MAURILIO PEREIRA GOMES

MAURILIO PEREIRA GOMES

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Study of recycling process viability of zirconium alloys chips for melting in VAR furnace
2017 - REIS, L.A.M.; ALENCAR, M.; GOMES, M.P.; PEREIRA, L.A.T.; MUCSI, C.S.; ROSSI, J.L.
Cavacos de ligas de zircônio (M5, Zirlo, Zircaloy) são gerados em elevadas quantidades na confecção de tubos e tampões das varetas que compõem o elemento combustível de reatores de potência refrigerados a água pressurizada (PWR). Essas são ligas importadas e por isso é mostrado interesse pela indústria de reciclagem na sua reutilização. Este trabalho apresenta os estudos de um processo de reciclagem e a obtenção de eletrodos prensados para serem fundidos em um forno VAR (Vacuum Arc Remelting). O processo se inicia com uma separação magnética, lavagem do fluido de corte que é solúvel em água, utilização de um desengraxante industrial, seguido por um enxágue com fluxo contínuo de água em alta pressão e secagem por fluxo de ar quente. Para a obtenção de eletrodos, os cavacos foram prensados em uma matriz de seção quadrada 40x40 mm² com 500 mm de comprimento, resultando num eletrodo com 20% da densidade aparente da liga. A fusão foi feita um forno VAR de laboratório no CCTM-IPEN, gerando um lingote maciço de 0,8 kg. A fusão dos cavacos é possível e viável em um forno VAR o que reduz em até 40 vezes o volume de armazenamento desse material.
Microstructural characterization of air quenched valve seat inserts obtained with AISI D2 tool steel
2017 - GOMES, M.P.; SANTOS, I.P.; COUTO, C.P.; BETINI, E.G.; COLOSIO, M.A.; ROSSI, J.L.
The obtention of valve seat insert (VSI) by powder metallurgy using a mixture of iron powder and tool steel is fulfilling the requirements for substitution of cobalt and lead in commercial parts, aiming cost reduction and avoid the lead toxicity. The aim of this work consisted of evaluate the influence of heat treatment on VSI obtained with AISI D2 tool steel powder. The AISI D2 tool steel powder was mixed with iron powder and additives such as manganese sulphide, zinc stearate, graphite and carbides. The heat treatment of the VSI consisted of air quenching followed by double tempering it at 500 °C. The microstructural characterization was performed using scanning electron microscopy and energy dispersive spectroscopy.
Influence of air quenching on apparent hardness of valve seat inserts obtained with AISI M2 high-speed steel powder
2017 - GOMES, M.P.; SANTOS, I.P.; REIS, L.A.M.; CIONE, F.C.; COLOSIO, M.A.; ROSSI, J.L.
The aim of this work consisted of evaluate the influence of heat treatment on sintered valve seat inserts (VSI) obtained with the AISI M2 high-speed steel powder. The AISI M2 high-speed steel powder was mixed with iron powder and additives such as manganese sulphide, zinc stearate, graphite and carbides. The heat treatment of the VSI consisted of air quenching followed by double tempering it in seven different equidistant temperatures, from 100 °C until 700 °C. The mechanical property was measured regarding the VSI apparent hardness. The results indicated that the VSI obtained with the AISI M2 high-speed steel powders mixtures showed the best results regarding its apparent hardness after air quenching and double tempering it at 600 °C.
Effect of the cooling rates on heat-affected zone of UNS S32304 duplex stainless steel welded by pulsed GTAW process
2017 - BETINI, E.G.; GOMES, M.P.; REIS, L.A.; MUCSI, C.S.; ALENCAR, M.C.; ORLANDO, M.T.D.; LUZ, T.S.; AVETTAND-FENOEL, M-N.; ROSSI, J.L.
Two thin plates of UNS 32304 of duplex stainless steel were joined by pulsed gas tungsten arc welding (GTAW) using a mixture 98% of argon plus 2% of nitrogen as shielding gas or pure argon as purging gas at the bottom of the plate without filler metal. The temperature profile close and away from the weld pool was measured using K type (Ni-Cr) thermocouples, connected to a digital data acquisition system. The thermal cycles was recorded in the heat-affected zone (HAZ) at a distance in between 1 and 3 mm from the joint line. The cooling rate and holding time were studied with respect to the used purging gas. Experimental thermal profiles are in good agreement with literature values. The joints welded without any purging gas revealed high peak temperature and cooling rates. The present investigation showed that temperature peaks are comprised in the phase transformation temperature ranges for the welded duplex stainless steel.
Characterization of sintered valve seat inserts obtained with AISI M2 high-speed steel after air quenching
2017 - GOMES, MAURILIO P.; SANTOS, IGOR P. dos; REIS, LUIS A.M. dos; COUTO, CAMILA P.; MUCSI, CRISTIANO S.; COLOSIO, MARCO A.; ROSSI, JESUALDO L.
The aim of this work was to heat treat and characterize sintered valve seat inserts (VSI). The powder metallurgy route was the only way found to substitute cobalt and lead, used in the VSI original alloy, due to their high cost and toxicological effect, respectively. The studied VSI was obtained with AISI M2 high-speed steel powder mixed with iron powder and other additives such as manganese sulphide, graphite, zinc stearate, carbides and copper, which was added by metallic infiltration. All the VSI were air quenched and double tempered, for one hour each, at seven different equidistantly temperatures, ranging from 100 °C up to 700 °C. The physical and mechanical properties were evaluated by means of the VSI apparent density, apparent hardness and crush radial strength. The chemical composition was determined through gas analysis, for the light elements such as carbon and sulfur, and energy dispersive X-ray fluorescence spectrometry for other elements. Microstructural characterization was performed with the support of scanning electron microscopy and energy dispersive spectroscopy. Regarding the VSI final application, the best results were achieved with the inserts air quenched and double tempered at 600 °C.
Characterization of PHS coating layer using GDOES technique
2017 - COUTO, C.P.; GOMES, M.P.; COSTA, P.D.O.; COLOSIO, M.A.; POLITANO, R.; ROSSI, J.L.
O objetivo do estudo foi analisar o perfil de composição química do revestimento Al-Si em aços PHS, por meio da técnica de GDOES. Devido às elevadas temperatura no processo de estampagem a quente ocorre à difusão dos elementos do revestimento e do substrato. Os resultados revelaram que na amostra como recebida, o revestimento apresenta grandes porcentagens de alumínio, silício e oxigênio, que se difundem e diminuem de concentração em direção ao substrato, enquanto que a porcentagem de ferro aumenta. Os resultados das amostras tratadas termicamente em laboratório e do produto final são muito similares, o que indica que o tratamento térmico realizado em laboratório simula corretamente o processo térmico da estampagem industrial. O revestimento é formado por alumínio e ferro, que variam uniformemente até atingir o substrato onde a porcentagem de alumínio diminui em relação à de ferro. A camada revestida também é composta por oxigênio e silício que se difundem em direção ao substrato, onde a porcentagem de oxigênio diminui gradativamente e a de silício não se altera. Os resultados de GDOES mostraram as alterações que ocorrem na camada revestida do aço PHS, e evidenciaram que após o processo de estampagem a quente podem ser formados óxidos e fases compostas por Al-Fe ou Al-Fe-Si.
Study on welding thermal cycle and residual stress of UNS S32304 duplex stainless steel selected as external shield for a transport packaging of Mo-99
2019 - BETINI, E.G.; GOMES, M.P.; MILAGRE, M.X.; MACHADO, C.S.C.; REIS, L.A.M.; MUCSI, C.S.; ORLANDO, M.T.D.; LUZ, T.S.; MARTINEZ, L.G.; ROSSI, J.L.
Thin plates of duplex stainless steel UNS S32304 were welded using the pulsed gas tungsten arc GTAW process (butt joint) without filler addition. The used shielding gas was pure argon and 98% argon plus 2% of nitrogen. The thermal cycles were acquired during welding, in regions near the melting pool. This alloy is candidate for the external clad of a cask for the transport of high activity radiopharmaceuticals substances. For the residual stress measurements in austenite phase an X-ray diffractometer was used in a Bragg-Brentano geometry with CuKα radiation (λ= 0.154 nm) and for ferrite phase was used a pseudo-parallel geometry with CrKα radiation (λ= 0.2291nm). The results of residual stress using sin2 methodology showed that the influence of the high welding temperature leads to compressive stresses for both phases of the duplex steels mainly in the heat-affected zone. It was observed a high temperature peak and an increase of the mean residual stress after addition of ni-trogen to the argon shielding gas.
Valve seat insert: air quenching and characterization of components obtained with AISI M3:2 high-speed steel
2018 - GOMES, M.P.; SANTOS, I.P.; REIS, L.A.M.; COUTO, C.P.; BETINI, E.G.; MUCSI, C.S.; COLOSIO, M.A.; ROSSI, J.L.
The development of components ecologically correct is something more and more necessary. The first developement of valve seat inserts (VSI) take in account the use of cobalt and lead in its chemical composition. Such elements are avoided in the current applications due to its high cost and toxicological effects, respectively. In the present work was used VSI developed with a new chemical composition. The aim of this work were to air quench and characterize such components. The studied VSI were obtained with AISI M3:2 high-speed steel admixed with iron powder and another additives such as manganese sulphide, graphite, zinc stearate and carbides. All the air quenched VSI were double tempered, for one hour each, at seven equidistant temperature from 100 °C until 700 °C. The air quenched components had its mechanical and physical properties determined by means of its apparent density, apparent hardness and crush radial strength. The chemical composition was measured through the gases analyses and energy dispersive X-ray fluorescence spectrometry techniques. Microstructural and phase characterizations were performed with the support of optical microscopy, scanning electron microscopy and energy dispersive spectroscopy. Regarding the VSI required properties, the best results were obtained with the components air quenched and double tempered at 600 °C.
Recycling process viability from zirconium alloys scraps of lathe melted in the vacuum arc remelting (VAR) furnace
2018 - REIS, L.A.M.; ALENCAR, M.C.; GOMES, M.P.; PEREIRA, L.A.T.; BARBOSA, L.P.; MUCSI, C.S.; ROSSI, J.L.
Pressurized water reactors (PWR) commonly use U235 enriched uranium dioxide pellets as a nuclear fuel, these are assembled and cladded in zirconium alloy (M5, Zirlo, Zircaloy) tubes and end caps. During the machining of these components, large amounts of turning lathe chips are generated which are contaminated with cutting fluid. Its storage presents safety and environmental risks due to its pyrophoric and reactive nature. Recycling industry has shown interest in its recycling due to its strategic importance of these scraps. This paper presents the steps on the recycling processes and the results for the search of an efficient way on the cleaning, quality control, manufacturing, and melting of electrodes for Vacuum Arc Remelting (VAR) furnace. The process starts with cutting oil washout and this step consists of a water dissolution followed by a degreasing process, the water rinse by continuous flow of water and finally drying in hot air. Process evaluation was first made by means the X-ray fluorescence tests in order to define the quality of the scraps that after washing were pressed in 20 mm diameter briquettes, melted and subjected to such analysis. The next step consists in the pressing with a die square section with 40 mm2 and 500 mm long, producing an electrode with 20% of the Zircaloy bulk density. The electrode was melted in a laboratory scale VAR furnace located at the CCTM – IPEN producing a 0.8 kg ingot. The microstructural and macro structural characterization is being done by analyzes performed in the optical microscope and scanning electron microscope (from portuguese Microscópio Eletronico de Varredura - MEV). Gas analyzes were carried out with the intention of evaluating possible gases resulting from the melting and evaluating their influence. X-ray diffraction analyzes were also performed to identify the phases present in the material after the melting process The authors conclude that the samples obtained from the fuel element industry can be melting in a VAR furnace reducing 40 times the storage volume, however, it is necessary to remelt the ingots by correcting their composition intended for reuse.
Effect of nitrogen addition to shielding gas on cooling rates and microstructure of thin plates of duplex stainless steel welded by pulsed GTAW process
2018 - BETINI, E.G.; GOMES, M.P.; MUCSI, C.S.; ORLANDO, M.T.; LUZ, T.S.; AVETTAND-FENOEL, M.; ROSSI, J.L.
The content of nitrogen to shielding gas and their effects on temperature distributions of the heat-affected zone of thin plates of duplex stainless steel during the pulsed GTAW process has been studied here. The duplex stainless steels have many features due to unique structural combination of austenite and ferrite grains. The phase balance can be easily altered to a mostly ferritic microstructures, depending on the welding parameters like shielding gas used. Microstructural examination showed that the austenite phase in the weld increases with the presence of nitrogen in the shielding gas. The additional nitrogen promoted the primary austenite formation and slightly increased the microhardness of the solidified zone. Microhardness mapping and metallographic imaging presented information about microstructures, confirming the formation of secondary phases and microstructure sensitization during thermal cycle in the temperature range 850-950°C. Two plates were welded using pure argon and pure argon plus 2% of nitrogen as shielding gas. The thermal profile had shown that N2-supplemented shielding gas lead to high peaks of temperature using similar welding parameters. The columnar and equiaxied ferrite grain size of solidified fusion zone was studied. Ferrite phase increased from 53 % in base metal to 78% to pure Ar and 63% using Ar+2%N2 as shielding gas. Control of ferrite in the welds is essential mainly to improve corrosion resistance.