Oxidação cíclica em alta temperatura de ligas ferrosas fundidas de baixo custo
Data
2017-11-15
Autores
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Biblioteca Digital de Teses e Dissertações da USP
Universidade de São Paulo
Escola de Engenharia de São Carlos
Universidade de São Paulo
Escola de Engenharia de São Carlos
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A oxidação cíclica é um fenômeno que pode trazer problemas a diversas indústrias e, apesar de estudada em grande medida para materiais de alto desempenho, como superligas, pesquisas em materiais menos nobres são incipientes. Essa tese teve como objetivo investigar as propriedades de oxidação cíclica de materiais ferrosos de baixo custo e compará-las com as do aço inoxidável fundido ASTM A 297 grau HH modificado. A motivação surgiu de uma análise de falha de componente feito com aço HH e da possibilidade de pesquisar materiais com melhor relação custo-benefício em aplicações onde a principal solicitação seja a de resistência à oxidação cíclica. Seis ligas ferrosas com teores de cromo e níquel menores que o do aço HH, ou sem esses elementos, compuseram o estudo. Nestas ligas, os elementos silício e alumínio (1 liga) foram utilizados como alternativa para resistir à oxidação. As composições das ligas (% em peso) foram aproximadamente Fe-15Al-1,1C, Fe-14,5Si-4Cr-0,75C, Fe-5Si-5Cr-V-C, Fe-5Si-5Cr-4Ni-Nb-C, Fe-17Mn-5Si-10Cr-4Ni-V-C e Fe-12Mn-5Si-10Cr-4Ni-Nb-C, além do aço HH modificado (HH-mod). Foram realizados ensaios de oxidação cíclica nas temperaturas de 800, 900 e 1000 ºC e ensaios de dureza, tração e impacto. As ligas mostraram fragilidade, com exceção das ligas com alto teor de manganês que superaram o aço HH-mod em tenacidade. Em oxidação cíclica, as ligas apresentaram boa resistência, com taxas de variação de massa pequenas ou moderadas, e quando houve destacamento, este foi menor que o apresentado pelo aço HH-mod. Camadas oxidadas foram caracterizadas por técnicas de microscopia eletrônica de varredura (MEV), espectroscopia por dispersão de energia de raios-X (EDX) e difração de raios-X (DRX). Foi possível verificar a formação de óxidos protetores de Si, Cr ou Al, mas também de Fe, Cu e principalmente Mn. Por fim, a determinação das cinéticas de ganho de massa e destacamento mostrou que apesar de algumas ligas apresentarem kp maiores que os do aço HH-mod, todas sofreram menores destacamentos, o que ocorreu para o aço HH-mod nas três temperaturas, devido à diferença entre coeficientes de expansão térmica da matriz austenítica e dos óxidos. Dentre as demais ligas, Fe-15Al-1,1C e Fe-5Si-5Cr-4Ni-Nb-C não sofreram destacamentos e apresentaram baixo ganho de massa, devido às finas camadas de óxido e assim apresentando os melhores resultados.
The cyclic oxidation phenomenon can cause problems to several industries. Although studied in high performance materials, as superalloys, researches on less noble materials are incipient. The aim of this thesis was investigate the cyclic oxidation properties of low cost iron-based alloys and compare them with a cast stainless steel ASTM A 297 HH modified grade. The motivation was a failure analysis on a component made of HH and the possibility of research materials with a better cost-benefit ratio for applications where the main solicitation is the cyclic oxidation resistance. Six alloys with less chromium and nickel amount than HH steel, or without these elements, constituted the study. In these alloys, silicon and aluminum (1 alloy) were used to improve the oxidation resistance. The alloy compositions (weight %) were nearly Fe-15Al-1,1C, Fe-14,5Si-4Cr-0,75C, Fe-5Si-5Cr-V-C, Fe-5Si-5Cr-4Ni-Nb-C, Fe-17Mn-5Si-10Cr-4Ni-V-C and Fe-12Mn-5Si-10Cr-4Ni-Nb-C, and the HH steel modified (HH-mod). Cyclic oxidation tests were performed at 800, 900 and 1000 ºC and also hardness, impact and tensile tests. The alloys studied presented brittleness, and only the high Mn alloys had better mechanical properties than HH-mod steel. The alloys presented good results on cyclic oxidation, with low or moderate oxidation rates and when suffering spallation, it was less than HH-mod steel. Oxidized scales were characterized by scanning electron microscope (SEM), energy dispersive spectroscopy (EDS) and X-Ray diffraction (XRD). The formation of protective oxide of Si, Cr or Al was noticed, but also Fe, Cu and Mn oxides were found. Finally, the mass gain and spallation kinetics was determined, and spite the fact of some alloys having higher kp values than HH-mod, no alloys suffered more spallation than HH steel. The austenitic matrix was considered the responsible of this behavior in all temperatures, due to the high thermal expansion coefficient compared with oxides. The better results were found to Fe-15Al-1,1C and Fe-5Si-5Cr-4Ni-Nb-C alloy, with low mass gain and without spalling, on account of the thin oxide scales formed.
The cyclic oxidation phenomenon can cause problems to several industries. Although studied in high performance materials, as superalloys, researches on less noble materials are incipient. The aim of this thesis was investigate the cyclic oxidation properties of low cost iron-based alloys and compare them with a cast stainless steel ASTM A 297 HH modified grade. The motivation was a failure analysis on a component made of HH and the possibility of research materials with a better cost-benefit ratio for applications where the main solicitation is the cyclic oxidation resistance. Six alloys with less chromium and nickel amount than HH steel, or without these elements, constituted the study. In these alloys, silicon and aluminum (1 alloy) were used to improve the oxidation resistance. The alloy compositions (weight %) were nearly Fe-15Al-1,1C, Fe-14,5Si-4Cr-0,75C, Fe-5Si-5Cr-V-C, Fe-5Si-5Cr-4Ni-Nb-C, Fe-17Mn-5Si-10Cr-4Ni-V-C and Fe-12Mn-5Si-10Cr-4Ni-Nb-C, and the HH steel modified (HH-mod). Cyclic oxidation tests were performed at 800, 900 and 1000 ºC and also hardness, impact and tensile tests. The alloys studied presented brittleness, and only the high Mn alloys had better mechanical properties than HH-mod steel. The alloys presented good results on cyclic oxidation, with low or moderate oxidation rates and when suffering spallation, it was less than HH-mod steel. Oxidized scales were characterized by scanning electron microscope (SEM), energy dispersive spectroscopy (EDS) and X-Ray diffraction (XRD). The formation of protective oxide of Si, Cr or Al was noticed, but also Fe, Cu and Mn oxides were found. Finally, the mass gain and spallation kinetics was determined, and spite the fact of some alloys having higher kp values than HH-mod, no alloys suffered more spallation than HH steel. The austenitic matrix was considered the responsible of this behavior in all temperatures, due to the high thermal expansion coefficient compared with oxides. The better results were found to Fe-15Al-1,1C and Fe-5Si-5Cr-4Ni-Nb-C alloy, with low mass gain and without spalling, on account of the thin oxide scales formed.
Palavras-chave
Aço HH, Ligas ferrosas, FeMnSiCrNi, Oxidação cíclica, Fe3Al, Cinética, Baixo custo, Caracterização, Cyclic oxidation, Low-cost, Kinetic, Iron-based alloys, HH steel, Characterization, Fe3Al, FeMnSiCrNi