Leakages from seals are one of the important factors that are taken into consideration while designing any machining element. This is because leakages can affect the performance of any component and can also turn into a catastrophe. If looked into it, many parameters can be pointed out that can enhance leakages within the system, some of them may be pressure, temperature, clamping force and bolt distance etc. But the main parameter is the surface roughness, higher the roughness more the leakage and vice-versa. Thus, in this thesis an attempt has been made how the surface roughness can affect the performance of the sealing concept for metal bounded gasket with above four mentioned parameters. Also how leak proof surface can be defined using standard tribological parameters is the aim of this thesis. This report includes the results for methodologies implemented during the thesis and track down the leakages. The leaked surfaces were carefully studied and analyzed using different standards compared with the non leaked surfaces’ roughness parameters. / Läckagerisk från tätande förband är en av de viktigaste faktorerna som beaktas vid utformning av konstruktionsartiklar. Detta på grund av att konsekvenserna kan bli förödande. Det tätande förbandet påverkas av många olika parametrar såsom till exempel tryck, temperatur, klämkraft, skruvavstånd och val av packning. En viktig faktor är ytans beskaffenhet; Generellt läcker en grov yta och vågig yta mer än en fin och plan yta. Således har i denna avhandling ytans beskaffenhet studerats tillsammans med en packning av typen metallburen gummipackning för att påvisa täthetfunktionen som en funktion av tryck, temperatur, klämkraft och skruvavstånd. Denna rapport innehåller resultat och analys av olika standardmetoder för de ytor som ingick i utredningen.

Zirconia has been established as a promising material for dental implants. Various surface treatment methods have been utilized to promote better osseointegration and improve the success rate of dental implants. However, a better understanding of the influences of topographic characteristics on cell attachment, proliferation, and differentiation is needed. Different surface topographic zirconia specimens, As sintered, Mild rough, Moderate rough, and Rough zirconia groups were fabricated with sandblasting method in various distances and stages. The surface texture, microstructure, and wettability were inspected with the optical profiler, SEM, and contact angle measurement respectfully. Human primary osteoblast cells were cultured on the four groups of zirconia with different surface modifications in 24 well plates and on plates without test material as control. Crystal violet and triton X-100 solution were used to evaluate cell attachment efficiency at 9 hours and proliferation rate at 7, 14, and 21 days after seeding. ALP activity was measured with fluorometric assay. The expression of osteocalcin was measured with an ELISA kit. Alizarin red staining was conducted to evaluate the mineralization. The cell morphologies were inspected under SEM after cell fixation and critical point drying process. The data were analyzed with one-way ANOVA for experiment on each time interval and two-way ANOVA for all time points. Tukey post hoc test was used for pairwise comparison. P value < 0.05 was considered statistically significant. Topographic parameters and contact angle measured in As sintered, Mild rough, Moderate rough, and Rough surface groups were as follow: Sa = 0.23, 0.50, 2.13, 5 µm, Sal = 49.88, 21.20, 30.42, 49.87 µm, Sdq = 64.64, 248.60, 511, 734.66 µm/mm, Sk = 0.7, 1.54, 4.19,16 µm, Spk = 0.31, 0.64, 1.47, 5.13 µm, Svk = 0.35, 0.71, 5.96, 6.18 µm respectively, and contact angle = 64.6°, 55.2°, 43.5°, 38.6° respectively. The result showed that Rough zirconia group induced the highest cell attachment efficiency at 9 hours (p<.001). As sintered zirconia group promoted significant cell proliferation rate at 21 days (p<.001) while Rough zirconia group drastically down-regulated cell proliferation (p<0.001). The most elevated levels of ALP, osteocalcin, and mineralization expressions at 21 days were found in the Moderate rough group with significant differences (p<.001, p<.001, p<.001 accordingly) Within the limitations of this in vitro study, it can be concluded 1) the modified microroughened zirconia surfaces of Sa 5 µm would promote human osteoblast attachment but down-regulate cell proliferation, 2) the As sintered zirconia surface would stimulate cell proliferation, and 3) the microroughened surfaces of Sa 2 µm would up-regulate osteoblast differentiation. These findings could be incorporated into designing and fabricating the dental implant surfaces for optimal osseointegration.

High Reynolds number turbulent boundary layers over both smooth and rough surfaces subjected to a systematically defined family of continually varying, bi-directional pressure gradient distributions are investigated in both wind tunnel experiments and steady 2D and 3D Reynolds Averaged-Navier-Stokes (RANS) computations. The effects of pressure gradient, pressure gradient history, roughness, combined roughness and pressure gradient, and combined roughness and pressure gradient history on boundary growth and the behavior of the underlying surface pressure spectrum are examined. Special attention is paid to how said pressure spectra may be effectively modeled and predicted by assessing existing empirical and analytical modeling formulations, proposing updates to those formulations, and assessing RANS flow modeling as it pertains to successful generation of spectral model inputs. It is found that the effect of pressure gradient on smooth wall boundary layers is strongly non-local. The boundary layer velocity profile, turbulence profiles, and associated parameters and local skin friction at a point that has seen non-constant upstream pressure gradient history will be dependent both on the local Reynolds number and pressure gradient as well as the Reynolds number and pressure gradient history. This shows itself most readily in observable downstream lagging in key observed behaviors. Steady RANS solutions are capable of predicting this out-of-equilibrium behavior if the pressure gradient distribution is captured correctly, however, capturing the correct pressure gradient is not as straightforward as may have previously been thought. Wind tunnel flows are three-dimensional, internal problems dominated by blockage effects that are in a state of non-equilibrium due to the presence of corner and juncture flows. Modeling a 3D tunnel flow is difficult with the standard eddy viscosity models, and requires the Quadratic Constitutive Relation for all practical simulations. Modeling in 2D is similarly complex, for, although 3D effects can be ignored, the absence of two walls worth of boundary layer and other interaction flows causes the pressure gradient to be captured incorrectly. These effects can be accounted for through careful setup of meshed geometry. Pressure gradient and history effects on the pressure spectra beneath smooth wall boundary layers show similar non-locality, in addition to exhibiting varying effects across different spectral regions. In general, adverse pressure gradient steepens the slope of the mid-frequency region while favorable shallows it, while the high frequency region shows self-similarity under viscous normalization independent of pressure gradient. The outer region is dominated by history effects. Modeling of such spectra is not straightforward; empirical models fail to incorporate the subtle changes in spectral shape as coherent functions of flow variables without becoming overly-defined and producing non-physical spectral shapes. Adopting an analytical formulation based on the pressure Poisson equation solves this issue, but brings into play model inputs that are difficult to predict from RANS. New modeling protocols are proposed that marry the assumptions and limitations of RANS results to the analytical spectral modeling. Rough surfaces subjected to pressure gradients show simplifications over their smooth wall relatives, including the validity of Townsend's outer-layer-Reynolds-number-similarity Hypothesis and shortened history effects. The underlying pressure spectra are also significantly simplified, scaling fully on a single outer variable scaling and showing no mid-frequency slope pressure gradient dependence. This enables the development of a robust and accurate empirical model for the pressure spectra beneath rough wall flows. Despite simplifications in the flow physics, modeling rough wall flows in a steady RANS environment is a challenge, due to a lack of understanding of the relationship between the rough wall physics and the RANS model turbulence parameters; there is no true physical basis for a steady RANS roughness boundary condition. Improvements can been made, however, by tuning a shifted wall distance, which also factors heavily into the mathematical character of the pressure spectrum and enables adaptations to the analytical model formulations that accurately predict rough wall pressure spectra. This work was sponsored by the Office of Naval Research, in particular Drs. Peter Chang and Julie Young under grants N00014-18-1-2455, N00014-19-1-2109, and N00014-20-2821. This work was also sponsored by the Department of Defense Science, Mathematics, and Research for Transformation (SMART) Fellowship Program and the Naval Air Warfare Center Aircraft Division (NAWCAD), in particular Mr. Frank Taverna and Dr. Phil Knowles. / Doctor of Philosophy / Very near to a solid surface, air or water flow tends to be highly turbulent: chaotic and random in nature. This is called a boundary layer, which is present on almost every system that involves a fluid and a solid with motion between them. When the boundary layer is turbulent, the surface of the solid body experiences pressures that fluctuate very rapidly, and this can fatigue the structure and create noise that radiates both into the structure to passengers and out from the structure to observers far away. These pressure fluctuations can be described in a statistical nature, but these statistics are not well understood, particularly when the surface is rough or the average pressure on the surface is changing. Improving the ability to predict the statistics of the pressure fluctuations will aid in the design of vehicles and engineering systems where those fluctuations can be damaging to the structure or the associated noise is detrimental to the role of the system. Wind turbine farm noise, airport community noise, and air/ship-frame longevity are all issues that stand to benefit from improved modeling of surface pressure fluctuations beneath turbulent boundary layers. This study aims to improve said modeling through the study of the effects of changing average surface pressure and surface roughness on the statistics of surface pressure fluctuations. This goal is accomplished through a combination of wind tunnel testing and computer simulation. It was found that the effect of gradients in the surface pressure is not local, meaning the effects are felt by the boundary layer at a different point than where the gradient was actually applied. This disconnect between cause and effect makes understanding and modeling the flow challenging, but adjustments to established modeling ideas are proposed that prove more effective than what exists in the literature for capturing those effects. Roughness on the surface causes the flow to become even more turbulent and the surface pressure fluctuations to become louder and more damaging. Fortunately, it is found that the combination of roughness with a gradient in surface pressure is actually simpler than equivalent smooth surfaces. These simplifications offer significant insight into the underlying physics at play and enable the development of the first analytically based model for rough wall pressure fluctuations.

Measurements were made in a zero pressure gradient turbulent boundary layer over two roughness patches containing hemispherical and cubical elements. The elements were 3 mm in height and spaced 16.5 mm apart in an array containing 7 streamwise rows and 6 spanwise columns for a total of 42 elements per patch. The boundary layer thickness was approximately 60 mm, so the ratio of element height to that thickness was a large amount at k/δ = 20. A three velocity component laser Doppler velocimeter measured instantaneous velocities. Mean flow and turbulence statistics were calculated as well velocity energy spectra. Surface pressure fluctuations were measured using a two-microphone subtraction method. The results show that hemispherical elements produce larger turbulence quantities in their wakes compared to the cubes. This is due to the hemispheres having a frontal area nearly 60% larger than that of the cubes. The turbulence levels behind the hemispheres is a maximum behind the first streamwise row of elements, and decreases afterwards. The cubical elements maintain a nearly constant amount of turbulence in their wake, signifying little interaction between cubical elements. Surface pressure fluctuations vary little in the streamwise direction of the patches. The hemispherical elements produce a larger sound pressure level behind them than the cube elements do. Velocity spectra results show large normal stress energy for regions at and below the element height. The energy for locations high in the boundary layer increases as the flow moves downstream. Coherency plots show that there is a large correlation between the turbulent structure and production of shear stress at the roughness height. Any measurements taken at or below the roughness height are highly correlated under 10 kHz, while locations higher in the boundary layer are correlated under 2 kHz. / Master of Science

The modern gas turbine engine requires innovative cooling techniques to protect its internal components from the harsh operating environment typically seen downstream of the combustor. Much research has been performed on the design of these cooling techniques thus allowing for combustion temperatures higher than the melting point of the parts within the turbine. As turbine inlet temperatures and efficiencies continue to increase, it becomes vitally important to correctly and realistically model all of the turbine's external cooling features so as to provide the most accurate representation of the associated heat transfer to the metal surfaces. This study examines the effect of several realistic endwall features for a turbine vane endwall. The first study addresses the effects of a mid-passage gap, endwall misalignment, and roughness on endwall film-cooling. The second study focuses on the effect of varying the combustor-to-turbine gap width. Both studies were performed in a large-scale low speed wind tunnel with the same vane geometry. Geometric and flow parameters were varied and the variation in endwall cooling effectiveness was evaluated. Results from these studies show that realistic features, such as surface roughness, can reduce the effectiveness of endwall cooling designs while other realistic features, such as varying the combustor-to-turbine gap width, can significantly improve endwall cooling effectiveness. It was found that, for a given coolant mass flowrate, a narrow combustor-turbine gap width greatly increased the coverage area of the leaked coolant, even increasing adiabatic effectiveness upstream of the vane stagnation point. The turbine designer can also more efficiently utilize leaked coolant from the combustor-to-turbine gap by controlling endwall misalignment, thereby reducing the overall amount of film-cooling needed for the first stage. / Master of Science

High strength boron steels are commonly used as structural reinforcements or energy absorbing systems in automobile applications due to their favourable strength to weight ratios. The high strength of these steels leads to several problems during forming such as poor formability, increased spring back, and tendency to work-harden. In view of these difficulties, high strength boron steels are usually formed by press hardening at elevated temperatures with a view to facilitate forming and simultaneous hardening by quenching of complex shaped parts.The high strength steel sheets are used with an Al–Si coating with a view e.g. to prevent scaling of components during hot-metal forming. The Al-Si coated high strength steel can lead to problems with galling (i.e. material transfer from the coated sheet to the tool surface) which have a negative influence on the quality of the produced parts as well as the process economy. The available results in the open literature pertaining to high temperature galling are very scarce. With this in view, the friction and wear behaviours of different tool steel coatings and different roughness lay directions sliding against Al–Si-coated high-strength steel at elevated temperatures have been investigated by using a high-temperature reciprocating friction and wear tester at temperature of 900 °C.The results have shown that parallel sliding with respect to the surface roughness lay reduces the severity of galling compared to perpendicular sliding. None of the coatings included in this study have shown beneficial effects in view of galling. The DLC coating experienced less galling compared to the AlCrN and TiAlN. Post polishing of the coated tool steel has resulted in more severe material transfer with higher and more unstable friction. / <p>Validerat; 20111022 (anonymous)</p>

Binder jetting is an additive manufacturing process that layer by layer builds a 3D model by selectively binding regions of powder using binder deposited though an inkjet printhead. The process offers several advantages over other additive manufacturing processes including fast build rates, vast material selection, decreased cost, and part resolution. The main disadvantage of binder jetting is poor mechanical properties, stemming from a poor understanding of the process physics. Porosity in final parts is not uncommon, but there is little understanding of where the porosity originates. The purpose of this thesis is to report the investigation of increased powder bed cohesion and its effects on part formation, part properties, and printing parameters in binder jetting. The interaction between binder and powder is complex. Binder exiting the printhead impacts the powder bed at speeds up to 10 m/s. The kinetic energy carried by the droplet disperses into the powder bed on impact, causing some powder particles to eject from the bed and other particles to rearrange within the bed. The particle ejection and rearrangement is theorized to be the physical cause of porous regions in binder jetted parts. This work uses a method called pre-wetting to introduce small amounts of moisture into the powder bed to effectively increase the cohesive forces between powder particles. Increased cohesion makes particle ejection and rearrangement during the powder/binder interaction more difficult. A method of accomplishing pre-wetting was developed and achieved successful moisture delivery using water and a water/tri-ethylene glycol mixture. Printed lines were used to characterize moisture content and study its effects on line formation and saturation levels. Low levels of moisture were shown to perform the best. Particle ejection and rearrangement was shown to decrease with moisture addition. Pre-wetting was shown to eliminate the defect known as balling, increasing the parameters known to successfully print lines. Water was identified as a poor substance for pre-wetting due to rapid evaporation, but tri-ethylene glycol/water solutions succeeded in proper moisture delivery. Saturation levels in lines decrease with added moisture and part dimensions increase. high-speed x-ray imaging verified pre-wetting reduction in particle ejection and rearrangement as well as supply some preliminary understanding of void formation during the printing process. The first few layers of the binder jetting process have been shown to increase in surface roughness values when compared to the undisturbed powder bed. This is likely due to a balling-like effect seen in layers. The effects of pre-wetting on layer and multi-layer formation were studied. Pre-wetting reduced the surface roughness levels in printed layers to the levels near the levels seen in undisturbed powder beds. In contrast, saturation levels in layers and multi-layers increased in value above those found in parts printed into dry powder, giving indication that porous regions within bound parts are being eliminated. Layer and multi-layer parts showed increased part dimensions with the addition of moisture. Overall, pre-wetting was shown to greatly reduce the effects of the binder/powder interaction and results strongly suggest that pre-wetting mitigates defect creation during the printing process. Further research should include testing of thicker multi-layer parts to study how saturation trends continue with increased layer numbers. In-process drying should be used in conjunction with pre-wetting in multi-layer parts to determine its effects on saturation levels and part dimensions. Post processing should be done to partially sinter, or infiltrate multi-layer parts created with and without pre-wetting to analyze porosity.

In the near future hydropower will be used to regulate intermittent energy sources, shallow water ways can then occur in close proximity to the power plants, where the bottom often consists of stones in a similar length scale as the water depth. The idea of this project, which has been initiated by Vattenfall R\&amp;D, is to compare experimental measurements in a laboratory environment with numerical simulations with CFD, this to find a way to represent roughness structures where there is low relative submergence. For the measurements in the lab, gravel were attached to the bottom of a flume and the water depth were measured for different flow rates and a CFD model were calibrated against the measurement data. A conversion of the Manning coefficient, originating from experimental measurements to equivalent Sand-grain size used in the CFD to model the roughness has been proposed and has shown good predictions of the maximum water depth. To capture the entire flow field, it is not enough to just model the friction from the roughness, it needs to be resolved and it may be necessary to consider the influence by form drag.

Castings made of aluminum 319 and A356.2 alloy were examined to determine the effectiveness of using pressure application during solidification to reduce porosity levels. Pyknometry was the method chosen to measure porosity. It was determined that the porosity of castings poured in both alloys was reduced in some instances. During the study, the surfaces of these castings were also examined and some were found to have defects present. After the porosity was evaluated, specimens of castings poured in both alloys were tested to determine whether or not the surface intrusions affected the castings. The defects were found to reduce the strength of the castings poured in aluminum 319. The castings poured in A356.2 did not have surface intrusions or any significant decreases in strength. Therefore it was concluded that of the two alloys tested, A356.2 alloy is most suited for using pressurization as a method of reducing porosity.

The Turbulent Heat Transfer Test Facility (THTTF) has been refurbished and the data acquisition system upgraded. The THTTF is now controlled by a LabView 4.1 program which replaces the old program in BASIC. Heat transfer data acquired using this new program is presented as Stanton number distributions. The new data set is compared to previously reported data obtained with this facility and other wellepted published data. This project has successfully qualified the THTTF for zero-pressure gradient, isothermal wall temperature, incompressible boundary-layer flow over smooth flat plates without transpiration. The THTTF is now set to accommodate modifications which will facilitate heat transfer investigations with high freestream turbulence.