materiais metÁlicos estudo de peças metálicas lata de refrigerantes em liga de alumínio pás de...

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


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 gramshttp://www.aluminum.org

Estudo de Peças MetálicasLata 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 200mm (10 gramas)

2010 – 10 g (Hydro website)

Lata de refrigerantes em Alumínio


http://www.aluminum.org/sites/default/files/KPI%20Report%202014_1.pdf

12 Oz.


¾ do alumínio produzido é usado em embalagens

(genéricas)

1993 – 140 x 109 unidades2000 – 230 x 109 unidades


MATERIAIS METÁLICOSLata de refrigerantes em Alumínio(2010) Beverage Cans: 220 x 109 + Can

Market




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:http://www.epa.gov/osw/nonhaz/municipal/pubs/2012_msw_fs.pdfand “NAPCOR Postconsumer PET Container Recycling Activity in 2013” report: http://www.napcor.com/pdf/NAPCOR_2013RateReport-FINAL.pdf4 Data for glass and plastic via the Environmental Protection Agency (EPA) Individual Waste Reduction Model (WARM): http://epa.gov/epawaste/conserve/tools/warm/pdfs/Glass.pdfhttp://epa.gov/epawaste/conserve/tools/warm/pdfs/Plastics.pdf5 Data based on a two-year rolling average of commodity prices from February 2012 –February 2014 for various material types via http://recyclingmarkets.net/. 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: http://www.epa.gov/epawaste/conserve/tools/iwarm/index.htm



Peso = 16,0 g (1990)

= 13,0 g (2013)

Capacidade = 0,33 l



RequesitosEnformabilidade Resistência MecânicaResistência à corrosãoToxicidadeCondutividade térmicaPesoPermeabilidade:

luz, O2, H2O, micro-organismos

Pintura

Reciclagem



Etapas do processo de enformação>500 unidades/min



Etapas do processo de enformação


MATERIAIS METÁLICOSLata de refrigerantes em Alumínio

Ironing of DWI (Drawn and wall ironed cans) Cans


Stretching and Ironing of TULC

(Lata de refrigerantes em Alumínio)


Controlo da textura – ausência de orelhas



Ano 2000:

Corpo da lata :folha da liga 3104 (Al-1.2 Mn)300mm espessuratêmpera H 19

Tampa da lata:folha da liga 5182 (Al 4.5Mg 0.3Mn)maior resistência.têmpera H 49



2010 Hydro website

Aluminium cans weigh 10 grams; can walls are 97 mm thick

Thickness (mm) Width (mm) Surface / Lacquer

Body: 3104 alloy0.24–0.35 300–2,000 Mill finish, electrostatically post- lubricated

End: 5182; 5052; 5027 alloys0.20–0.35 101–2,000 Coil coated with approved lacquers,

solvent based as well as water soluble (post-lubrication optional)

Tab: 5182 alloy0.22–0.34 30 – 100 Coated or plain / re-oiled

5042 alloy0.25–0.50 30 – 100 Coated or plain / re-oiled



Corpo da lata: a ciência e tecnologia por detrás dos resultados

1. Lingotes DC liga 3104

2. Homogeneização em dois estágios570ºC arrefecimento lento 510ºC

3. Laminagem a quente: 450ºC60mm 25mm

4. Laminagem morna 275ºC25mm 2,5mm (desenvolvimento de textura)

(continua)



Corpo da lata: a ciência e tecnologia por trás dos resultados

5. Recozimento 2H:

aquecimento lento até 350ºC, recristalizaçãocom 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



Corpo da lata : liga 3104, 300mm espessuraA ciência e tecnologia por detrás dos resultados



http://www.youtube.com/watch?v=_8rg8bSOUpY&feature=related

http://www.youtube.com/watch?v=hcsDxCagWrY

http://www.youtube.com/watch?v=7dK1VVtja5c










Metallic component case studiesSingle Crystal Turbine Blades

MATERIAIS METÁLICOSSingle 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

www.turbokart.com


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 engineDiagrams after Michael Cervenka, Rolls-Royce.

~ 4 MPa

http://www.msm.cam.ac.uk/phase-trans/mphil/Trent1/sld001.htm

http://www.msm.cam.ac.uk/phase-trans/mphil/Trent1/sld001.htm


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

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 1100 ºC).

The thermal coat takes another 100-200 ºC leading to a metal temperature in the vicinity of 930 ºC.


Nickel Superalloy


Schematic illustration of the cooling configurations used for turbine blade aerofoils:

(a) Single-pass cooling

(b) Multipass ‘serpentine’ cooling.

In both cases, holes for film cooling are present

(Source of Rolls-Royce)


Evolution in engine efficiency, after Pratt & Withney.

SFC Thrust specific fuel consumption


Trends in turbine inlet temperature (Koff, 1991)

650 870 1095 1315 1540 1760 1980 2200 2425

Turbine Rotor Inlet Temperature (ºC)


Trends in engine bypass ratio (Epstein, 1998)


900

Schulz et al, Aero. Sci. Techn.7, 73-80 (2003)

2003


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.

nickel-base superalloy containing a large volume of ’ precipitates

Single-crystal matrix

The blade is directionally-solidified via a spiral selector, which permits only one crystal to grow into the blade.


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)


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


nickel-base single crystal superalloys - alloying elements

The Al-Ni phase diagram

’


nickel-base single crystal superalloys - alloying elements


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 — — 5.0 1.5 — — — —

Rene N4 9.8 7.5 1.5 6.0 4.8 — 0.5 4.2 3.5 0.15 0.05 0.00 —

CMSX-3 8.0 5.0 0.6 8.0 6.0 — — 5.6 1.0 0.10 — — —

Second-Generation Single-Crystal Alloys

PWA 1484 5.0 10.0 2.0 6.0 9.0 3.0 — 5.6 — 0.10 — — —

Rene N5 7.0 7.5 1.5 5.0 6.5 3.0 — 6.2 — 0.15 0.05 0.00 0.01

CMSX-4 6.5 9.0 0.6 6.0 6.5 3.0 — 5.6 1.0 0.10 — — —

Third-Generation Single-Crystal Alloys

Rene N6 4.2 12.5 1.4 6.0 7.2 5.4 — 5.8 — 0.15 0.05 0.00 0.01

CMSX-10 2.0 3.0 0.4 5.0 8.0 6.0 0.1 5.7 0.2 0.03 — — —

Fouth-Generation Single-Crystal Alloys (2009)

MC-NG 4 <0.2 1 5 5 4 6.0 0.5 0.10 4

MX4/PW1497 2 16.5 2.0 6.0 8.25 5.95 — 5.55 — 0.15 0.03 0.004 3

TMS-138 2.8 5.8 2.9 6.1 5.6 5.1 — 5.8 — 0.05 — — 1.9

TMS-162 2.9 5.8 3.9 5.8 5.6 4.9 — 5.8 — 0.09 — — 6



Comparative Larson–Miller stress-rupture curves forsecond and third generation SC superalloys.Pierre Caron and Tasadduq Khan Aerosp. Sci. Technol (1999)

3th

2nd



Partition coefficients for second- and third-generation alloys and corresponding densities of pure elements at 20ºC

Source: Pollock and Tin (2006)

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

Variation in dendrite morphology and primary dendrite arm spacing (PDAS) with cooling rate (G*R) during solidification.


nickel-base superalloy containing about 65% of ’ precipitates

(a) Electron diffraction pattern from the (cubic-F) phase.

(b) Electron diffraction pattern from the ' (cubic-P) phase. The two electron diffraction patterns are presented in their correct relative orientation.

(c) Dark field transmission electron micrograph of the phase.

(d) Dark field transmission electron micrograph of the ' phase



/’ 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.


nickel-base superalloy - coatings

The result of 2500 h low altitude sea flight service on an uncoated and NiAl coated blade turbine bladeEskner (2004)

Oxidation and creep failure


Single Crystal Turbine Bladesnickel-base superalloy - coatings

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.

Tem

per

atu

re /

ºC

x


Single Crystal Turbine Bladesnickel-base single crystal superalloys - coatings

Heat Transfer TGO: Thermally grown oxide (Al2O3)

Turbine blade with TBC (ZrO2-YO1.5)


Single Crystal Turbine Bladesnickel-base single crystal superalloys - coatings

http://www.msm.cam.ac.uk/phase-trans/2003/Superalloys/coatings/

Schematic illustration of NiCrAlY microstructure.

Al diffusion to the oxide layer and the substrate result in depletion of from both sides.


nickel-base single crystal superalloys - coatings

Ashutosh S. Gandhi 4th Indo-American Frontiers of Engineering Symposium 2012

• 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

Future TBC System Erosion/CMAS resistant Layer

Luminescent Layer

Low-k TBC

Luminescent Layer

YSZ Interlayer

TGO (Al2O3)

Bond Coat

Diffusion Barrier

Superalloy


Pt-aluminide coated jet engine HPT blade(Pt electroplating 5-10 μm)

Photo courtesy S. Tin, Rolls-Royce UTC.

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 € (≈ 10.000 $ 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.

nickel-base superalloy

http://www.msm.cam.ac.uk/UTC/

http://www.rweinnogy.com/index.asp

http://www.rweinnogy.com/index.asp


Nickel Monthly Price USD/MTNickel, melting grade, LME spot price, CIF European ports (source: World Bank)

Ni highest≈50$/kg


7/1/2

011

9/1/2

011

11/1/2

011

1/1/2

012

3/1/2

012

5/1/2

012

7/1/2

012

9/1/2

012

11/1/2

012

1/1/2

0133,400.0

3,800.0

4,200.0

4,600.0

5,000.0

99.9% Re - USD/Kg

US

D/K

g

Rhenium 99.99%China Domestic Market USD/KGSource - Shanghai Metals Market


Estudo de Peças MetálicasCondensadores de Tântalo

1-Ju

n-11

1-Aug

-11

1-Oct

-11

1-Dec

-11

1-Feb

-12

1-Apr

-12

1-Ju

n-12

1-Aug

-12

1-Oct

-12

1-Dec

-12

350.0

360.0

370.0

380.0

390.0

400.0

410.0

420.0

Tantalum Scrap 99.9 Vacuum Processor USD/Kg

US

D/K

g


Condensadores de Tântalo


CAPACITOR GRADE TANTALUM POWDERS

PowderAngularor EB

Nodular Flake

ManufacturingProcess

ElectronBeam Melted

Chemicallyreduced

Chemically Reduced,Physically Formed

Primary Particle Size(m) 1 to 10 0.2 to 2

Aspect Ratio20 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 -

TypicalApplications

High Voltage,High Reliability

Low Voltage,High Capacitance

Medium Voltage,Medium Capacitance



Powder STA-20 KF STA-50 KF STA-100 KF

ManufacturingProcess Sodium reduced Sodium reduced Magnesium

reduced

Primary Particle SizeFisher Number (m)

2 - 3.0 2.5

2.2 - 3.5 < 2.3

1.3 - 2.3 < 1.9

Surface Area(m2/g)

max. 1.20.9

Max. 2.22.0

Specific Capacitance (CV/g)

22500 (1500°C) 30000 (1400°C)

42500 (1510°C) 50000 (1450°C)

90000 (1310°C) 80000 (1360°C)

Sintering conditions(vacuum) Press Density < 10-4 mbar < 10-4 mbar

5.75 g/ccm < 10-4 mbar 5.00 g/ccm

Sintering conditionsTemperature ºC

1450 (15 min.) 1510 (15 min.)

1450 (10 min.) 1510 (10 min.)

1310°C (10 min.)1360°C (10 min.)

TypicalApplications

lower voltage applications (max. 20 VW capacitors)

High capacitance High capacitance



20 nm



STA-50 KF STA-100 KF STA-30 KF



Pore diameters are in the range of 10 - 100 nm.The surface area is up to four times that of low CV powders.

MATERIAIS METÁLICOSCondensadores de Tântalo


FIM

materiais metÁlicos estudo de peças metálicas lata de refrigerantes em liga de alumínio pás de...

Documents