Nitrocarburizing is considered one of the most important thermochemical treatments for surface modification of metallic materials and involves the simultaneous diffusion of nitrogen and carbon onto the surface. Understanding and controlling the formation of the nitrocarburized layer have considerable industrial interest due to the improvements regarding wear, fatigue, and corrosion resistances. DIN 100Cr6 steel samples were treated by plasma nitrocarburizing for two hours, with two treatment temperatures (550 and 600°C) and four methane concentrations in the gas mixture composition (0, 1.0, 1.5, and 2.0%). SEM and XRD analyses, and wear resistance tests were used to characterize the samples. Results showed that the treatment temperature and atmosphere composition had considerable influence on the compound layer morphology. For nitrided samples the compound layer consists of γ'-Fe4N phase, and the presence of carbon in the gas mixture helps stabilize the ɛ-Fe2-3N phase. Higher CH4 concentration in the treatment atmosphere improve the sample superficial wear resistance.

Supermartensitic stainles steels (SMSS's) are a new generation of martensitic steels that have been increasingly used in oil and gas applications due to their adequate corrosion resistance and mechanical properties. In the present study, SMSS specimens (UNS S41425) were solution heat treated and air cooled followed by plasma nitriding and nitrocarburising at 400, 450 and 500°C for 5h. The produced layers were characterized by optical microscopy, microhardness testing, X-ray diffraction and corrosion testing in NaCl 3.5% solution. Surface alloying with nitrogen or both nitrogen and carbon results in increased surface hardness and homogeneous layers in which layer thickness increases with temperature. However, plasma nitriding yields a slightly thicker case than nitrocarburising. X-ray diffraction indicates very broad and overlapped peaks for the treatments conducted at 400°C. Increasing treatment temperature appears to result in the formation of chromium nitrides and iron nitrides and carbides, depending on the treatment. It was also found that treatment temperature drastically affects the corrosion response of the steel. The untreated steel presented a pitting potential close to 250mV. Plasma nitriding at 400°C was the only condition in which significant improvement of corrosion is observed. For plasma nitriding and nitrocarburising at 450 and 500°C, some pitting was detected.

Samples of ductile cast irons alloyed with Cu, Cu-Ni and Cu-Ni-Mo were austempered, borided and boro-austempered and characterized for hardness and micro-adhesive wear behavior. The kinetics of layer formation was also studied. The boriding method used was molten borax bath, in periods of 2 and 4 hours at temperatures of 850, 900 and 950 ºC. The direct austempering treatment was performed immediately following the boriding treatment (from 850, 900 and 950 ºC) using molten salt baths at temperatures of 240, 300 and 360 ºC for 4 hours (boro-austempering treatment). For comparative purposes, the conventional austempering treatment was also conducted. Optical microscopy, scanning electron microscopy, Brinell hardness measurements (on the substrate) and Vickers (on the layers) were performed, along with micro-adhesive wear tests. The boriding treatment resulted in the formation of high hardness layers, in the range of 1450 to 1750 HV, with high wear resistance. The wear resistance of borided and boro-austempered samples were increased by 40 times when compared to as cast or austempered samples, indicating the high efficiency of this type of treatment in increasing the wear resistance of this material.

Austenitic-ferritic stainless steels containing 0.2% and 0.5% niobium were evaluated with respect to the microstructures, microhardness, pitting potential resistance, electrochemical impedance and wearing tests. Niobium is an alphagenic element and has a great influence on phase transformation of duplex stainless steels. In the present investigation, the samples were annealed at 1050 ºC and aged at 850 ºC to promote the formation of sigma phase. The pitting potential resistance and electrochemical impedance were evaluated in 3.5 % sodium chloride solution. The wear coefficients were calculated by micro-wear tests conducted using a fixed ball machine and aluminum oxide as abrasive. The results show that the niobium content lead to increase on Laves phase formation. This phase, in association with the sigma phase, causes a significant increase in the hardness and wear resistance with a decrease on corrosion resistance of the austenitic-ferritic stainless steels.

Os aços inoxidáveis austeno-ferríticos apresentam melhor combinação de propriedades mecânicas e resistência à corrosão que os inoxidáveis austeníticos e ferríticos. A microestrutura desses aços depende da composição química e tratamentos térmicos. Nos aços inoxidáveis austeno-ferríticos, a solidificação inicia a 1450ºC com a formação de ferrita, austenita a 1300ºC e fase sigma na faixa de 600 a 950ºC. Esta última compromete a resistência à corrosão e a tenacidade desses aços. Conforme a literatura, o nióbio tem grande influência na transformação de fases dos aços inoxidáveis austeno-ferríticos. Essa pesquisa avaliou o efeito do nióbio na microestrutura, dureza e resistência de transferência de carga de um aço inoxidável austeno-ferrítico. As amostras foram solubilizadas a 1050ºC e envelhecidas a 850ºC, para promover a formação da fase sigma. Os ensaios de corrosão foram realizados em meio de saliva artificial. Os resultados mostram que a adição de 0.5% Nb no aço provoca a formação da fase de Laves. Essa fase, associada à fase sigma, aumenta a dureza do aço, reduzindo, porém, os valores da resistência de transferência de carga.

The austenitic-ferritic stainless steels present a better combination of mechanical properties and stress corrosion resistance than the ferritic or austenitic ones. The microstructures of these steels depend on the chemical compositions and heat treatments. In these steels, solidification starts at about 1450ºC with the formation of ferrite, austenite at about 1300ºC and sigma phase in the range of 600 to 950ºC.The latter undertakes the corrosion resistance and the toughness of these steels. According to literature, niobium has a great influence in the transformation phase of austenitic-ferritic stainless steels. This study evaluated the effect of niobium in the microstructure, microhardness and charge transfer resistance of one austenitic-ferritic stainless steel. The samples were annealed at 1050ºC and aged at 850ºC to promote formation of the sigma phase. The corrosion testes were carried out in artificial saliva solution. The addition of 0.5% Nb in the steel led to the formation of the Laves phase.This phase, associated with the sigma phase, increases the hardness of the steel, although with a reduction in the values of the charge transfer resistance.

A nitretação por plasma consiste num tratamento efetivo para o aumento das durezas superficiais dos aços inoxidáveis, podendo ser realizada em temperaturas inferiores às usadas nos processos convencionais, evitando-se assim, a formação de nitretos de cromo, que prejudicariam a resistência à corrosão do material. Os aços inoxidáveis endurecíveis por precipitação foram desenvolvidos após a Segunda Guerra Mundial em decorrência das necessidades da indústria aeroespacial, que necessitava de materiais resistentes à corrosão em temperaturas mais elevadas. Nesse trabalho, foi produzido um aço inoxidável endurecível por precipitação com uso de Nb e um aço comercial PH 13-8Mo endurecível por precipitados à base de Cu, para fins de comparação em termos de produção de camadas nitretadas e de resistências ao desgaste abrasivo. O Nb mostrou-se um eficiente formador de precipitados endurecedores do aço, com o pico de dureza ocorrendo em poucos minutos de tratamento. Nos dois aços, obtiveram-se camadas nitretadas com boa uniformidade. A resistência ao desgaste do aço com Nb nitretado foi muito superior à do aço PH 13-8Mo também nitretado.

Plasma nitriding is an effective treatment to increase the surface hardness of stainless steel and may be performed in temperatures below those used in conventional nitriding procedures, thereby avoiding the formation of chromium nitrides that would deteriorate the corrosion resistance of the material. The precipitation hardened stainless steels were developed after the Second World War as a result of the needs of the aerospace industry, which needed materials resistant to corrosion at higher temperatures. In this research, a precipitation hardening Nb stainless steel and a PH 13-8Mo precipitation hardened stainless steels with Cu were produced, for purposes of comparison in terms of the production of nitrided layers and abrasive wear resistances. Nb proved to be an effective hardening precipitate former, with the hardness peak occurring within minutes of treatment. In both steels, nitrided layers with good uniformity were obtained. The wear resistance of the nitrided Nb steel was much higher than that presented by the PH 13-8Mo nitrided steel.

Entre as técnicas utilizadas no melhoramento de desempenho de materiais, a deposição na superfície de componentes pode ser eficaz para recuperação de elementos desgastados. Os processos de aspersão térmica, devido a sua versatilidade, quanto à aplicação, tipos de camadas e espessuras, constituem-se numa forma bastante adequada na obtenção de camadas de elevada dureza para proteção ou reparo do componente base, sendo possível revestir substratos metálicos com polímeros, metais ou cerâmicas. Entre esses processos, destacam-se: HVOF (High Velocity Oxygen Fuel), Arc-spray (arco elétrico) e Flame-spray (chama-pó). A seleção de um aço inoxidável, para aplicação, envolve algumas considerações como resistência à corrosão da liga, propriedades mecânicas, fabricabilidade e custo. Nesse trabalho foram usadas amostras do aço AISI 1045, revestidas, com aço inoxidável AISI 420, por meio das técnicas de Arc-Spray, HVOF e Flame-Spray, para o estudo comparativo de suas resistências à corrosão em água do mar, visando à produção de peças de menor custo, em comparação com peças maciças desse aço. Os melhores desempenhos em termos de dureza, porosidade e resistência à corrosão ocorreram na seguinte seqüência crescente: Flame-Spray, Arc-Spray, e HVOF.

Among the techniques used to improve materials performance, deposition on the surface of components is a proper way of recovering worn elements. Thermal spraying processes were developed during the last few years and they are a very suitable method to obtain layers with high hardness for protecting or repairing the base component. Employing these processes, it is possible to overlay metallic substrates with polymers, metals and ceramics. Among these processes are: HVOF, Arc-Spray and Flame-Spray. The selection of a particular type of stainless steel for an application involves some considerations, as the corrosion resistance of the alloy, mechanical properties, manufacture feasibility and cost. In this work, used were samples of AISI 1045 steel, coated with stainless steel AISI 420, using the techniques of Arc-Spray, HVOF and Flame-Spray for the comparative study of their corrosion resistance in sea water, aimed at producing low-cost alternative pieces, compared with massive pieces of steel. The best performances in terms of hardness, porosity levels and corrosion resistance of the layers occurred in the following sequence growing: Flame-Spray, Arc-Spray, and HVOF.

Os aços inoxidáveis endurecíveis por precipitação foram desenvolvidos a partir de 1945, em decorrência das necessidades da indústria aeroespacial em termos da disponibilidade de aços com resistência mecânica e à corrosão, em temperaturas mais elevadas, superiores às dos aços inoxidáveis tradicionais, aliadas à facilidade de soldagem. Esses aços apresentam microestruturas martensíticas do tipo substitucional, endurecidas posteriormente por precipitados. Nesse trabalho, foram produzidos dois aços com composições alternativas usando o Nb como formador de precipitados, bem como um aço PH13-8Mo para efeito de comparação, em termos de resistências mecânica e à corrosão. O Aço 1 apresentou resistência à corrosão semelhante à do aço PH13-8Mo e o Aço 2 apresentou resistência mecânica próxima à do aço PH13-8Mo.

Precipitate-hardened stainless steel was developed in 1945 as a consequence of the aerospace industry’s need for a high-strength steel that would be resistant to corrosion at high temperatures, and easily welded exceeding the properties of conventional stainless steel. This steel possesses substitutional martensitic microstructures that can afterwards be hardened by precipitation. For this research, two types of steel with alternative compositions were produced by using Nb as a precipitate producer, and PH13-8Mo steel for comparison purposes in terms of mechanical and corrosive resistance. Steel 1 showed corrosive resistance similar to PH13-8Mo and Steel 2 presented mechanical resistance close to that of PH13-8Mo.

Os aços inoxidáveis supermartensíticos (SMSS) são usados em ambientes agressivos devido à sua boa soldabilidade, boas propriedades mecânicas em temperaturas elevadas e superior resistência à corrosão sob tensão. Aplicações na exploração de petróleo demandam superior combinação de propriedades e os aços inoxidáveis duplex e superduplex têm sido aplicados nessa área, a despeito de seus custos elevados. Os SMSS consistem numa alternativa técnica e econômica ao uso daqueles aços. Nesse trabalho, adições de Nb e Ti foram realizadas com o intuito de minimizar o efeito de sensitização, promover o refino de grãos e foram estudados os aspectos microestruturais e a resistência à corrosão por pites em água do mar. A formação e a evolução dos pites foram acompanhadas por ensaios de corrosão, microscopia óptica e eletrônica, focalizando suas morfologias. O aço com Ti apresentou o melhor desempenho quanto à corrosão, com o maior potencial de corrosão e menor potencial de pite entre os aços em estudo. O aço com Nb, apesar de apresentar potencial de corrosão superior ao do aço sem adição, teve um potencial de pite inferior ao do mesmo.

Supermartensitic stainless steel (SMSS) is increasingly used in harsh environments due to its good weldability and mechanical properties at higher temperatures and high resistance to corrosion under stress. Applications in oil exploration demand a superior combination of properties and duplex and superduplex stainless steels have been widely applied in this area, despite their high costs. SMSS provides a technical and economical alternative for these steels. In this research, additions of Nb and Ti were made in order to minimize the sensitization effect and to promote grain refinement, studying the microstructural aspects and the pitting corrosion resistance in seawater. Pitting formation and evolution were accompanied by corrosion testing, optical and electronic microscopy. The Ti alloyed steel showed the best corrosion performance, with the greatest corrosion potential and the lowest pitting potential. The steel with Nb addition presented a higher corrosion potential than that of the steel without additions but had a lower pitting potential.

A dureza e, conseqüentemente, a resistência ao desgaste dos aços inoxidáveis austeníticos podem ser acentuadamente aumentadas, sem perdas na resistência à corrosão, com a produção de camadas superficiais pelo tratamento de nitrocementação por plasma. Nesse trabalho, foram nitrocementadas por plasma, na temperatura de 450°C, amostras do aço AISI 316L. As camadas obtidas foram caracterizadas por meio de ensaios micrográficos, de microdureza e de microdesgaste. A camada produzida constituiu-se de duas regiões, sendo a mais externa constituída de nitrocarbonetos de cromo e, abaixo dela, verificou-se a presença de austenita expandida, rica em nitrogênio, com dureza próxima a 850HV. A espessura média total da camada foi de, aproximadamente, 40µm. Sua resistência ao desgaste foi muito superior à do substrato.

Hardness and consequently wear resistance of austenitic stainless steel can be highly increased, without losing corrosion resistance, by plasma nitrocarburizing surface treatment. In this re-search, an AISI 316L stainless steel was plasma nitrocarburized at 450°C, and the obtained layers were characterized by optical microscopy, microhardness and micro-wear tests. It was verified that the layer is composed of chromium nitrides precipitates and beneath them, a nitrogen rich expanded austenite, with hardness around 850HV. The total average thickness of the layer was about 40µm and presented good uniformity. The wear resistance of the layer was much higher than that of the substrate.