Estudo de Peças Metálicas

Estudo de Peças Metálicas
MATERIAIS METÁLICOS Estudo de Peças Metálicas Lata de refrigerantes em liga de Alumínio Pás de turbina Monocristalinas em Superliga de Níquel Condensadores de Tântalo/MnO2

Estudo de Peças Metálicas Lata de refrigerantes em Alumínio
MATERIAIS METÁLICOS Estudo de Peças Metálicas Lata de refrigerantes em Alumínio The modern aluminum beverage can traces its origins to 1959, when Coors introduced the first all-aluminum, seamless two-piece beverage container. In addition to providing a superior taste to the steel and tin cans then in vogue, the new package was recyclable: Coors would pay one cent for each can returned to the brewery. According to the Can Manufacturers Institute, this first generation of aluminum cans weighed approximately 85.6 grams per unit. In the half century since, aluminum beverage can manufacturers have lightened the package ever further - reducing the gauge required to fabricate both the cans and the ends. Today’s (2013) cans weigh less than 12,98 grams 6,6 x weight reduction in 55 years

Lata de refrigerantes em Alumínio
MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio História do Al: corpo da lata (33cc): 1959 – 1ª lata toda de duas peças sem costura, toda em alumínio (Coors) (85.6 gramas) 1962 – tampa de Al em lata de aço (500mm espessura) 1970 – lata de duas peças em Al em lata de aço corpo da lata 440mm espessura 1993 – corpo da lata 300mm espessura (28 gramas) Século XXI mm (10 gramas) 2010 – 10 g (Hydro website) Aluminum Cans Enter the Soft Drink Market Aluminum cans would make inroads into the soft drink market in 1964, when Royal Crown Cola released both its RC Cola and Diet Rite beverages in a two-piece, 12-oz. (0,355 l) aluminum container. In addition to being lighter-weight than their steel predecessors, these new aluminum cans provided a superior surface upon which to print text and graphics to help promote brand awareness. In their first year on the market, one million cases of soda were packaged in aluminum cans. A range of other factors contributed to the aluminum can’s early adoption by beverage manufacturers: it was easily molded (and hence its ability to be formed in only two pieces), it was highly resistant to corrosion and would not rust, and it admirably supported the carbonation pressure required to package soda (aluminum cans withstand pressure of up to 620 kPa). Such advantages were not lost on Coca-Cola and Pepsi-Cola who, in 1967, adopted the aluminum can for Coke, Pepsi, and Diet Pepsi. The aluminum can revolution was under way—but its biggest boost had yet to come.

MATERIAIS METÁLICOS 12 Oz.

MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio ¾ do alumínio produzido é usado em embalagens (genéricas) 1993 – 140 x 109 unidades 2000 – 230 x 109 unidades

MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio (2010) Beverage Cans: 220 x Can Market

MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio Sustainability Key Performance Indicators Aluminum Beverage Can December 2014

MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio Sustainability Key Performance Indicators Aluminium Beverage Can December 2014 Confront - Product Life cycle assessment 2 No equivalent data available for glass or plastic bottles. 3 Data for glass and plastic via the Environmental Protection Agency (EPA) Municipal Solid Waste Report 2012: and “NAPCOR Postconsumer PET Container Recycling Activity in 2013” report: 4 Data for glass and plastic via the Environmental Protection Agency (EPA) Individual Waste Reduction Model (WARM): 5 Data based on a two-year rolling average of commodity prices from February 2012 –February 2014 for various material types via 6 Weights based on 12 - oz aluminum can; 12-ozglass bottle; 20-oz plastic (PET) bottle. Aluminum data from the Can Manufacturers Institute. Glass and plastic data from EPA EPA Individual Waste Reduction (iWARM) model:

MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio Peso = 16,0 g (1990) = 13,0 g (2013) Capacidade = 0,33 l

MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio Requesitos Enformabilidade Resistência Mecânica Resistência à corrosão Toxicidade Condutividade térmica Peso Permeabilidade: luz, O2, H2O, micro-organismos Pintura Reciclagem

MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio Starting material – aluminium coil. Etapas do processo de enformação >500 unidades/min

MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio Etapas do processo de enformação

MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio Ironing of DWI (Drawn and wall ironed cans) Cans Ironing of DWI (Drawn and wall ironed cans) Cans Can body is ironed and thinned by placing the material (in the form of a cup) between a punch sleeve and a set of ironing dies. Coolant is sprayed to lubricate and cool the tools and materials during this process, and thus coolant rinsing and waste water treatment are necessary. (draw and wall ironing cans)

(Lata de refrigerantes em Alumínio)
MATERIAIS METÁLICOS (Lata de refrigerantes em Alumínio) Stretching and Ironing of TULC (Toyo Ultimate Can) "Stretch-ironing" is a basic moulding method for TULC which was developed from the "tension and bending" process. “Stretch-draw-ironing”, is used to iron materials while applying a back tension. PET film laminate acts as lubricant to allow moulding without using coolant and water. This enabled us to reduce can weight significantly as well as environmental burden without water use Stretching and Ironing of TULC

MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio Controlo da textura – ausência de orelhas

MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio Ano 2000: Corpo da lata : folha da liga 3104 (Al-1.2 Mn) 300mm espessura têmpera H 19 Tampa da lata: folha da liga 5182 (Al 4.5Mg 0.3Mn) maior resistência. têmpera H 49

MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio 2010 Hydro website Aluminium cans weigh 10 grams; can walls are 97 mm thick Thickness (mm) Width (mm) Surface / Lacquer Body: alloy 0.24– –2,000 Mill finish, electrostatically post- lubricated End: 5182; 5052; 5027 alloys 0.20– –2,000 Coil coated with approved lacquers, solvent based as well as water soluble (post-lubrication optional) Tab: alloy 0.22– – 100 Coated or plain / re-oiled 5042 alloy 0.25– – 100 Coated or plain / re-oiled

Corpo da lata: a ciência e tecnologia por detrás dos resultados
MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio Corpo da lata: a ciência e tecnologia por detrás dos resultados 1. Lingotes DC liga 3104 2. Homogeneização em dois estágios 570ºC arrefecimento lento ºC 3. Laminagem a quente: 450ºC 60mm mm 4. Laminagem morna 275ºC 25mm ,5mm (desenvolvimento de textura) (continua)

Corpo da lata: a ciência e tecnologia por trás dos resultados
MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio Corpo da lata: a ciência e tecnologia por trás dos resultados 5. Recozimento 2H: aquecimento lento até 350ºC, recristalização com desenvolvimento de textura, arrefecimento até TA 6. Laminagem a frio em vários passos: desenvolvimento de textura (ausência de orelhas) têmpera H19 (se0,2%=290 MPa; sUTS =310 MPa; e = 10%) espessura: 300 mm

MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio Corpo da lata : liga 3104, 300mm espessura A ciência e tecnologia por detrás dos resultados

MATERIAIS METÁLICOS Lata de refrigerantes em Alumínio

Metallic component case studies Single Crystal Turbine Blades
MATERIAIS METÁLICOS Metallic component case studies Single Crystal Turbine Blades

Single Crystal Turbine Blades
MATERIAIS METÁLICOS Single Crystal Turbine Blades Commercial Aircraft engine General Electric GE90-115B high bypass turbofan Developed for the Boeing 777 airliner Militar Aircraft engine Eurojet EJ200 Low Bypass Augmented Turbofan Low bypass ratio augmented turbofan engine, designed for the Eurofighter EF2000 Typhoon

~ 4 MPa MATERIAIS METÁLICOS Single Crystal Turbine Blades Rolls-Royce Trent 800 Jet engine different stages: low pressure compressor (LPC) high pressure compressor (HPC) high pressure turbine (HPT) intermediate pressure turbine (IPT) low pressure turbine (LPT) Pressure and temperature profiles along the engine Diagrams after Michael Cervenka, Rolls-Royce.

MATERIAIS METÁLICOS Single Crystal Turbine Blades The most severe conditions are met in the first row of the high pressure turbine. The entry temperature is around 1400 ºC. Temperatures are kept lower at the surface of the blade because of the cooling system (ceramic surface approaching ºC). The thermal coat takes another ºC leading to a metal temperature in the vicinity of 930 ºC. The different materials used in a Rolls-Royce jet engine: BLUE: titanium ideal for its strength and density but not at high temperatures RED: nickel superalloys ideal for strength at high temperatures ORANGE: steel used for the static parts of the compressor. Image courtesy Michael Cervenka, Rolls-Royce

MATERIAIS METÁLICOS Single Crystal Turbine Blades Nickel Superalloy

MATERIAIS METÁLICOS Single Crystal Turbine Blades Schematic illustration of the cooling configurations used for turbine blade aerofoils: Single-pass cooling Multipass ‘serpentine’ cooling. In both cases, holes for film cooling are present (Source of Rolls-Royce)

MATERIAIS METÁLICOS Single Crystal Turbine Blades SFC Thrust specific fuel consumption Thrust specific fuel consumption (TSFC) TSFC or SFC for thrust engines is the mass of fuel needed to provide the net thrust for a given period e.g. g/(s·kN) (grams of fuel per second-kilonewton). Specific fuel consumption of air-breathing jet engines at their maximum efficiency varies more or less inversely with speed, which means that the fuel consumption per mile or per km can be a more appropriate comparison for aircraft that travel at very different speeds. The bypass ratio (BPR) of a turbofan engine is the ratio between the mass flow rate of air drawn through the fan disk that bypasses the engine core (un-combusted air) to the mass flow rate passing through the engine core that is involved in combustion to produce mechanical energy. The ducted fan, rather than combustion gases expanding in a nozzle, produces the vast majority of the thrust in high-bypass designs. A high bypass ratio provides a lower thrust specific fuel consumption (grams/sec fuel per unit of thrust in kN using SI units, especially at zero velocity (at takeoff) and at the cruise speed of most commercial jet aircraft; however, the lower exhaust velocities of high-bypass designs also figure strongly in lower noise output, which is a decided advantage over earlier low or zero bypass designs. High bypass designs are by far the dominant type for all commercial passenger aircraft and both civilian and military jet transports. Military combat aircraft usually use engines with low bypass ratios to compromise between fuel economy and the requirements of combat: high power-to-weight ratios, supersonic performance, and the ability to use afterburners, all of which are more compatible with low bypass engines. Unducted Fan (UDF) or propfan: hybrid between a turbofan and a turboprop (A turboprop engine is a turbine engine that drives an aircraft propeller. The engine's exhaust gases do not contain enough energy to create significant thrust, since almost all of the engine's power is used to drive the propeller). Ver também: e páginas relacionadas Evolution in engine efficiency, after Pratt & Withney.

MATERIAIS METÁLICOS Single Crystal Turbine Blades Turbine Rotor Inlet Temperature (ºC) Trends in turbine inlet temperature (Koff, 1991)

MATERIAIS METÁLICOS Single Crystal Turbine Blades Trends in engine bypass ratio (Epstein, 1998)

MATERIAIS METÁLICOS Single Crystal Turbine Blades 900 2003 Schulz et al, Aero. Sci. Techn.7, (2003)

MATERIAIS METÁLICOS Single Crystal Turbine Blades

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base superalloy containing a large volume of ’ precipitates Polycrystalline  matrix The creep life of the blades is limited by the grain boundaries which are easy diffusion paths. Polycrystalline aligned  matrix It has been directionally solidified, resulting in a columnar grain structure which mitigates grain-boundary induced creep. Single-crystal  matrix The blade is directionally-solidified via a spiral selector, which permits only one crystal to grow into the blade.

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base superalloy - the Trent 800 high-pressure turbine blade Different stages of production by investment casting: (a) wax model containing ceramic core, ready to receive the investment shell. (b) finished casting with pig-tail selector removed. (c) finished blade, after machining. (a) (b) (c)

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base superalloy Ceramic investment casting mould with single-crystal starter at the bottom of the plate and single-crystal plate following directional solidification and removal of ceramic mould

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base single crystal superalloys - alloying elements ’  The Al-Ni phase diagram

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base single crystal superalloys - alloying elements

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base superalloy generations Table 1 Compositions of commercial Ni-based superalloys (wt. %, bal. Ni) Alloy Cr Co Mo W Ta Re Nb Al Ti Hf C B Y Ru First-Generation Single-Crystal Alloys PWA 1480 10.0 5.0 — 4.0 12.0 1.5 Rene N4 9.8 7.5 6.0 4.8 0.5 4.2 3.5 0.15 0.05 0.00 CMSX-3 8.0 0.6 5.6 1.0 0.10 Second-Generation Single-Crystal Alloys PWA 1484 2.0 9.0 3.0 Rene N5 7.0 6.5 6.2 0.01 CMSX-4 Third-Generation Single-Crystal Alloys Rene N6 12.5 1.4 7.2 5.4 5.8 CMSX-10 0.4 0.1 5.7 0.2 0.03 Fouth-Generation Single-Crystal Alloys (2009) MC-NG 4 <0.2 1 5 MX4/PW1497 2 16.5 8.25 5.95 5.55 0.004 3 TMS-138 2.8 2.9 6.1 5.1 1.9 TMS-162 3.9 4.9 0.09 6

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base superalloy generations 3th 2nd Comparative Larson–Miller stress-rupture curves for second and third generation SC superalloys. Pierre Caron and Tasadduq Khan Aerosp. Sci. Technol (1999)

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base superalloy generations Variation in dendrite morphology and primary dendrite arm spacing (PDAS) with cooling rate (G*R) during solidification. Partition coefficients for second- and third-generation alloys and corresponding densities of pure elements at 20ºC Al Cr Co Ta W Re Mo Partition coefficient, k 0.81–0.95 1.05–1.17 1.03–1.13 0.67–0.80 1.28–1.58 1.23–1.60 1.13–1.46 Density (20ºC) 2.7 7.2 8.8 16.7 19.3 21.0 10.2 Source: Pollock and Tin (2006)

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base superalloy containing about 65% of ’ precipitates Electron diffraction pattern from the  (cubic-F) phase. Electron diffraction pattern from the  ' (cubic-P) phase. The two electron diffraction patterns are presented in their correct relative orientation. Dark field transmission electron micrograph of the  phase. Dark field transmission electron micrograph of the  ' phase

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base superalloy generations /’ microstructure of the CMSX-4 single-crystal superalloy - 2nd generation alloy- (SEM) (Nirundorn Matan.) Rafting: directional coarsening at elevated temperatures results in the formation of  rafts aligned perpendicular to the direction of the applied stress.

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base superalloy - coatings TGO - thermally grown oxide alfa-Al2O3 Examples: bond coating material NiCrAlY. YSZ top coating layer. The result of 2500 h low altitude sea flight service on an uncoated and NiAl coated blade turbine blade Eskner (2004) Oxidation and creep failure

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base superalloy - coatings Temperature /ºC x Typical coatings for high-temperature applications involve an oxidation resistant coating (thermally grown oxide (TGO), α-alumina ) and a thermal barrier coating (TBC). The bond coat provides a layer on which the ceramic TBC can adhere. TGO - thermally grown oxide alfa-Al2O3 Examples: bond coating material NiCrAlY. YSZ top coating layer.

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base single crystal superalloys - coatings Heat Transfer TGO: Thermally grown oxide (Al2O3) Turbine blade with TBC (ZrO2-YO1.5)

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base single crystal superalloys - coatings Composition and role of additions The M of MCrAlY stands for either Ni or Co, depending on the type of superalloy. Co-based appear to have superior resistance to corrosion. Cr provides hot-corrosion resistance, but the amount that can be added is limited by the effect it is expected to have on the substrate, and the formation of Cr-rich phases in the coating. Al content is typically around wt%. Since oxidation life is essentially controlled by the availability of Al, it would be tempting to increases the aluminium content. However, this results in significant reduction of ductility (for example, Sivakumar, 1989). MCrAlY also typically contain 1 wt% yttrium (Y), which enhances adherence of the oxide layer. The main role of Y is to combine with sulfur and prevent its segregation to the oxide layer, which is otherwise detrimental to its adhesion. Additions of hafnium (Hf) play a similar role. The effect of other additions has also been investigated (Nicoll, 1982). It was found that silicon (Si) significantly improved cyclic oxydation resistance, however it also decreases the melting point of the coating. 5 wt% are enough to lower the melting temperature to about 1140 oC. Additions of rhenium (Re) have been shown to improve isothermal or cyclic oxidation resistance, and thermal cycle fatigue (Czech et al., 1994). Additions of tantalum (Ta) can also increase the oxidation resistance. Schematic illustration of NiCrAlY microstructure. Al diffusion to the oxide layer and the substrate result in depletion of  from both sides.

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base single crystal superalloys - coatings Future TBC System Erosion/CMAS resistant Layer Luminescent Layer Low-k TBC YSZ Interlayer TGO (Al2O3) Bond Coat Diffusion Barrier Superalloy Diffusion barrier to minimize bond coat – superalloy interaction YSZ interlayer to prevent reaction with TGO Luminescent layers for monitoring remaining life Top layer with erosion and CMAS resistance Combination of materials Dust ingested into the gas turbine consists of calcium aluminium magnesium silicates (CMAS) Volcanic ash and sand behave differently: Different compositions, melting points and viscosities Ashutosh S. Gandhi 4th Indo-American Frontiers of Engineering Symposium 2012

MATERIAIS METÁLICOS Single Crystal Turbine Blades nickel-base superalloy Jet engines high pressure turbine blades (HPT blades) are expected to last for ~30,000 h. For land-based power generation, this time can vary between 50,000 and 75,000 h (about 9 years). HPT blades in jet engine typically undergo one refurbishment (strip coating and re-coat) throughout their life; in power generation applications, one or two refurbishments depending on the target life. At 2004, rough estimates of costs provided by RWE Innogy are (power generation): set of blades for HPT: 1.7 million € (≈ $ each (RR turbofan engine 2009)) cost of refurbishment: variable: 0.34 to 1.1 million €. The HPT blades in jet engines mainly suffer from oxidation; Pt-aluminide coatings are preferred in these conditions and are commonly used to coat the main surface. Rolls Royce turbine blades. Each turbine blade can fit in the hand and costs about $10,000 each. Rolls-Royce's executives like to point out that their big engines, of almost six tonnes, are worth their weight in silver. Turbine blades are difficult to make because they have to survive high temperatures and huge stresses. The air inside big jet engines reaches about 1,600°C in places, 400ºC hotter than the melting point of the metal from which the turbine blades are made. (Without a proper cooling system, this would be like trying to stir a cup of hot coffee with a spoon made of ice.) Each blade is grown from a single crystal of alloy for strength and then coated with tough ceramics. A network of tiny air holes then creates a thin blanket of cool air that stops it from melting (the Economist 2009). Pt-aluminide coated jet engine HPT blade (Pt electroplating 5-10 μm) Photo courtesy S. Tin, Rolls-Royce UTC.

MATERIAIS METÁLICOS Single Crystal Turbine Blades Nickel Monthly Price USD/MT Nickel, melting grade, LME spot price, CIF European ports (source: World Bank) Ni highest ≈50$/kg LME – London Metal Exchange CIF - `Cost, Insurance and Freight´: A trade term requiring the seller to arrange for the carriage of goods by sea to a port of destination, and provide the buyer with the documents necessary to obtain the goods from the carrier.

MATERIAIS METÁLICOS Single Crystal Turbine Blades LME – London Metal Exchange Rhenium 99.99% China Domestic Market USD/KG Source - Shanghai Metals Market

Estudo de Peças Metálicas Condensadores de Tântalo
MATERIAIS METÁLICOS Estudo de Peças Metálicas Condensadores de Tântalo

Condensadores de Tântalo
MATERIAIS METÁLICOS Condensadores de Tântalo

CAPACITOR GRADE TANTALUM POWDERS
MATERIAIS METÁLICOS CAPACITOR GRADE TANTALUM POWDERS Powder Angular or EB Nodular Flake Manufacturing Process Electron Beam Melted Chemically reduced Chemically Reduced, Physically Formed Primary Particle Size (m) 1 to 10 0.2 to 2 Aspect Ratio 20 to 50 Aggregate Size (m) 50 to 300 20 to 250 25 to 200 Surface Area (m2/g) < 0.3 0.3 to 0.9 - Typical Applications High Voltage, High Reliability Low Voltage, High Capacitance Medium Voltage, Medium Capacitance

MATERIAIS METÁLICOS CAPACITOR GRADE TANTALUM POWDERS Powder STA-20 KF STA-50 KF STA-100 KF Manufacturing Process Sodium reduced Magnesium reduced Primary Particle Size Fisher Number (m) 2.5 < 2.3 < 1.9 Surface Area (m2/g) max. 1.2 0.9 Max. 2.2 2.0 Specific Capacitance (CV/g) (1500°C) (1400°C) (1510°C) (1450°C) (1310°C) (1360°C) Sintering conditions (vacuum) Press Density < 10-4 mbar 5.75 g/ccm 5.00 g/ccm Temperature ºC 1450 (15 min.) 1510 (15 min.) 1450 (10 min.) 1510 (10 min.) 1310°C (10 min.) 1360°C (10 min.) Typical Applications lower voltage applications (max. 20 VW capacitors) High capacitance

MATERIAIS METÁLICOS CAPACITOR GRADE TANTALUM POWDERS 20 nm

MATERIAIS METÁLICOS CAPACITOR GRADE TANTALUM POWDERS STA-30 KF STA-50 KF STA-100 KF reduced tantalum powder for lower voltage applications (max. 20 VW capacitors)

MATERIAIS METÁLICOS CAPACITOR GRADE TANTALUM POWDERS Pore diameters are in the range of nm. The surface area is up to four times that of low CV powders.

MATERIAIS METÁLICOS CAPACITOR GRADE TANTALUM POWDERS

MATERIAIS METÁLICOS FIM

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