The development of accurate constitutive equations is important for the success of computer simulations of high temperature forming operations. Often, these simulations must be made on alloys that have not been completely characterized. For that reason physically-based constitutive equations taking the chemical composition into consideration, involving deformation mechanisms and characteristic properties of the material are necessary. The influence that exerts the solute elements to an alloy on the mechanisms of diffusion on deformation processes at high temperatures is not an easy subject and the available information in literature is scarce.

This study examines that influence working on the basis of eight structural plain carbon steels with the chemical composition ranging between 0.15-0.45%C, 0.2-0.4%Si and 0.6-1.6%Mn produced by Electro-Slag Remelting ESR process and tested by isothermal uniaxial compression technique. The studied deformation conditions include strain rates ranging between 5·10−4 to 1·10−1 s−1 and temperatures between 0.6-0.75Tm, with Tm the melting temperature.

A constitutive expression for the hot working behavior is proposed, it includes the variation of the diffusion parameters with the chemical composition. To such aim the effect of the chemical composition of the alloy on the pre-exponential factor D0 of the gamma iron self-diffusion coefficient Dsd is included. Finally, a comparison of the experimental and predicted results shows the good agreement of the model with experimental flow data.

The sintering of tantalum carbide nanopowders by spark plasma sintering (SPS) is investigated. The washing procedure for the powders is modified from previous work to eliminate excess lithium in the powders that is left over from the synthesis process. The sintering behavior of the nanopowders is investigated by X-ray diffraction and scanning electron microscopy by studying specimens that were sintered to different temperatures. To improve the homogeneity of the microstructure of the specimens, milling procedures were implemented. Vaporization during sintering is observed, and the usefulness of carbon additions and systematic decreases in temperature to curb this behavior was explored. Future experiments to achieve full density and to maintain a nanostructure of the specimens include sintering with higher pressures, lower temperatures, and longer dwell times. Additives for maintaining a nanostructure and developing suitable high-temperature properties are also discussed.

Poly(acrylonitrile) fibers are used in the manufacture of activated carbon fibers, which are activated with phosphate groups for the removal of lead ions in aqueous solutions. Removal of lead ions is performed in a water bath at 30°C. Trough isotherm models of Langmuir and Freundlich analyzed the aqueous solution. Kinetic analysis is performed using the model pseudo-first and pseudo-second order. The result show that adsorption equilibrium is adjusted to the Freundlich model and the kinetic model of pseudo-second order led to the best fit correlation.

Steel quenching from the austenite region is a widely used industrial process to increase strength and hardness through the martensitic transformation. It is well known, however, that it is very likely that macroscopic distortion occurs during the quenching process. This distortion is caused by the rapidly varying internal stress fields, which may change sign between tension and compression several times during quenching. If the maximum internal stress is greater than the yield stress at given processing temperature, plastic deformation will occur and, depending on its magnitude, macroscopic distortion may become apparent.

The complex interaction between thermal contraction and the expansion resulting from the martensitic transformation is behind the sign changes in the internal stress fields. Variations in the steel composition and cooling rate will result in a number of different paths, which the internal stresses will follow during processing. Depending on the route followed, the martensitic transformation may hinder the thermal stresses evolution to the point where the stress fields throughout the component may actually be reverted. A different path may support the thermal stresses evolution further increasing their magnitude. The cross-sectional area also affects the internal stresses magnitude, since smaller areas will have further trouble to accommodate stress, thus increasing the distortion. Additionally, the bainitic transformation occurring during relatively slow cooling rates may have an important effect in the final stress field state.

A finite-element (FE) model of steel quenching has been developed in the DEFORM 3D simulation environment. This model has taken into account the kinetics of both austenite-bainite and austenite-martensite transformations in a simplified leaf spring geometry. The results are discussed in terms of the optimal processing parameters obtained by the simulation against the limitations in current industrial practice.

Shot peening is a widely applied surface treatment in a number of manufacturing processes in several industries including automotive, mechanical and aeronautical. This surface treatment is used with the aim of increasing surface toughness and extending fatigue life. The increased performance during fatigue testing of the peened components is mainly the result of the sub-surface compressive residual stress field resulting from the plastic deformation of the surface layers of the target material, caused by the high-velocity impact of the shot. This compressive residual stress field hinders the propagation and coalescence of cracks during the second stage of fatigue testing, effectively increasing the fatigue life well beyond the expected life of a non-peened component.

This paper describes a 3D computational model of spherical projectiles impacting simultaneously upon a flat surface. The multi-impact model was developed in ABAQUS/Explicit using finite element method (FEM) and taking into account controlling parameters such as the velocity of the projectiles, their incidence angle and different impact locations in the target surface. Additionally, a parametric study of the physical properties of the target material was carried out in order to assess the effect of temperature on the residual stress field.

The simulation has been able to successfully represent a multi-impact processing scenario, showing the indentation caused by each individual shot, as well as the residual stress field for each impact and the interaction between each one of them. It has been found that there is a beneficial effect on the residual stress field magnitude when shot peening is carried out at a relatively high temperature. The results are discussed in terms of the current shot-peening practice in the local industry and the leading edge developments of new peening technologies. Finally, an improved and affordable processing route to increase the fatigue life of automotive components is suggested.

A full-scale water physical model of a degassing unit is built and used to evaluate the performance of several impeller designs. Four impeller designs are tested: a) one smooth not commercial impeller for reference purposes, b) a commercial design by FOSECO®, called standard impeller in this work, c) a commercial design by FOSECO® with notches, and d) a new design proposed in this work. Since the physical model is easy and safe to operate, a full experimental design is performed to evaluate the effect of the most important process variables, such as impeller rotating speed, gas flow rate, impeller design and the point of gas injection (a conventional gas injection through the shaft and a novel method of injecting gas through the bottom of the ladle) on the kinetics of oxygen desorption of water which is similar to dehydrogenation of liquid aluminum. The new design of impeller proposed in this work shows the best performance in degassing of all impellers tested in this study. It is found that the rotor speed and its design are the most significant variables affecting degassing kinetics, and therefore the analysis of the existing commercial impeller designs may be useful to optimize the fluid dynamics of the process, which in turn would increase efficiency and productivity of the process. Finally, the novel gas injection method through the bottom, proposed by our own group, presents slightly faster degassing kinetics than the conventional injection of purge gas in the conventional way through the impeller.

Glass-Ceramic monoliths of the SiO2-CaO-MgO-Al2O3 system are obtained in this research. Due to its potential dual role as a flux and as a nucleating agent, two CaF2 levels (X = 3 and X = 6 mol.%) are investigated in the parent glass composition. Due to its good mechanical properties, we intend to obtain Diopside-type pyroxene [(Ca)(Mg,Al)(Al,Si)2O6] as the main crystalline phase in the synthesized glass-ceramics. Vickers microhardness (HV), density and type of crystallization are determined in the latter materials. The morphology and size of the Diopside crystals, as well as the crystallized fraction, are determined with the help of Scanning Electron Microscopy (SEM) and X-Ray Diffraction (XRD). Both materials exhibit surface crystallization with Diopside-type pyroxene phase with acicular morphology homogeneously distributed in the glassy matrix. The specimen with the least amount of added fluorine shows the highest microhardness value, as well as the largest and thickest acicular crystals of Diopside-type pyroxene, the lowest apparent density and the largest crystallized fraction. Our results indicate that CaF2 added in the amounts used by us does not act as nucleating agent, but it does affect the growth of the acicular crystals of the Diopside-type pyroxene phase. This is attributed mainly to the effect of fluorine on the glass structure and properties. The materials developed in this study may be considered as viable alternatives for applications in abrasive and corrosive environments, as well as for substrates for metallic coatings, and for abrasion-resistant floor tiles and other structural applications.

Corrosion attack is implemented on the aluminum alloy AISI 6063-T5 for six different non corroded and pre-corroded specimens. Concerning pre-corroded specimens, they are divided in two groups; the first one is immersed for 1 and 2 minutes in hydrochloric acid with 20% concentration, and the second group for 2, 4, 6 minutes of immersion but in HCl with 38% of concentration. Rotating bending fatigue tests are carried out on corroded and non-corroded specimens at the frequency of 50 Hz, at room temperature and without control of environmental humidity. Loading conditions are fixed by Finite Element numerical simulation; the loading ranges are 90%, 80%, 70% and 60% of the yield stress of this aluminum alloy. A numerical simulation study is carried out by means of the Ansys software to investigate the stress concentration factor variation induced by the proximity of two close pitting holes: in longitudinal and transversal direction regarding the principal applying loading. Finally, optical microscopy is used to analyze the fracture surfaces in longitudinal and transversal directions, in order to establish possible causes of fatigue fracture.

In the present work modified titanium dioxide products are prepared. The influence of introduced modifiers (phosphorus, potassium, aluminium, and tin) on the photoactivity, optical properties, and phase composition of titanium dioxide is studied. The molar contents of P2O5, K2O, Al2O3, and SnO2 in relation to TiO2 are 0.10, 0.18, 0.24, and 0.08-1.32 mol%, respectively. The research is aimed at obtaining the pigmentary rutile TiO2 with the highest possible photostability and improved optical properties.

The phase formation in the zone of directional laser irradiation of compacted Al2O3–TiO2–Y2O3 mixtures has been investigated. It is established that phase formation is carried out within the framework of binary mixtures Al2O3 – Y2O3 and Y2O3 – TiO2.

This investigation deals with the production process and the characterization of ceramic materials consisting of magnetic particles in an insulating matrix. Composites made of magnetite particles (Fe3O4 or MgFe2O4) in a wüstite or magnesiowüstite matrix (FexO or Mg1-xFexO), respectively, have been produced by means of mechanical milling and spark plasma sintering. As-milled powders have a nanocrystalline structure in both systems. As a function of milling time, low energy milling gives rise to an increasingly higher volume fraction of wüstite in the FexO-Fe3O4 system while it promotes increasing amounts of magnesiowüstite (MgxFe1-xO). Sintering is performed from 673 to 1273 K in vacuum. Sintering at low temperatures allows retention of nanosized grains containing a fine dispersion of magnetic particles in a wüstite and magnesiowüstite matrix. Measurement of magnetic properties reflects the constitution of the sintered samples and the effect of grain size. It also allows determination of the transformation sequence both during mechanical milling and sintering

In this research the thermal and mechanical properties of composites based on recycled high-density polyethylene (HDPE) and recycled Tetrapak have been investigated. The matrix and filler are recovered from landfills. Multicolor HDPE mixtures, with varying concentration of tetrapack flakes, are hot pressed, as well as single color HDPE flakes. Previous studies determine that the nature of the pigment (organics vs. inorganics) strongly influence the mechanical behavior of multicolor HDPE-tetrapack composites. Thus, this research focuses on single color HDPE hot pressed plaques. The kinetics of crystallization under isothermal conditions is determined by differential scanning calorimetry (DSC). The results show that the crystallization kinetics obeys the Avrami theory, and that the Avrami exponent is 1, irrespective of the pigment in use. Small-angle light scattering is applied to investigate the internal structure of the pigmented HDPE. SALS patterns show that the samples exhibited oriented morphologies. However, after melting and slow cooling under pressure the samples exhibit an isotropic morphology. This is confirmed by polarized optical microscopy. Mechanical properties such as Young’s modulus, yield stress and ultimate tensile stress are obtained under uniaxial tensile deformation at room temperature. For the single color HDPE plaques the Young’s modulus is reduced (after melting), suggesting that the anisotropic molecular chains contribute to the higher value of Young’s modulus.

The aim of the present research work is to investigate the influence of B addition on the phase transformation kinetics under continuous cooling conditions. In order to perform this study, the behavior of two low carbon advanced ultra-high strength steels (A-UHSS) is analyzed during dilatometry tests over the cooling rate range of 0.1-200°C/s. The start and finish points of the austenite transformation are identified from the dilatation curves and then the continuous cooling transformation (CCT) diagrams are constructed. These diagrams are verified by microstructural characterization and Vickers micro-hardness. In general, results revealed that for slower cooling rates (0.1-0.5 °C/s) the present phases are mainly ferritic-pearlitic (F+P) structures. By contrast, a mixture of bainitic-martensitic structures predominates at higher cooling rates (50-200°C/s). On the other hand, CCT diagrams show that B addition delays the decomposition kinetics of austenite to ferrite, thereby promoting the formation of bainitic-martensitic structures. In the case of B microalloyed steel, the CCT curve is displaced to the right, increasing the hardenability. These results are associated with the ability of B atoms to segregate towards austenitic grain boundaries, which reduce the preferential sites for nucleation and development of F+P structures.

The effect of mechanical activation (MA) of the precursor mixture of raw materials and/or the parent glass, on the microstructure and physical and mechanical properties of iron-rich glass-ceramic materials of the system SiO2-B2O3-BaO-Fe2O3, has been studied. MA of the materials is conducted for 0, 2 or 6h using a high energy attrition milling device. Crystallization treatments are given to the parent glass at 650, 750 or 850°C for 5h. Crystallization of the samples is promoted by increased treatment temperature, and especially also by double MA at 850°C. With increasing crystallization temperature, both the density and the compressive strength increase, while porosity decreases. However, at 850°C, prolonged MA decreases both the density and the compressive strength due to an increment in porosity caused by the growth of the BaFe12O19 crystals.

Resistance spot welding (RSW) of dual-phase (DP) steel subjected to various conditions of cooling rate (holding time) is studied in this work. Lap-shear tensile testing is used in order to evaluate the mechanical performance of the weldments. The microstructure is analyzed through optical and electron microscopy and the hardness is obtained through Vickers method. Results indicate an effective tempered region along the sub-critical heat affected zone in all the samples. A broken morphology accompanied with presence of small carbides within tempered martensite phase is consistently observed. Variations in the cooling rate (holding time) indicate minimal effect on the degree of softening and on the mechanical performance of the welds.

A 1/6th water physical model of a 140 tons gas-stirred steel ladle is used to evaluate mixing times (τm at 95% of chemical uniformity) in a two phase system without slag (air-water) and in a more realistic three phase system (air-water-oil) to simulate the argon-steel-slag system and quantify the effect of the slag layer on the mixing time. Slag layer is kept constant at 0.004 m. Mixing times are estimated through measured changes in pH due to the addition of a tracer (NaOH 1 M). The effect of the following variables on the mixing time is evaluated for a single injector: gas flow rate (7, 17 y 37 l/min) and the injector position (R/r= 0, 1/3, ½, 2/3 and 4/5). Experimental results obtained in this work show good agreement when compared against mixing time correlations reported by Mazumdar for the two phase air-water case (no slag considered). Another comparison is done using the new concept called “effective bath height” proposed by Barati, where the mixing time is a function of the size of the slag layer since this layer dissipates part of the total amount of stirring energy introduced into the ladle by the injection of gas. Agreement is not good in this case. Finally, an estimation of the percentage of the stirring energy dissipated by the slag is computed, including other factors that govern the dissipation of stirring energy. Percentage of energy dissipated by the slag is found to be between 2.7 to 12 % depending on the process conditions.

Ba0.75Sr0.25AlSi2O8 (SBAS) - Al2O3 composites, with SBAS/Al2O3 weight ratios of: (a) 90/10, (b) 70/30, and (c) 50/50, are in situ synthesized by reactive sintering at 900-1500°C/5h. The effect of mechanical activation of the precursor mixtures for 0, 4 or 8h in an attrition milling device on the microstructure and phase composition of the composites is studied. Only SBAS and Al2O3 phases are obtained at 1300-1500°C, independently of milling time. In general, the relative proportion of the desirable monoclinic SBAS (Celsian) phase increases in the materials with increasing milling time and sintering temperature, which is enhanced by their SrO content. The promotion of surface nucleation of the undesirable hexagonal SBAS (Hexacelsian) phase by mechanical activation results in a maximum Hexacelsian to Celsian conversion fraction of only 81.4%, obtained for composition 2 milled for 8h and sintered at 1500°C/5h. Under these synthesis conditions, an increment in the amount and size of the Al2O3 particles in the composites is detrimental for the Hexacelsian to Celsian conversion.

This investigation deals with the effect of 2/0, 1/1 and 1/0.5 Cr/Mo ratios on the local fraction, distribution and the comparative size of carbides precipitated in cast nodular iron. “Y” block castings with a thickness of 1.5 cm are cast in green sand molds. Two samples are cut from each casting, one located on the center and another on the wall. The carbide volume fraction is evaluated by a digital analysis system. Each sample is analyzed in three zones: bottom, middle and top. Carbide mappings are generated according to the average local carbide fraction in order to get the distribution of carbides on the casting. Results show that higher volume fractions of carbides precipitate for the ratio 2/0 of Cr/Mo with values between 28.5 and 19.5%. The lowest fraction of carbides is presented in nodular iron alloyed with a Cr/Mo ratio of 1/1 between 6.5 and 4.6%. Also a very heterogeneous distribution of the carbides is observed in the three alloys and massive carbides are observed in the last freezing zone of the castings.

The high temperature decarburization-oxidation behavior of hot rolled, non-oriented electrical steel strips is investigated during air-annealing treatments. Annealing temperature and time are varied from 700 – 1050 °C and 10 to 150 min, respectively. The experimental results show that uniform external oxidation affects strongly the rate at which carbon can be removed from this material. The thickness of the oxide layer formed after 150 minutes of annealing increases linearly with increasing temperature in the range 828 and 920 °C. The effect of temperature on the thickness of the oxide scale at temperatures outside this range is significantly smaller. These results indicate that the rate of oxidation in this material is strongly influenced by the microstructure of the steel during annealing. Decarburization rates are very slow during annealing at T ≤ 750 °C where the oxide layer is thin and porous. In contrast, fast and intense decarburization of the strips is observed as a result of annealing at temperatures between 800 and 850 °C. Finally, decarburization at T ≥ 875 °C becomes slower as the temperature is increased until at T ≥ 950 °C this process is practically inhibited. Measurements of C content as a function of time and temperature show that the observed decarburization kinetics follows Wagner’s model at 800 and 850 °C. However, at higher annealing temperatures decarburization is slower than that predicted by the model. This behavior is related to the increment of the oxide scale thickness and a transition from cracked to crack-free oxide structure which makes C diffusion through the oxide film very difficult.