This study focused on the effects of different peak (austenitizing) temperatures (Tp) over the martensite start temperature (Ms) and its influence on the final residual stresses after welding simulation. For this purpose, the expansion coefficients obtained through physical (dilatometric) simulations of a high-strength low-alloy steel were considered for three peak temperatures: 1300 °C, 1150 °C, and 920 °C and a cooling rate of 25 °C/s. Aiming at clarifying the physical phenomenon behind GTAW welding, one carried out nonlinear transient thermomechanical finite-element (FE) analyses to reconstitute the welding process and simulate the subsequent formation of residual stresses in the HAZ. Once the heat source simulation was calibrated, four material models were created, one for each Tp, and a fourth model considering a constant expansion coefficient, without considering the martensite transformation for comparison. A Three-bar model was evaluated to isolate the effects of Tp (Ms) in the residual stresses. A composite plate model was also considered, in which the sheet HAZ was subdivided according to the reached peak temperature, and the respective material models were applied. The results show the importance of martensite transformation on the welding-induced residual stress and a clear trend of decreasing tensions with lowering the Tp, especially over HAZ.

This study is focused on the performance evaluation of flash-butt-welded rail joints concerning their mechanical strength and fatigue life. Residual stresses created in the heat-affected zone were measured and the effects of the welding process and notch sensitivity on the fatigue behavior in the weld region were experimentally assessed. Aiming at clarifying the physical phenomenon behind the flash-butt welding, nonlinear transient thermomechanical finite-element analyses were performed to reconstitute the welding process and to simulate the subsequent formation of residual stresses. A new hypothesis for explaining higher temperatures in the rail web than in the rail foot and head was suggested and numerically verified. Experimental fatigue results showed high notch sensitivity and highlighted the effects of microstructure variations on the fatigue life. In general, a good agreement was achieved between numerical and experimental measurements of residual stresses, which was essential for understanding the fatigue phenomenon and the formation of residual stresses in flash-butt-welded rail joints. A relevant outcome is the simulation of the hot burrs from the welding process as prescribed heat inputs on a convenient part of the rail surface. This simulation strategy has shown adequate to explain the non-uniform temperature changes and the corresponding originated residual stresses. flashbuttwelded flash butt welded life heataffected affected assessed flashbutt finiteelement finite element verified general surface nonuniform non uniform

Abstract The kinetics of phase transformations in isothermal processes is well described by the classic JMAK model. However, it is known that most industrial facilities employ continuous cooling processes and, for this condition, the JMAK model is adapted but, sometimes, without success. Considering the importance to predict critical temperatures, the present work proposes an alternative empirical functional equation to describe the kinetics of steel phase transformation under continuous cooling, being useful when the JMAK use is not successful. In this study, the continuous cooling austenite to ferrite transformation was experimentally characterized by dilatometry for an IF-Ti-stabilized steel. The proposed equation was compared with the classic adapted JMAK model regarding to evaluate its efficacy to fit the dilatometric experimental data. Using the constants obtained by the both model fittings as input parameters, a computational simulation was performed to determine the CCT diagram of the IF-Ti steel. The proposed functional equation was efficient to predict the critical temperatures, the kinetics of austenite decomposition and the CCT diagram of the studied steel. The results predicted by the proposed model greatly met the experimental data measured by dilatometry.

Abstract This paper presents the characterization of austenite to pearlite transformation in rail steels (premium and standard) using dilatometry. The critical transformation temperatures were measured as a cooling rate function and the obtained microstructures were qualitatively and quantitatively characterized. Aiming to study the transformation kinetics, three equations proposed by technical literature were evaluated in order to predict the transformation evolution. Experimental and calculated CCT diagrams were compared. It was concluded once the kinetics of phase transformation in rail steels is well characterized, it can be used as reference to enable suitable heat treatment to obtain pearlitic microstructures for the standard steel as refined as those of premium. The minor prior austenite grain size of the standard steel favoured the pearlite nucleation, however its highest Mn, Nb and Si contents delayed the growth stage. All equations evaluated in order to predict the kinetics of austenite to pearlite transformation under continuous cooling were satisfactory.

Abstract The effects of the austenitizing temperature and the cooling rate upon the kinetic of athermal martensitic transformation in a microalloyed steel were evaluated. Considering the studied steel, the knowledge about these effects on the martensitic transformation has a great relevance for naval manufacturers and steel researchers. In this study, computational simulation was performed aiming to evaluate the phase’s stability. Specimens were submitted to quenching simulations in a dilatometer, considering four different austenitizing temperatures and four cooling rates. The results shown that the austenite chemical composition was not significantly affected by the austenitizing temperatures. Both the austenitic grain size and the cooling rate affected the martensitic transformation kinetics. The larger the austenitic grain size, the higher the Ms. The austenitic grain growth promoted a decrease in the required chemical energy to compensate the free energy increase associated with the lattice strain and the creation of new interfaces, leading to a lower austenite undercooling. An extrinsic effect of the cooling rate on the Ms was observed. For lower cooling rates, the carbide precipitation modified que austenite chemical composition, changing its stability and increasing Ms. A predictability equation, correlating the MS with the austenite grain size and the steel cooling rate, was proposed.

Resumo: Trilhos longos soldados por centelhamento elétrico (Flash Butt Welding - FBW) apresentam características desejáveis do ponto de vista do comportamento dinâmico da via, no entanto, as soldas são regiões de descontinuidade estrutural e mecânica onde se originam tensões residuais, e que estão associadas a falhas prematuras por fadiga. Ensaios de dilatometria foram empregados para simular os efeitos do tamanho de grão austenítico sobre a evolução microestrutural pós-soldagem. Simulações numéricas termomecânicas, não-lineares, no domínio do tempo, pelo Método dos Elementos Finitos (MEF), foram empregadas para avaliar os efeitos de modificações de parâmetros do processo de soldagem sobre as tensões residuais. Os resultados apresentados permitem compreender os mecanismos das alterações morfológicas da perlita na Zona Termicamente Afetada (ZTA) em termos de transformações de fases e podem ser utilizados para sistematicamente orientar mudanças nos parâmetros do processo ou controlar a taxa de resfriamento de modo a obter melhores condições metalúrgicas/mecânicas. Ademais, os resultados dos modelos numéricos mostram como a adoção de ZTA estreita influencia nas taxas de resfriamento e no desenvolvimento de tensões residuais em regiões críticas do componente.

Abstract: Long rails, welded by the Flash-Butt Welding process present desirable characteristics concerning the dynamic behavior of the track, however flash-butt-welded joints are regions of structural and mechanical discontinuity where high residual stresses originate, and, consequently, premature-fatigue failures may take place. This paper employs dilatometric analysis to simulate the austenitic grain size effects on the postweld microstructural evolution. Finite Element Method (FEM) is used to carry out transient, physically non-linear thermo-mechanical analyses to evaluate the effects of the welding parameters on residual stresses. The results allow understanding the mechanisms associated with the morphological changes of the pearlite in the HAZ in terms of phase transformation and can be used to systematically guide changes in the process parameters or to control the cooling rate in order to obtain better metallurgical/mechanical conditions. In addition, from the results of the numerical models, it is demonstrated how the adoption of narrow HAZ influences cooling rates and the development of residual stresses in critical regions of the welded component.

This work presents the characterization of austenite decomposition kinetics in two steels during continuous cooling considering non-deformed austenite grains. Two different chemical concepts of steels were evaluated: low carbon - high manganese and a relatively new concept based on low carbon - low manganese - high niobium contents. Dilatometric experiments, microstructural characterization procedures and microhardness tests were carried out. Experimental and calculated CCT diagrams were plotted and the adapted JMAK model was applied aiming to predict the austenite decomposition kinetics. The low carbon - high manganese steel was the most sensitive to the applied cooling rates and, due to that, presented the higher grain refinement and hardness increasing after continuous cooling. These results highlight that the Mn content decreasing may promote a potential loss of grain refinement in procedures of continuous cooling where the structure recrystallization does not occur, as in some welding procedures or conventional heat treatments applied in the seamed pipe manufacturing process.

Resumo Aços IF são amplamente empregados na indústria automobilística. No decorrer das aplicações de soldagem, eles passam pela transformação de fase austenita (γ) → ferrita (α) que ocorre por nucleação e crescimento de grão e, em condições isotérmicas, é descrita pela equação JMAK. Todavia, as transformações de fases pós-soldagem acontecem a partir de resfriamento contínuo. Assim, o presente trabalho caracterizou a cinética de transformação γ → α e propôs um modelo empírico para prever as temperaturas críticas durante o resfriamento contínuo em zonas termicamente afetadas de três tipos de aços IF. Amostras dos aços foram submetidas a ensaios dilatométricos com diferentes taxas de resfriamento contínuo. Determinaram-se as temperaturas críticas de transformação de fase (γ→α) e obteve-se uma equação empírica que correlacionou a temperatura crítica com a taxa de resfriamento e que viabilizou a previsibilidade da cinética de transformação de fases. Processo de soldagem TIG mecanizado foi aplicado nos aços IF com monitoramento de ciclos térmicos e, em regiões da ZTA com condições de austenitização e taxa de resfriamento similares às utilizadas nos ensaios dilatométricos, verificou-se que a equação empírica obtida é uma alternativa viável para prever as temperaturas críticas e a microestrutura durante o resfriamento contínuo na ZTA destes materiais.

Abstract IF steels are widely used in the automotive industry. In the course of the welding applications, they undergo the transformation of austenite (γ) → ferrite (α) phase that occurs by nucleation and grain growth and, under isothermal conditions, is described by the JMAK equation. However, post-weld phase transformations occur under continuous cooling conditions. Thus, the present work characterized the transformation kinetics γ → α and proposed an empirical model to predict critical temperatures during continuous cooling in heat affected zones of three types of IF steels. Samples of the steels were submitted to dilatometric tests with different rates of continuous cooling. The critical phase transformation temperatures (γ → α) were determined and an empirical equation was obtained which correlated the critical temperature with the cooling rate, which enabled the predictability of phase transformation kinetics. Mechanized TIG process was applied to IF steels with thermal cycling monitoring and, in regions of the HAZ with austenitizing conditions and cooling rates similar to those used in the dilatometric tests, it was verified that the obtained empirical equation is a viable alternative to predict the critical temperatures and the microstructure during the continuous cooling in the HAZ of these steels.

Seamless steel pipes for application in the oil and gas industries are manufactured from quenched and tempered steel. Aiming to meet the required characteristics, it is necessary that the microstructure and the mechanical properties are homogeneous along the wall thickness of the pipes, which is even more critical for thick wall pipes. Considering the seamless steel pipe manufacturing process, any chemical segregation along the thickness could affect the phase transformation kinetics during heat treatments and, consequently, microstructure and mechanical properties. In this context, this pioneer work when evaluating the effect of the chemical homogeneity of a seamless pipe on the mechanical properties and phase transformations. The studied pipe was manufactured by a C-Mn steel designed for oil and gas industry applications. Two regions of the pipe wall were analyzed - a region close to the inner surface and another near the outer surface. The steel was subjected to quenching and tempering heat treatments. Scanning electron and optical microscopy techniques were used to characterize the resultant microstructures. Microhardness and Charpy impact tests were performed aiming to analyze the pipe mechanical behavior in the studied regions. In addition, dilatometric tests were performed in order to determine the continuous cooling transformation diagrams of these regions.

Resumo Trilhos longos, soldados pelo processo Flash Butt Welding (FBW), são a realidade das ferrovias brasileiras de média e alta carga por eixo. Embora apresentem características desejáveis do ponto de vista do comportamento dinâmico da via, as soldas são regiões de descontinuidade estrutural e mecânica onde se originam tensões residuais, e que estão associadas a falhas prematuras por fadiga. Simulações numéricas termomecânicas, fisicamente não-lineares, no domínio do tempo, pelo Método dos Elementos Finitos (MEF), foram empregadas para avaliar o desenvolvimento de tensões residuais originadas durante o processo de soldagem. Uma nova abordagem para a inclusão do aporte de calor envolvido no processo é proposta. Os resultados numéricos são comparados a medidas experimentais de tensões residuais superficiais e aspectos macrográficos das juntas, incluindo largura da Zona Termicamente Afetada (ZTA) e dados de taxas de resfriamento. Os resultados mostram boa correlação entre as análises numéricas e medidas experimentais de tensões residuais. Aspectos fundamentais relacionados ao desenvolvimento de tensões residuais são esclarecidos a partir da correlação entre análises numérica e experimental. Ademais, verifica-se que os modelos computacionais podem ser utilizados na previsão de pontos críticos para nucleação de trincas por fadiga e/ou avaliar efeitos de variáveis de processo sobre o campo de tensões residuais.

Abstract Long rails, welded by the Flash-Butt Welding (FBW) process, are the reality of the Brazilian railroads for medium and high axle loads. Although they present desirable characteristics concerning the dynamic behavior of the track, welded joints are regions of structural and mechanical discontinuity where high residual stresses originate, and, consequently, premature fatigue failures may take place. This paper employs the Finite Element Method (FEM) to carry out transient, physically non-linear thermo-mechanical analyses to evaluate residual stresses evolved in the welding process. A new approach is proposed to take into account the heat input involved in the process. The numerical results are compared to experimentally measured surface residual stresses, and to the macrographic joint aspects, including the HAZ width and cooling rate data. The results show a good correlation between the numerical and experimental measurements of residual stresses. Fundamental aspects related to the development of residual stresses are clarified, correlating numerical and experimental analyses. In addition, it is verified that the computational models can be used to predict critical crack nucleation points by fatigue, and/or to evaluate effects of process parameters on the residual stress field.

RESUMO Estudou-se o efeito da taxa de resfriamento sobre a cinética de formação da martensita e sua evolução microestrutural em um aço inoxidável ferrítico com 0,011 %C - 11,1 %Cr - 0,013 N, usando a técnica de dilatometria e a microscopia ótica. Amostras foram austenitizadas a 1000°C por um minuto, seguida de resfriamento sob várias taxas até a temperatura ambiente. A microestrutura obtida é composta, predominantemente, por martensita temperada com uma pequena fração volumétrica de ferrita, com valores de microdureza Vickers variando de 319±4 HV0.2 a 338±4 HV0.2, quando as taxas de resfriamento aumentam de 0,5 para 100 °C/s. Os resultados mostram que as temperaturas de início e fim de formação da martensita diminuem com o aumento da taxa de resfriamento. A taxa de transformação martensítica cresce abruptamente alcançando o valor máximo quando a fração de martensita atinge aproximadamente 42 %, e então, essa taxa diminui até zero quando a transformação da martensita chega ao fim. A taxa máxima da transformação martensítica cresce com o aumento da taxa de resfriamento, sendo 0,01 s-1 a 0,5 °C/s e 2,54 s-1 para 100 °C/s.

ABSTRACT The effect of the cooling rate on martensite formation kinetic and its microstructural evolution in a ferritic stainless steel with 0.011 %C - 11.1 %Cr - 0.013 N was studied, using the dilatometric technique and optical microscopy. Samples were austenitized at 1000°C during one minute, followed by cooling under various rates to room temperature. The microstructure consists predominantly composed of martensite with a small volumetric fraction of ferrite, and the values of Vickers microhardness vary from 319±4 HV0.2 to 338±4 HV0.2 when the cooling rates increase from 0.5 to 100 °C/s. The results show that the martensite start and finish temperatures decrease when the cooling rate increases. The martensitic transformation rate grows abruptly reaching the maximum value when the martensitic fraction is about 42 % and then it decreases to zero when the martensitic transformation comes to the end. The maximum rate of martensitic transformation grows with increase of cooling rate, being 0.01 s-1 to 0.5 °C/s and 2,54 s-1 to 100 °C/s.

This study aimed to assess the effect of casting speed and the addition of Al5%Ti1%B inoculant in the casted AA5052 aluminum alloy plate manufactured by the Direct Chill process. The focus of this work was to decrease the rejection index of rolled products due to the occurrence of superficial flaws on plates. These defects impact directly on the production costs and on the rolled product quality. The main cause of those flaws is associated with the billet porosity that is related with the excess of atomic hydrogen incorporated into the metallic bath and with the metal shrinkage during solidification. Four different cast conditions were industrially tested, combining two casting speeds and two inoculants amounts. The effect of those variables on the alloy mechanical properties and on their performance in rolling process was also assessed. It was observed that the higher the casting speed and the inoculant fraction, the more refined the microstructure and the lower the fraction and diameter of formed micropores. The increase of casting speed and the inoculant fraction improved the AA5052 alloy rolling performance. The application of these results in an industrial scale performed a decrease from 5.03% to 0.39% per month in the rejection index of rolled products.

The superficial coatings in micro-alloyed steel pipes has been a pointed way to decrease the corrosion problems in oil and gas industry. However, little emphasis has been given to the substrate. The effects of the deposition method on the steel microstructure and properties are still not well described. In this context, this work studied the effect of Ni superalloys clads on the phase transformations, microstructure and hardness of the heat-affected zone (HAZ) of an API steel. The underestimate of the HAZ might be dangerous, since, despite the coating good corrosion performance, the substrate HAZ may present a weak region, which may lead to an in-service coating tearing. In this work, Inconel 625 and Hastelloy C276 superalloys were clad on the steel surface by a laser deposition. Dilatometry, optical and scanning electron microscopy, and computational simulation were applied. The studied steel was originally constituted by tempered martensite. The austentizing temperature had a strong influence on the austenite grain size and on the steel CCT diagram. Due to that, the laser superalloy deposits promoted a complex HAZ, where grain growth occurred. A post-cladding heat treatment was proposed to homogenize the steel microstructure and to decrease the hardness gradient at the superalloy-steel interface.

Aiming to better understand the effects of heat treatment parameters on Ferrite-Austenite phase transformation in a 2304 duplex stainless steel different thermal cycles were applied to this steel in a quenching dilatometer. The obtained microstructures were characterized by optical microscopy, transmission electron microscopy and electron backscatter diffraction. It was noticed that the austenite formation mechanism is strongly dependent on initial ferritized state. If the initial structure is completely ferritized, the nitrogen supersaturated solid solution leads to chromium nitrides precipitation and the rate of austenite nucleation decreases. For higher cooling rates, the ferrite grain boundaries control the austenite nucleation rate. The higher the ferrite grain size, the lower the final austenite fraction. If the steel is cooled from a partial ferritized state, the ferrite-austenite phase boundaries work as austenite nucleation site and the austenite growth rate is favored due to the high interfacial energy and the austenitic structures becomes coarser.

Abstract The corrosion of C-Mn steels in the presence of hydrogen sulfide (H2S) represents a significant challenge to oil production and natural gas treatment facilities. The failure mechanism induced by hydrogen-induced cracking (HIC) in a Inconel 625 coating / C-Mn steel has not been extensively investigated in the past. In the present work, an API 5CT steel was coated with In625 alloy using laser cladding and the HIC resistance of different regions, such as the coating surface, the substrate and HAZ, were evaluated. SEM observations illustrated that all HIC cracks were formed at the hard HAZ after 96h of exposure. No HIC cracks were observed in the substrate and the In625 coating after the same exposure duration. Pitting was recorded in the substrate caused by non-metallic inclusion dissolving.