aço de baixo carbono em compressores rotativos (rolete excêntrico), utilizados em aparelhos de ar condicionado. A solda realizada de maneira falha pode permitir a perda do entreferro do motor, resultando em um ruído característico, chamado stall. Este trabalho avaliou diferentes tipos de arames, buscando garantir um processo com qualidade e baixo custo. Testes foram realizados utilizando como peças teste carcaças e mancais dos compressores. Verificou-se que o arame sólido ANSI/AWS A5.18 ER70S-6, atualmente utilizado, não é o mais indicado para a respectiva soldagem, em virtude da microestrutura e da resistência da soldagem obtida. A solução técnica apropriada é a utilização do arame ERNiFeMn-CI que elimina a fragilização das zonas parcialmente fundidas e diluídas próximos ao metal de solda, enquanto o arame metal cored E70C-6M representa um compromisso entre as propriedades da junta soldada e custo do processo.
Nowadays, with the highly selective market, with several manufacturers and suppliers of various types of products and services, quality has become a pressing need, in which a company that provides services with a low quality at serious risk of being discarded by the consumer markets. Thus, the importance of quality is that it has become a basic requirement for a company to compete and stay in the market. Companies see the Quality as a tool to reduce costs and to improve its image with the consumer market. In this context, the improvement of the image with the consumer market and costs reduction, this study was conducted in a major traditional large multinational that produces hermetic compressors to refrigeration, in order to study the welding of cast iron bearings with low carbon steel houses in rotary compressors (eccentric roller) used in air conditioners. The welding performed in a failure may allow loss of the air gap of the motor, resulting in a characteristic noise, called stall. This study evaluated different types of alloys, aiming to ensure process quality and low cost. Trials were done using low carbon steel houses and cast iron bearings of the compressors. After innumerous tests, it was found that the ANSI/AWS A5.18 ER70S-6 solid wire, currently used, is not the most suitable for their welding, in view of microstructure and resistance of the weld obtained. The appropriate technical solution is to use the wire ERNiFeMn-CI eliminating the weakening of partially melted and diluted zones near the weld metal, while metal cored wire E70C-6M represents a compromise between the properties of welded joint and the cost of the process.

It is an established fact that segregation during casting affects the physical properties of carbon-based ferro alloys; this motivates the study of the segregation behaviour of carbon and carbide-forming solute elements. In this context, this thesis investigates two different situations: the effects of cooling rate and turbulence on the precipitation behaviour of the graphite nodules in nodular cast iron; the nature of carbide precipitation in a bearing steel grade and the effects of subsequent soaking on these carbides. The structures of boiling water reactor inserts cast by the uphill and downhill casting of nodular cast iron were examined. The samples were taken from representative locations in the top, middle and bottom cross sections of the castings. It was observed that in uphill-cast inserts the nodules were larger but fewer in number the bottom section, whereas in downhill-cast inserts the nodules in the bottom section were smaller, but greater in number. Variation in volume fraction of the graphite nodules across the inserts was also observed. The probable cause of this variation was the difference in cooling rate in different sections of the insert. Between the steel tubes located at the central part of the casting, the fraction of graphite was lower, which could be the result of carburization of the steel tubes. To study the effects of melt stirring during the solidification of nodular cast iron, several experiments were conducted at variable cooling rates and for different stirring times. Examination of the microstructure was conducted using Light Optical Microscope (LOM) and Scanning Electron Microscope (SEM). It was observed that during stirring the melt oxidized and oxide nuclei were formed. The number of nucleation sites for the precipitation of graphite nodules increased, which raised the nodule count and the fraction of the graphite precipitated. The matrix transformed from pearlite to ferrite, which could be due to the fact that more carbon had diffused out of the matrix. The segregation behaviour in hypereutectoid bearing steel produced by ingot casting was also studied. The effects of soaking on micro and macro segregation was investigated in samples taken from as cast and soaked ingots; emphasis was laid on the bulk matrix and A-segregation channels. Samples were also taken from ingots which were soaked and then hot worked. The micro and macro examination of the microstructure was conducted using LOM and SEM. Quantitative and qualitative composition analysis was performed using Energy-dispersive X-ray spectroscopy (EDX) and an electron micro probe analyzer (EMPA). It was observed that M3C, M2C and M6C had precipitated. The carbide morphology in the bulk matrix was different to that in the A-segregation channels. All the primary carbides in the bulk matrix were found to have dissolved after 4 hours of soaking at 1200oC.
Det är ett faktum att segringar som uppstår under gjutning påverkar materialegenskaperna hos kolbaserade järnlegeringar; detta utgör motivationen till studien av segringsuppträdandet hos kol och karbidbildande ämnen. Denna avhandling behandlar två olika aspekter inom ramen för detta ämne: påverkan av kylningshastighet och turbulens på kärnbildningen av grafitnoduler i nodulärt gjutjärn samt karbidbildning i kullagerstål och dess påverkan på den efterföljande värmebehandlingen av dessa karbider. Strukturen hos rör till vattenkokare som tillverkats av nodulärt gjutjärn som gjutits med fyllning från botten eller från toppen undersöktes. Prover togs från representativa tvärsnittspositioner från toppen, mitten och botten av de gjutna ämnena. Resultaten visade att användandet av bottenfyllda kokiller gav upphov till större men färre karbider i nedre delen av ämnet, medans användandet av toppfyllda kokiller gav upphov till mindre men fler karbider i nedre delen av ämnet. Variationer av volymfraktionen av grafitnoduler längs tvärsnitten observerades också. Den mest sannolika orsaken till denna variation var skillnaden i kylhastighet i de olika områdena av tvärsnitten. Hos rör tillverkade av det centrala delen av ämnet så var fraktionen grafit lägre, vilket kan bero på en uppkolning av rören. Ett flertal experiment utfördes med varierande kylningshastigheter och olika omrörningstider för att studera inverkan av omrörning av smältan på stelningen av nodulärt gjutjärn. Studier av mikrostrukturen genomfördes med ljusoptisk mikroskopi och svepelektronmikroskopi. Resultaten visade att smältan oxiderades under omrörningen, vilket resulterade i bildandet av oxider. Detta ledde till en ökning av kärnbildningsområden för grafitnoduler, vilket ledde till en ökning av antalet noduler samt fraktionen av grafit som fälldes ut. Strukturen omvandlades från perlit till ferrit, vilket troligen orsakades av att kol hade diffunderat ut från strukturen. Segringsbeteendet hos hypereutektoida kullagerstål tillverkade genom götgjutning undersöktes också. Effekten av värmebehandling på mikro- och makrosegringar undersöktes i prover tagna från gjutna och värmebehandlade ämnen. Fokus var på att studera strukturen i ämnena samt A-segringar. Dessutom togs prover från ämnen som först värmebehandlats och därefter varmbearbetats. Både mikro- och makroundersökningar av mikrostrukturen utfördes med ljusoptisk mikroskopi och svepelektronmikroskopi. Dessutom så genomfördes kvantitativa sammansättningsbestämningar med energidispersiv röntgenspektroskopi och elektronmikroprobsanalys. Resultaten visade att M3C, M2C och M6C karbider hade fällts ut. Karbidmorfologin i huvuddelen av strukturen skiljde sig från den som återfanns i A-segringar. Samtliga primära karbider i huvuddelen av strukturen hade lösts upp efter 4 timmars värmebehandling vid 1200oC.

QC 20180523

Thesis (M.S.)--University of Wisconsin--Madison, 1994.
Typescript. eContent provider-neutral record in process. Description based on print version record. Includes bibliographical references (leaves vi-vii).

碩士
大同大學
材料工程研究所
88
In the process to make the thin plate castings, both the factors are large cooling rate and chemical composition; it produced the primary carbide in the matrix in the casting material. If the casting material exists the primary carbide, it became inferior quality on mechanical properties. In this study, carbide produced by different type of mold and the content of silicon. The effects of different content of primary carbide on mechanical properties of ductile cast iron of various thickness in as-cast state. The results indicated that the strength and hardness increased with amount of carbide, but the ductility and impact values decreased, obviously.

碩士
國立臺灣科技大學
機械工程系
98
In this research it is aimed to investigate the high temperature oxidation behavior of high silicon ductile iron and high silicon cast steel in air. The relationship between morphology of oxide layers and internal oxidation of silicon element is studied. Oxidation tests were carried in a furnace at 500, 600, 700, and 800 ℃, respectively; the extent of oxidation was measured by the change of weight of specimen or by the thickness of oxide layers; the microstructure of oxide layers and internal oxidation were examined by OM, SEM, and EDS. The results show that: for high silicon cast steels, the oxidation weight gains decrease with Si content increased, this conforms that the addition of Si will improve the oxidation resistance of steel; the oxidation modes different for high silicon ductile iron to high silicon cast steels, the oxidation behavior of high silicon ductile iron is linear, and high silicon cast steels is toward parabolic; oxidation at 500℃, high silicon ductile iron with 4.71 wt. % has the best oxidation resistance; oxidation at 600 and 700℃, high silicon ductile iron also showed a better resistance in the early stage, but a inferior resistance in the late oxidation. The internal oxidation of Si was not occurred in 500℃, but occurred in temperatures higher than 600 ℃; high silicon cast steels was not observed the internal oxidation of Si at 800℃. As time increasing, the shape of internal oxidation changes from dense to loose, and as temperature increasing, the particles gets thicker. In addition, the internal oxidation layer of high silicon cast steels is more dense and smaller than high silicon ductile iron.

碩士
遠東科技大學
機械工程研究所
102
Spheroidal graphite (SG) cast iron and medium carbon steel are widely used in components such as thrust washer, rollers and forming molds. Since these components are likely to be exposed to wear, corrosion and thermal oxidation in actual use, several methods are available that can improve their strength and hardness. A common method is the plasma transferred arc overlaying process for surface modification. In this process, these wear components are overlaid with high speed steel (HSS) coatings to increase the wear resistance of SG cast iron and medium carbon steel. On the other hand, the oxynitriding process is a surface treatment method developed to improve the less than satisfactory corrosion resistance of post-nitriding surfaces. By using computer-aided control of nitrogen potential in the furnace atmosphere and the post-oxidation process, wear-, erosion- and corrosion-resistant hardened layers are generated on surfaces. To achieve this, this study proposed the combination of the two processes, oxynitriding and plasma transferred arc overlaying, for the surface modification of SG cast iron and medium carbon steel as well as the use of HSS coated alloy commonly used in wear components and forming molds. The resultant HSS coated layers after plasma transferred arc overlaying followed by oxynitriding were then subject to microstructure analysis for investigating the effects of various carbides, nitrides and oxides on the hardness of modified layers. Experiment results showed that approximately 10m thick oxynitrided layers were generated on the plasma transferred coated layers after oxynitriding. Moreover, the hardness of the original coated layers increased by HRC 65 because the oxynitriding temperature was also that for HSS tempering and the distribution of hardness in their cross-sections revealed the maximum hardness up to Hv 1400. Results of X-ray diffraction analysis showed that the main constituent phases of the original coated layers were austenite, V8C7 and M23C6 while those of the oxynitriding-treated layers were-Fe, Fe3O4 and Fe4N. Polarization testing revealed that the oxynitriding-treated layers had lower corrosion current densities in a 3.5 wt.% NaCl corrosion solution that simulated seawater and suspected passivation occurred when the corrosion potential (Ecorr.) was -0.5V, which improved the corrosion resistance of the coated layers.

碩士
遠東科技大學
機械工程研究所
103
This study used SCM440 Cr-Mo steel, a common element in wearable materials, as substrates, which were subjected to electrical discharge alloying (EDA) for steel surface modification. Two types of cast iron with lubricating graphite phase and different graphite patterns, i.e. flake graphite (FG) (FC250) and spheroidal graphite (SG) (FCD450), were selected as the electrodes in alloying. The approach with fixed discharge current and duty factor and varying pulse durations (100~1000ms) was used to find the machining parameters that lead to the optimal pulse durations for both the FG and SG cast iron electrodes in an attempt to obtain the alloy layers that contain graphite phase and have adequate hardness, corrosion resistance and surface roughness. On the other hand, assessment was made on whether it is feasible to increase the amounts of alloy elements diffused into the alloy layers, the number of eutectic graphite nodules and the thickness of these layers while maintaining better corrosion resistance and surface roughness. As such, two-stage variation of discharge current was considered. The discharge current was set at the high value of 50A for a machining duration of 5 minutes in the first stage and at the low value of 20 A for a machining duration of 25 minutes in the second stage. This was done to examine how variation of machining parameters (two-stage variation of discharge current) affects the microstructural characteristics, corrosion behavior and surface roughness on the alloy layers of the FG and SG cast iron electrodes. The experimental results show that the FC250 electrodes have produced thicker EDA alloy layers in the pulse durations of 500 ms and 1000 uns compared to the FCD450 electrodes and have produced alloy layers with maximum hardness up to Hv 1172 in the pulse duration of 100 ms. The alloy layers produced by the FC250 electrodes exhibit lower corrosion current (Icorr.=1.255 A • cm-2) compared to those produced by the FCD450 electrodes (Ecorr.=-0.4619 V). Both types of electrodes have produced alloy layers of which the surface roughness is directly proportional to the pulse duration. In addition, comparison of surface properties between EDA alloy layers produced respectively with one stage of discharge current, 20A, and two stages of discharge current, 50A and 20A, reveals that those in the latter case exhibit poorer thickness, hardness and surface roughness than those in the former case, with the exception that the FCD450 electrodes exhibit better corrosion resistance in the pulse duration of 1000ms. Moreover, X-ray diffraction analysis of the 20A-FC250, 20A-FCD450 and 50A+20A-FC250 specimens reveals that all the alloy layers have Cr3C2, Fe3C, C0.17Fe0.81Si0.02 and MoFe phases and only the 50A+20A-FCD450 specimens have all the phases except Fe3C. Keywords: Cr-Mo steel, electrical discharge alloying, cast iron, machining parameters

碩士
遠東科技大學
機械工程研究所
103
WC/Co thermal spray coating features excellent high hardness, high wear resistance, high elastic modulus, chemical intertness and low coefficient of friction. These unique qualities have made WC/Co coating an ideal candidate for enhancing wear resistance of engineering components such as cutting tools, extrusion molds and rolls etc. With features such as high stacking rate, high adhesion and lower porosity, high velocity oxygen fuel (HVOF) can reduce oxidation of thermal spray coatings and increase their compactness and adhesion. The problem faced by the industry now is that the WC/Co powder is expensive and it is even more costly if they choose the WC/Co nanopowder, which features low loss rate, better coating performance and deposition efficiency, making WC/Co a less competitive thermal spray coating option for wearable components. As such, this study examined the microstructures and coating performance of medium carbon steel substrates respectively coated with HVOF WC/Co, WC/Co reinforced phase cast iron and the same plus graphitizing heat treatment. For the three types of coating, two types of commercial WC/Co powder (WC-12wt%Co and WC-17wt%Co) were used, which were not added with commercial cast iron powder for the first type of coating and were added with the cast iron powder in the ratio 1:1 for the latter two types of coating. The substrates were S50C medium carbon steel and respectively received HVOF WC/Co coating, WC/Co reinforced phase cast iron coating and the same plus graphitizing heat treatment for subsequent characteristic analysis and performance testing.The experimental results show that the HVOF WC/Co coating has main constituent phases including WC, Co, Co6W6C and W2C while the other two types of coating have main constituent phases including WC, Co, Co6W6C, W2C and -Fe. Coating hardness testing reveals that the WC/Co coating is harder than the other two types. Polarization testing shows that the WC-12wt%Co reinforced phase cast iron coating has greater corrosion resistance and better corrosion current density (Icorr.) and corrosion potential (Ecorr.) than the other specimens.

Dissertação de mestrado integrado em Engenharia Mecânica
O projecto da estrutura das máquinas-ferramentas está fortemente influenciado pelos materiais utilizados nos produtos a trabalhar e também pela quantidade de máquinas-ferramentas a produzir, podendo ser uma produção em série ou mesmo uma produção unitária e especifica para cada cliente. Este último aspecto está inteiramente ligado aos materiais utilizados na concepção da estrutura das máquinas-ferramentas, sendo que numa produção unitária, os materiais estruturais usualmente utilizados em produções em série, tornam-se extremamente dispendiosos. O ferro fundido e o aço são os materiais tradicionalmente utilizados na fabricação de componentes estruturais de máquinas-ferramentas, principalmente do barramento principal. Neste tipo de componentes a estabilidade dimensional, térmica, amortecimento de vibrações e capacidade de suportar acções são fundamentais no seu bom desempenho. Prever o comportamento dinâmico de uma estrutura deste género é de grande importância, uma vez que só desta forma é possível obter soluções inteligentes para a resolução de problemas de vibrações. A avaliação e modificação das soluções estruturais que permitem uma boa resposta das estruturas às solicitações dinâmicas constituem uma mais-valia a complementar o projecto estático e dinâmicos tradicionais. Esta dissertação de mestrado tem como objectivo desenvolver, caracterizar e avaliar materiais alternativos para a estrutura de máquinas-ferramentas de arranque de apara, tendo como base o betão polimérico. De modo a alcançar o objectivo proposto, é necessário realizar vários ensaios, de forma a determinar as propriedades dos materiais. Assim sendo, é possível efectuar uma avaliação que permita concluir que as propriedades determinadas satisfazem, ou não, as necessidades impostas.
The draft of the structure of machine tools is strongly influenced by the materials used in the products work and also by the amount of machine tools to produce, and may be a serial production or even a production unit and specifies for each client. This last aspect is entirely linked to the materials used in the design of the structure of machine tools, and in a production unit, the structural materials used in serial production, become extremely costly. The cast iron and steel are the materials traditionally used in the manufacture of structural components for machine tools, especially the bedways. In this type of components, dimensional stability, thermal, vibration damping and ability to support the actions to which this subject, are fundamental in its good performance. To predict the dynamic behavior of a structure of this kind is of great importance, since only in this way can it obtain structural solutions that allow a good response of the structures dynamic requests constitute an asset to complement the traditional dynamic and static project. The objective of this masters’ dissertation is to develop, characterize and evaluate alternative materials for the structure of machine-tools for chipping, with polymeric concrete. In order to achieve the proposed objective, and need to perform several tests to determine the properties of the materials. Therefore, it is possible to carry out an assessment which allows concluding that certain properties may be expected to satisfy, or not, the needs imposed.

Ziel der Arbeit war die Entwicklung des Elektronenstrahl-Mehrspot/Mehrprozess-Schweißens für Gusseisen/Gusseisen- und Gusseisen/Stahl-Verbindungen ohne Schweißzusatzstoffe. Im Vergleich zum Einbad-Schweißen entsteht beim Mehrbad-Schweißen eine porenarme Schweißnaht, gleichzeitig senkt sich die Schweißnahthärte geringfügig ab. Dabei kann die Kaltrissbildung in der Schweißnaht für arteigene Gusseisen-Verbindungen nicht unterdrückt werden. Für Mischverbindungen ist der Strahlversatz der bestimmende Schweißparameter beim Mehrbad-Schweißen. Über diesen kann sowohl die chemische Zusammensetzung der Schweißnaht eingestellt als auch ohne Vorwärmen eine kaltrissfreie Schweißnaht für Gusseisen/Stahl-Verbindungen erzeugt werden. Für die prozessintegrierte Wärmebehandlung der Fügezone wurde ein neues EB-Thermofeld entwickelt. Durch den Thermofeldeinsatz konnte die Aufhärtung in der Schmelz- und Wärmeeinflusszone signifikant reduziert werden und die mechanischen Eigenschaften der Schweißverbindungen wurden deutlich verbessert.