This master thesis studies the behaviour of two aluminium alloys in ultrasonic cleaning at two different intensities, as well as the effect of a cleaning solution, Formula 815 GD-NF on the same surface have been studied with respect to surface roughness and material composition. Methods like Light Optical Microscopy (LOM), Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS) and 3D topography using white light interferometry (VSI) was used to study the surface and material composition. It was found that both the ultrasonic cleaning, as well as the solution itself both increase surface roughness of the samples. When crossing a threshold in ultrasonic intensity micro jet cavitation dislodge precipitates, or areas weakened by precipitate to form a large pit. And the following heat from the jet causes the surface to oxidise, becoming more brittle, and be broken up by other cavitation phenomena to cause rapid acceleration of surface roughness in an area originating from the pit.

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In der vorliegenden Arbeit wurden facettierte Nanolegierungen aus Gold und Palladium in der Größenordnung von 1 – 3 nm synthetisiert und charakterisiert. Die Synthese erfolgte in sphärischen Polyelektrolytbürsten (SPB), welche als Stabilisatorsystem fungierten. Die Strukturaufklärung erfolgte mittels hochauflösender Transmissionselektronenmikroskopie (HR-TEM) und Extended X-ray Absorption Fine Structure (EXAFS) Spektroskopie. Die Nanolegierungen wurden als Katalysatoren zur Reduktion von 4-Nitrophenol verwendet, wobei eine gesteigerte katalytische Aktivität, im Vergleich zu monometallischen Nanopartikeln, beobachtet wurde. Im HR-TEM wurden auf den Kanten der Metallkristalle Oberflächendefekte in Form von Stufen sichtbar, wobei eine Korrelation der Oberflächendefekte zur katalytischen Aktivität hergestellt wurde. Durch EXAFS-Analysen konnte nachgewiesen werden, dass eine Zusammensetzung von 75 mol-% Gold und 25 mol-% Palladium annähernd eine statistische Mischung aufweist. Mit steigendem Palladiumgehalt wurde eine leichte Anreicherung von Palladium an der Oberfläche der Partikel, sowie nichtmetallisches Palladium der Oxidationsstufe 2+ gefunden. Diese unterschiedliche Anordnung der Elemente für verschiedene Zusammensetzungen korreliert ebenfalls mit der katalytischen Aktivität. Ferner konnte eine Kontraktion des Netzebenenabstands für kleine Partikel mittels EXAFS nachgewiesen werden. Bei der Verwendung als Katalysatoren wurde eine zeitliche Reaktionsverzögerung festgestellt, welche auf die Oberflächenrestrukturierung der Metallnanopartikel hinweist. Zusätzlich konnte durch den Vergleich von SPB stabilisierten und stabilisatorfreien Goldnanopartikeln festgestellt werden, dass das SPB System die katalytische Aktivität nicht signifikant beeinträchtigt. / In this work facetted gold-palladium nanoalloys have been synthesized and characterized in the range of 1 – 3 nm. The spherical polyelectrolyte brushes (SPB) have been used during synthesis and for stabilization of the nanoparticles. Structural analyses have been done by high resolution transmission electron microscopy (HR-TEM) and extended X-ray absorption fine structure (EXAFS) spectroscopy. The nanoalloys have been used as catalysts for the reaction of 4-nitrophenol, where an enhanced catalytic activity has been found compared to monometallic nanoparticles. Surface defects are visible by steps at the edge of the metallic crystal where a correlation of these surface defects and the catalytic activity has been found. By EXAFS spectroscopy an almost statistic mixture for a composition of 75 mol-% gold and 25 mol-% palladium, slight enrichment of palladium at the surface of the particle, and the presence of nonmetallic palladium with an oxidation number of 2+ has been observed. This different atomistic arrangement correlates with the catalytic activity as well. In addition, a contraction of the lattice parameter has been observed for small particles by EXAFS measurements. Using the nanoalloys as catalyst, a delay time for the reaction has been found which indicates a restructuring of the surface of the metal nanoparticles. By comparison of SPB stabilized and support-free gold nanoparticles no significant influence of the SPB system on the catalytic activity has been observed.

In industrial use of paint systems a swift processing is crucial. Another very important issue is to improve the quality of the final coating. This report investigates the film formation process of powder coatings, specially the spreading of individual powder particles. The obtained results can be used to understand and control the film formation process. In this way the desired levelling can be achieved and thus the desired gloss or other surface characteristics that may be required. This means that the method could be used when evaluating different polymer and additive combinations that could be used to change film formation behaviour or curing time for powder coating systems to suit various substrates. It makes it possible to avoid and minimize different surface defects as orange peel or cratering in the powder coated film. We used a reflection optical microscope to better understand the film formation process and especially the spreading of a powder melt on surfaces with various surface energies. The obtained data were: the particle diameter, the area, area ratio and the contact angle of the powder particle as a function of time and temperature. This information can be used to derive the surface tension of any powder melt. In this report we evaluate the dependencies of temperature, heat rate and surface energy for powder coatings on different substrates. The method provides information that can be used to optimize the film formation of a specific powder coating/substrate combination. This method can be used to evaluate the powder spreading and levelling on different substrates from a surface tension point of view. We found, as expected, that the powder flows out on a hydrophilic surface and is inhibited by a hydrophobic. The increase of the area ratio on a hydrophilic surface was about five times as the initial area coverage and on a hydrophobic surface only two times the initial area coverage. The contact angle between the melted powder particle on the different surface types could be calculated. The melt surface tension could be calculated since three substrates surfaces with various surface energies were used. The melt surface tension was found to be about 18.5 mN/m. / Sammanfattning Vid industriell användning av ett färgsystem är det viktigt med en snabb och smidig målningsprocess. En viktig del är att förbättra kvaliteten på den färdiga ytan. Denna rapport undersöker filmbildningsprocessen för pulverfärg, närmare bestämt spridningen av individuella pulverpartiklar. Resultaten från utvärderingen av denna metod kan användas för att bättre förstå och få kontroll över filmbildningsprocessen. Med denna undersökningsmetod kan den önskade utslätningen uppnås och därmed den önskade glansen eller annan yteffekt som kan vara önskvärd. Metoden kan användas för att utvärdera olika polymer- och additivkombinationer som kan användas för att ändra filmbildningens uppförande eller bestämma härdningstiden för en pulverfärg att passa ett visst substrat. Metoden gör det möjligt att förhindra och minska olika ytdefekter såsom apelsinskals- eller kratereffekter i pulverfärgens yta. Ett optiskt reflectionsmikroskop användes för att bättre kunna förstå filmbildningsprocessen och särskilt spridningen av smält pulver på substrat med olika ytenergier. De mätdata vi fick var partikeldiameter, area, areaförändring och kontaktvinkeln för pulverpartiklar som funktion av tid och temperatur. Ur denna information kunde pulversmältans ytenergier härledas. I denna rapport utvärderas pulvrets beroende av temperatur, uppvärmning och ytenergi på olika substrat. Denna metod ger information som kan användas för att optimera filmbildningen av en specifik kombination av pulverfärg och substrat. Denna metod kan också användas för att utvärdera pulverspridning och utjämning av färgfilmen på olika substrat med avseende på ytenergierna. Som förväntat flyter pulvret ut på hydrofila ytor och utflytningen ändras på en hydrofob yta. På en hydrofil yta sprider sig partikeln till fem gånger den ursprungliga arean över substratet och motsvarande två gånger för en hydrofob yta. Kontaktvinkeln mellan en smält pulverpartikel på olika sorters substrat från utförda mätningar beräknas utifrån utförda mätningar. Kontaktvinklar mellan pulver och olika substrat kan användas för att beräkna smältans ytspänning. Smältans ytspänning kan beräknas då experiment gjorts på tre sorters ytor med olika kända ytenergier. Smältans ytspänning var 18,5 mN/m. Slutsatsen är att det går att observera och utvärdera resultaten av utsmältningsförloppet för pulverfärg med denna metod.

[pt] O presente trabalho se baseia na teoria dos defeitos equivalentes, também conhecida como teoria de Murakami, que permite a predição da vida-fadiga de materiais estruturais adotando o parâmetro (raiz quadrada de area), responsável por uma equivalência quantitativa entre heterogeneidades microestruturais (inclusões metalúrgicas) existentes na região de análise do material e descontinuidades mecânicas (furos) usinados nos corpos de prova. Neste contexto, a tese propõe novas equações, a partir da teoria de Murakami, para prever falhas por fadiga em carregamentos ultralongos (fadiga de altíssimo ciclo, VHCF) do aço DIN42CrMo4, de larga aplicação na fabricação de eixos virabrequins para unidades geradoras de usinas termoelétricas. Corpos de prova do aço DIN42CrMo4 foram usinados com furos de diâmetros variando entre 0,18 mm e 0,70 mm e ensaiados num regime de fadiga de altíssimo ciclo, variando o valor da amplitude de tensão do ensaio, para assim determinar em quais condições o material falha e obter a curva experimental S-N do aço DIN42CrMo4 na presença de diferentes tamanhos de defeitos (furos). Os resultados experimentais permitiram o desenvolvimento de equações em função do parâmetro e curvas de Wohler do material, em conformidade com diferentes descontinuidades mecânicas nos corpos de prova e resistências à fadiga do material. Consequentemente, se estabeleceu uma metodologia que permite uma correlação entre inclusões metalúrgicas, tensão aplicada e vida superlonga em fadiga de eixos virabrequins em serviço em usinas termoelétricas. / [en] The present work is based on the theory of equivalent defects, also known as Murakami s theory, which allows the prediction of the fatigue life of structural materials by adopting the parameter (square root of area), responsible for a quantitative equivalence between microstructural heterogeneities (metallurgical inclusions) existing in the region analysis of the material and mechanical discontinuities (holes) machined in the specimens. In this context, the thesis proposes new equations, based on Murakami s theory, to predict fatigue failures in ultralong loads (very high cycle fatigue, VHCF) of DIN42CrMo4 steel, widely used in the manufacture of crankshafts for generating units of thermoelectric power plants. DIN42CrMo4 steel specimens were machined with holes with diameters varying between 018 mm and 0.70 mm and tested in a very high cycle fatigue regime, varying the value of the test stress amplitude, to determine under what conditions the material failure and obtain the experimental S-N curve of DIN42CrMo4 steel in the presence of different sizes of defects (holes). The experimental results allowed the development of equations as a function of the parameter and Wohler curves of the material, in accordance with different mechanical discontinuities in the test specimens and resistance to fatigue of the material. Consequently, a methodology was established that allows a correlation between metallurgical inclusions, applied stress and super-long fatigue life of crankshafts in service in thermoelectric power plants.