Short Summary on Materials Testing and Analysis

Transcription

1 Short Summary on Matrials Tsting and Analysis Parts that wr analyzd Stl parts Worm with garing Bowl Spindl Hat tratabl stl C45 Hat tratabl stl C45 Polymr parts Sal Rings Rctangular Rings O-Rings Polyamid PA66 Nitril rubbr compound NRC Nitril rubbr compound NRC Masurmnts prformd during th study componnts Worms (C45) Parts no Bowl Spindls (C45) Parts no Sal Rings (PA66) Parts no Rctangular Rings (NRC) Parts no /02/ O-Rings (NRC) Parts no no. of sampls gomtrical - baring sats - garing - baring sats - con position - diamtr - hight / width (uppr and lowr fac) - diamtr - width - diamtr - width analyzd proprtis / masurmnts - hardnss / lastic indntation modulus - hardnss / lastic indntation modulus - hardnss mchanical - hardnss - tnsil strngth - hardnss - tnsil strngth othr - chmical analysis - mtallography - chmical analysis - mtallography - thrmal analysis - microscopy - optical comparison - analysis xtractabl lmnts - spctroscopy - thrmal analysis - optical comparison - optical comparison TTI GmbH an dr Univrsität Stuttgart Comparativ Study and Evaluation of Spar Parts for Sparators in Naval Application Projct Rport for Chifmar s.r.l., Gnova, Italy pag 1

2 Stl Componnts: Worm with Garing (part no ) Dsign sktch of Chifmar worm componnt: Gomtrical analysis of: quality of th garing Gar masuring cntr dimnsional and positional tolrancs of th baring sats 3D-coordinat masurmnt machin Gar masuring cntr: rotatabl mounting dvic and masuring had TTI GmbH an dr Univrsität Stuttgart Position of componnt coordinat systms for worm and bowl spindl and planning of analysis of th dimnsional and positional tolrancs Comparativ Study and Evaluation of Spar Parts for Sparators in Naval Application Projct Rport for Chifmar s.r.l., Gnova, Italy pag 2

3 Quality of th Worm Garing (Profil and Trac Analysis) Masurmnt rport of th Chifmar garing TTI GmbH an dr Univrsität Stuttgart Masurmnt rport of th Alfa Laval garing Comparativ Study and Evaluation of Spar Parts for Sparators in Naval Application Projct Rport for Chifmar s.r.l., Gnova, Italy pag 3

4 Mtallography of th Worm Garing Chifmar gar tooth, Ovrviw Alfa Laval gar tooth, Ovrviw Chifmar gar tooth, Cor matrial Alfa Laval gar tooth, Cor matrial grain siz of Chifmar matrial is slightly largr, parlit is finr for Alfa Laval matrial mchanical proprtis will b poorr in small xtnt for Chifmar componnts this ffct is mainly for th nar-surfac rgion larg diffrnc in parlit structur for matrial in th componnts cor suggsts vry slow cooling of th Chifmar matrial will b improvd by hat tratmnt of componnt aftr machining Light optical micrographs of garing tth, Chifmar and Alfa Laval worms Lft: ovrviw of th microstructur Right: matrial in th cntr of th gar tth with highr magnification TTI GmbH an drunivrsität Stuttgart Comparativ Study and Evaluation of Spar Parts for Sparators in Naval Application Projct Rport for Chifmar s.r.l., Gnova, Italy pag 4

5 Microstructural Analysis of th Worm Baring Sats (Mtallography) Location of mtallographic prparations: sat A garing Chifmar, baring sat A, surfac sat B Alfa Laval, baring sat A, surfac analyzd positions: garing and baring sats location of th mtallographic prparations Chifmar, baring sat A, cor Alfa Laval, baring sat A, cor TTI GmbH an drunivrsität Stuttgart grain sizs ar comparabl diffrncs ar low btwn surfac and cor matrial Comparativ Study and Evaluation of Spar Parts for Sparators in Naval Application Projct Rport for Chifmar s.r.l., Gnova, Italy pag 5

6 Hardnss Analysis by Vickrs Indntation on Worm Componnts Principl of th indntation tst mthod for hardnss masurmnt (Martns hardnss): α = 136 Vickrs hardnss HV W-C H-A W-AL-A W-C H-B W-AL-B dpth from surfac (µm) Chifmar worm garing tooth tip Alfa Laval worm garing tooth tip Vickrs hardnss/dpth profils for baring sats Tabl: Surfac Vickrs hardnss of baring sats manufacturr baring sat A baring sat B Chifmar 205 HV HV Light optical microscopis of th indntations for Vickrs hardnss/dpth profil analysis on worm garing tooth tips Tabl: Vickrs hardnss, avrag valus ovr th masuring dpth for garing tth manufacturr tooth tip tooth flank tooth bas Chifmar HV HV HV Alfa Laval HV HV HV Alfa Laval 292 HV HV baring sats: ovrall comparabl hardnss valus, but highr surfac hardnss for Alfa Laval matrial can b improvd by surfac hat tratmnt garing: sam hardnss rang; gradint for Chifmar matrial from tooth tip to bas. TTI GmbH an dr Univrsität Stuttgart Comparativ Study and Evaluation of Spar Parts for Sparators in Naval Application Projct Rport for Chifmar s.r.l., Gnova, Italy pag 6

7 Dsign sktch Chifmar spindl componnt: Stl Componnts: Bowl Spindl (part no ) Pos. 1 sat A Pos. 3 analyzd positions: con and baring sats location of th mtallographic prparations sat B Pos. 4 Gomtrical analysis of: dimnsional and positional tolrancs of th baring sats and of th con 3D-coordinat masurmnt machin Rsults: mor accuracy for Chifmar spindl xcpt for th con position asy to fix problm Furthr analysis: matrial analysis microscopy hardnss masurmnt (Vickrs hardnss and lastic indntation modulus) chmical analysis (EBMA* mthod) Location of mtallographic prparations on spindl componnts TTI GmbH an dr Univrsität Stuttgart * EBMA: Elctron Bam Microprob Analysis Comparativ Study and Evaluation of Spar Parts for Sparators in Naval Application Projct Rport for Chifmar s.r.l., Gnova, Italy pag 7

8 Main Rsults of th Study: Stl Componnts C45 Worm Componnts: Dimnsional and Positional Tolrancs Matrials Proprtis Garing: Bttr tolrancs and quality (tooth profils and flank shaps as wll as gar pitchs) for Chifmar than Alfa Laval, but finishing of th dgs could b improvd Baring sats: positional tolrancs wr good for all parts Baring sats: dimnsional tolrancs hav to b improvd for Chifmar parts by bttr machining accuracy Matrial: hat tratabl stl for Chifmar and Alfa Laval with no rmarkabl diffrncs (Alfa Laval matrial could b C60, but this is not sur; Chifmar matrial is C45) Hat tratmnt: was not don for both manufacturrs; howvr, a hat tratmnt procss would improv th mchanical proprtis of th garing and th baring sats Mchanical proprtis: similar for th two manufacturrs; could asily b improvd at critical rgions (baring sats) by hat tratmnt lik annaling or surfac hardning C45 Spindl Componnts: Dimnsional and Positional Tolrancs Matrials Proprtis Highr accuracy (in gnral) for th Chifmar componnt Th con of th spindl has to b improvd by bttr accuracy and manufacturing mtrology during machining Matrial: similar matrial for Chifmar worm and spindl componnt (C45), whil Alfa Laval matrial could b lowr alloyd (.g. C40) No hat tratmnt of th matrials for both manufacturrs and no diffrncs in microstructurs Hardnss of th baring sats is slightly highr for Alfa Laval componnts Hat tratmnt of baring sats could improv th mchanical proprtis in a larg xtnt TTI GmbH an dr Univrsität Stuttgart Comparativ Study and Evaluation of Spar Parts for Sparators in Naval Application Projct Rport for Chifmar s.r.l., Gnova, Italy pag 8

9 Matrial Analysis for Sal Rings PA66 sal rings, rsults of th DSC analysis during hating ^ndo Intgral 537,45 mj Intgral 594,52 mj normalis. 68,30 Jg^-1 normalis. 66,67 Jg^-1 Pak 264,67 C Pak 263,64 C Intgral 528,97 mj normalis. 66,86 Jg^-1 Pak 263,07 C 2 Wg^-1 Prob: M S-AL, , 7,8690 mg Prob: M S-AL, , 7,9120 mg Prob: M S-AL, , 8,9170 mg Prob: M S-CH, 71440, 9,5870 mg Prob: M S-CH, , 9,7240 mg Prob: M S-CH, , 8,6600 mg Intgral 668,16 mj normalis. 69,69 Jg^-1 Pak 263,75 C Intgral 665,88 mj normalis. 68,48 Jg^-1 Pak 263,92 C Intgral 598,58 mj normalis. 69,12 Jg^-1 Pak 264,41 C C Thrmal analysis with th DSC mthod (diffrntial scanning calorimtry): matrial was idntifid as polyamid 66 for Chifmar and Alfa Laval (sam mlting tmpraturs) small diffrncs in mlting nthalpy and crystallization tmpratur thr ar diffrncs in th composition or structur (cross linking) of th final polymrs thrmal durability slightly highr for Chifmar matrial TTI GmbH an dr Univrsität Stuttgart Comparativ Study and Evaluation of Spar Parts for Sparators in Naval Application Projct Rport for Chifmar s.r.l., Gnova, Italy pag 9

10 Polymr Componnts: Rctangular Rings and O-Rings Parts no /02/003, , , (rctangular rings) and (o-rings) Dsign sktch of Chifmar rctangular ring: Schmatic stup of Shor A hardnss tsts on NRC rctangular rings: F Gomtrical analysis of: diamtr of th rings patntd optical masuring dvic cross sction hight and width masurmnt with lasr scan micromtr Furthr analyss: mchanical proprtis hardnss analysis (Shor A) and tnsil tsting standardizd matrial analysis thrmogravimtric analysis (TGA) xtraction analysis Fourir transform infrard (FT-IR) spctroscopy Rsults gomtry: good analogy btwn Chifmar and Alfa Laval rctangular rings and o-rings hardnss: hardnss diffrncs ar small (ngligibl) no hardnss influnc on opration bhavior TTI GmbH an dr Univrsität Stuttgart Comparativ Study and Evaluation of Spar Parts for Sparators in Naval Application Projct Rport for Chifmar s.r.l., Gnova, Italy pag 10

11 Mchanical Proprtis of Rctangular Rings and O-Rings Load-displacmnt diagram of tnsil tsts on NRC rctangular rings and o-rings load-displacmnt curv! Tnsil tst rsults statistical accuracy is not givn du to low numbr of tst spcimns rctangular rings: trnd to highr strngth for Alfa Laval rings o-rings: diffrnc in tnsil strngth is ngligibl Tabl: Rsults of tnsil tsts on NRC o-rings according to DIN spc. no. 001-O-CH 002-O-AL load maximum (N) load at 100 mm (N) load at 200 mm (N) load at 300 mm (N) load at 400 mm (N) rmarks max. longation max. longation TTI GmbH an dr Univrsität Stuttgart Comparativ Study and Evaluation of Spar Parts for Sparators in Naval Application Projct Rport for Chifmar s.r.l., Gnova, Italy pag 11

12 Chmical Composition of NRC Rings Suprposition of FT-IRspctroscopis of th pyrolyzats of Chifmar (blu) and Alfa Laval (rd) rctangular rings Rmark: Only on Chifmar ring and on from Alfa Laval wr analyzd du to high costs of th analysis! Consistnt ingrdints of th pyrolyzats of xtractabl lmnts: butadin and acrylonitril Matrial analysis of nitril rubbr compound (NRC) for rctangular rings: thrmogravimtry discovrs largr fraction of lastomrs for Alfa Laval matrial xtraction and subsqunt FT-IR spctroscopy yild th chmicals usd for plastification (plastisizrs) diffrncs in th chmical composition of th plastisizrs matrials ar quit similar, but with som diffrncs in chmical composition and mass fractions of polymrs, plastisizrs and fillrs TTI GmbH an dr Univrsität Stuttgart Comparativ Study and Evaluation of Spar Parts for Sparators in Naval Application Projct Rport for Chifmar s.r.l., Gnova, Italy pag 12

13 Main Rsults of th Study: Polymr Componnts PA66 Sal Rings: Dimnsional and Positional Tolrancs Manufacturing Procss Matrials Proprtis Quality of dimnsional tolrancs is th sam for th two manufacturrs (could b improvd) Quality of th cross sction shap could b improvd for both manufacturrs; this could b achivd by mor rmaining (cooling) tim of th componnt in th di aftr injction moulding Di is diffrnt with rspct to numbr of injction gats; this mans that th manufacturing procss should b optimizd in trms of polymr mass tmpratur, di tmpratur and mould rlas agnt that ar usd Hardnss: highr for Chifmar componnts, and thrby, th lastic modulus is highr as wll Thrmal bhaviour (mlting and solidification): shows that PA66 was usd by both manufacturrs; thrmal durability is highr for th Chifmar matrial (indicats that th molcular arrangmnt of th polymr is diffrnt du to diffrnt manufacturing paramtrs) NRC Rctangular Rings and O-Rings: Dimnsional and Positional Tolrancs Mchanical Proprtis Matrial Composition (analysis of 2 rings only!) Gomtry and dimnsions of th various rings ar comparabl for Chifmar and Alfa Laval Diffrncs in th dimnsions of th rctangular ring cross sctions in th rgion of mm Hardnss: Masurmnt by Shor A showd sam hardnss for both manufacturrs Tnsil strngth: difficult masurmnts du to limitd numbr of tst componnts; almost no diffrnc in strngth (with a small trnd to highr valus for Alfa Laval NRC rings) Thrmal dcomposition analysis: mass fractions of volatil constitunts, polymric fractions, carbon and ash fillr matrial similar with slightly largr fractions of lastomrs for Alfa Laval (5 wt.% mor) and fillr matrial for Chifmar (2 wt.% mor) Elmntal analysis (spctroscopy) of xtractabl lmnts: rathr similar matrials of th two manufacturrs with diffrncs in chmical composition of th plasticizrs (dilunts) TTI GmbH an dr Univrsität Stuttgart Comparativ Study and Evaluation of Spar Parts for Sparators in Naval Application Projct Rport for Chifmar s.r.l., Gnova, Italy pag 13

14 Summary and Conclusions Diffrncs btwn Chifmar and Alfa Laval componnts ar small, both for polymr and stl componnts Chifmar stl componnts hav similar matrial lik Alfa Laval componnts; matrial proprtis only diffr slightly, but Chifmar could improv thir componnts significantly by additional hat tratmnt at critical positions (lik baring sats) Th accuracy of th stl componnts is in gnral comparabl; howvr, a bttr attntion on manufacturing mtrology (.g., lngth masurmnts) will improv quality and lad to bttr ovrall prformanc Dimnsional and mchanical proprtis of th polymr parts ar vry similar btwn th two manufacturrs (highr hardnss of th Chifmar PA66, highr strngth of th Alfa Laval NRC) For th sal rings, optimization of th manufacturing procss would incras componnt proprtis and accuracy (.g., bttr cooling aftr manufacturing) For th NRC matrial (rctangular rings and O-rings), thr ar diffrncs in chmical composition; largr fractions of lastomrs could lad to bttr tnsil strngth of th Alfa Laval rings; howvr, th tru influnc of diffrnt polymrs and plastisizrs (or dilunts) in th NRC matrials cannot b appointd for sur, bcaus th composition of rubbr compounds is complx All masurmnts in this study wr mad on nw polymr and stl componnts from Chifmar and Alfa Laval. Thrfor, statistical vidnc of th rsults is not possibl. If customrs would rturn damagd parts, failur analysis could lad to bttr undrstanding of spcific applicationorintd problms and improvmnt of th componnt dsign and manufacturing. TTI GmbH an dr Univrsität Stuttgart Comparativ Study and Evaluation of Spar Parts for Sparators in Naval Application Projct Rport for Chifmar s.r.l., Gnova, Italy pag 14