Cette thèse a pour but d’augmenter la durée de vie des moules pour l’injection plastique. Les principaux phénomènes à refréner sont l’usure par abrasion et l’usure par corrosion. Pour ce faire, deux familles de matériaux ont été présélectionnées. Il s’agit des aciers à outils inoxydables et des verres métalliques massifs. Ces travaux détaillent donc la sélection, le développement et la caractérisation d’une nuance pour chacune de ces familles. In fine, cette thèse délivre un nouvel acier adapté à la fabrication additive et aux moules d’injection plastique, allant de l’élaboration de la poudre à l’optimisation des paramètres LBM et de ceux du traitement thermique. Cet acier permet d’offrir un bon compromis en termes de propriétés thermiques, mécaniques et de résistance à la corrosion. Quant au verre métallique massif, ces travaux de thèse démontrent que la nuance choisie permet de conserver suffisamment de matériau amorphe pour induire des propriétés exceptionnelles. / The aim of this thesis is to increase molds lifetime. Mains phenomena to limit are abrasion wear and corrosion. For this purpose, two material families have been preselected. They have been identified among stainless steels and bulk metallic glasses. This work details their selection, development in additive manufacturing and characterization for both materials. In the end, this thesis delivers a new steel grade adapted to the additive manufacturing and plastic injection molds, which affords good corrosion resistance, high hardness and a comparatively good thermal conduction. Concerning the bulk metallic glass, this work shows that the chosen composition allowed to preserve enough amorphous material to induce exceptional properties and give strong hopes to continue in this vein.

As órteses de membro superior são dispositivos que auxiliam na reabilitação da mão e que tem como objetivo estabilizar, imobilizar, prevenir e corrigir deformidades, melhorando assim a função. O processo tradicional de confecção de órteses é realizado por meio do uso de termoplásticos de baixa temperatura, material moldado diretamente sobre o membro do usuário, sendo neste processo relatados inúmeros problemas, que envolvem desconforto durante o processo, alto custo e baixa adesão do paciente ao uso. O presente trabalho, portanto, teve por objetivo propor a construção de um framework com abordagem metodológica projetual para a produção de órteses de membro superior baseada no processo de design e design colaborativo, com auxílio de recursos de fabricação digital, como digitalização tridimensional e manufatura aditiva (impressão 3D). Através de uma pesquisa exploratória, foram discutidas questões relativas ao projeto de órteses de membro superior (MMSS) pela forma tradicional, utilizando termoplástico de baixa temperatura, e questões do processo de design no desenvolvimento de novos produtos a serem aplicadas do desenvolvimento de órteses utilizando a manufatura aditiva A coleta de dados contou com a participação dos principais personagens envolvidos no processo, usuários de órteses, Terapeutas Ocupacionais e Designers. Com base na técnica de card sorting e entrevistas, foi elaborado um framework da abordagem projetual para a criação de órteses utilizando processos de fabricação digital, de forma colaborativa. O framework ainda foi aplicado no desenvolvimento de uma órtese a fim de avaliar os resultados e melhorias levantadas durante a fase de entrevistas com profissionais e usuários. Ao final do processo, obteve-se uma órtese funcional em que foram atendidos os requisitos necessários para a produção de uma órtese levantada pelo trabalho, além da criação do framework servindo como um guia para o desenvolvimento de órteses utilizando a manufatura aditiva. / Upper limb orthoses are devices that assist in the rehabilitation of the hand and that aim to stabilize, immobilize, prevent and correct deformities, thus improving the function. The traditional process of making orthotics is accomplished through the use of thermoplastics of low temperature, molded material directly on the member of the user, being in this process reported numerous problems, that involve discomfort during the process, high cost and low adhesion of the patient to the use. The present work, therefore, aimed to propose the construction of a framework with a design methodological approach for the production of upper limb orthosis based on the process of design and collaborative design, with the aid of digital manufacturing resources such as three - dimensional digitization and additive manufacturing (3D printing). Through an exploratory research, questions regarding the design of upper limb orthoses (MMSS) in the traditional way, using low-temperature thermoplastic, and design process issues in the development of new products to be applied in the development of orthoses using the additive manufacture The data collection was attended by the main characters involved in the process, users of orthoses, Occupational Therapists, and Designers. Based on the technique of card sorting and interviews, a framework of the design approach for the creation of orthoses using digital manufacturing processes was developed in a collaborative way. The framework was also applied in the development of a bracing in order to collaborate with the results and improvements raised during the interviews phase with professionals and users. At the end of the process, a functional orthosis was obtained, in which the necessary requirements for the production of an orthosis were obtained by the work, besides the creation of a framework serving as a guide for the development of orthoses using the additive manufacture.

This thesis describes design, development and testing work on a plasma cathode electron beam gun as well as plasma diagnosis experiments and Electron Beam (EB) current measurements carried out with the aim of maximising the power of the EB extracted and optimising the electron beam gun system for material processing applications. The elements which influence EB gun design are described and put into practice in a thermionic EB gun case study. The relevant principles of plasma EB gun systems, such low-temperature, low-pressure, RF excitation, are described along with the test rigs developed to investigate different plasma cathode configurations. The first experimental setup was for optical spectroscopy measurements of the light emitted from the plasma and the second included current measurements from EBs generated at –30 and –60 kV as well as the spectroscopic measurements. Comparison of EB current measurements with different plasma cathode configurations and correlation with spectroscopic measurements are presented. The maximum current extracted from the Radiofrequency (RF) gun was 38 mA at –60 kV using a hollow cathode geometry and permanent magnets for electron confinement. The RF gun was compared to a Direct Current (DC) gun which generated higher currents. This was reflected in the spectra which indicated a higher ionisation level than in the RF plasma. Simulation work carried out using Opera-2d to model beam trajectories indicated that the beam shape is largely influenced by the plasma boundary. Particle In Cell (PIC) simulations of a parallel plate RF plasma cathode demonstrated that higher excitation frequencies produced higher ionisation, however the RF sheaths were larger and thus the current extracted may be limited in practice due to fewer electrons being available near the aperture. The sheath thickness decreased in the simulations as the discharge gap was increased. RF plasma also produced larger currents from larger plasma chambers.

abstract: The microstructure development of Inconel alloy 718 (IN718) during conventional processing has been extensively studied and much has been discovered as to the mechanisms behind the exceptional creep resistance that the alloy exhibits. More recently with the development of large scale 3D printing of alloys such as IN718 a new dimension of complexity has emerged in the understanding of alloy microstructure development, hence, potential alloy development opportunity for IN718. This study is a broad stroke at discovering possible alternate microstructures developing in Direct-Metal-Laser-Sintering (DMLS) processed IN718 compared to those in conventional wrought IN718. The main inspiration for this study came from creep test results from several DMLS IN718 samples at Honeywell that showed a significant improvement in creep capabilities for DMLS718 compared to cast and wrought IN718 (Honeywell). From this data the steady-state creep rates were evaluated and fitted to current creep models in order to identify active creep mechanisms in conventional and DMLS IN718 and illuminate the potential factors responsible for the improved creep behavior in DMSL processed IN718. Because rapid heating and cooling can introduce high internal stress and impact microstructural development, such as gamma double prime formations (Oblak et al.), leading to differences in material behavior, DMLS and conventional IN718 materials are studied using SEM and TEM characterization to investigate sub-micron and/or nano-scale microstructural differences developed in the DMLS samples as a result of their complex thermal history and internal stress. The preliminary analysis presented in this body of work is an attempt to better understand the effect of DMLS processing in quest for development of optimization techniques for DMLS as a whole. A historical sketch of nickel alloys and the development of IN718 is given. A literature review detailing the microstructure of IN718 is presented. Creep data analysis and identification of active creep mechanisms are evaluated. High-resolution microstructural characterization of DMLS and wrought IN718 are discussed in detail throughout various chapters of this thesis. Finally, an initial effort in developing a processing model that would allow for parameter optimization is presented. / Dissertation/Thesis / Masters Thesis Engineering 2017

abstract: Presented below is the design and fabrication of prosthetic components consisting of an attachment, tactile sensing, and actuator systems with Fused Filament Fabrication (FFF) technique. The attachment system is a thermoplastic osseointegrated upper limb prosthesis for average adult trans-humeral amputation with mechanical properties greater than upper limb skeletal bone. The prosthetic designed has: a one-step surgical process, large cavities for bone tissue ingrowth, uses a material that has an elastic modulus less than skeletal bone, and can be fabricated on one system. FFF osseointegration screw is an improvement upon the current two-part osseointegrated prosthetics that are composed of a fixture and abutment. The current prosthetic design requires two invasive surgeries for implantation and are made of titanium, which has an elastic modulus greater than bone. An elastic modulus greater than bone causes stress shielding and overtime can cause loosening of the prosthetic. The tactile sensor is a thermoplastic piezo-resistive sensor for daily activities for a prosthetic’s feedback system. The tactile sensor is manufactured from a low elastic modulus composite comprising of a compressible thermoplastic elastomer and conductive carbon. Carbon is in graphite form and added in high filler ratios. The printed sensors were compared to sensors that were fabricated in a gravity mold to highlight the difference in FFF sensors to molded sensors. The 3D printed tactile sensor has a thickness and feel similar to human skin, has a simple fabrication technique, can detect forces needed for daily activities, and can be manufactured in to user specific geometries. Lastly, a biomimicking skeletal muscle actuator for prosthetics was developed. The actuator developed is manufactured with Fuse Filament Fabrication using a shape memory polymer composite that has non-linear contractile and passive forces, contractile forces and strains comparable to mammalian skeletal muscle, reaction time under one second, low operating temperature, and has a low mass, volume, and material costs. The actuator improves upon current prosthetic actuators that provide rigid, linear force with high weight, cost, and noise. / Dissertation/Thesis / Doctoral Dissertation Biomedical Engineering 2017

Användningen och intresset för additiv tillverkning (AM) har ökat markant de senaste åren och det finns en teori kring att tillverkningsmetoden kan vara det nästa steget i den industriella revolutionen. Eftersom AM fortfarande befinner sig i utvecklingsstatidet går det att anta att tekniken ännu inte uppnått sin fulla potential och att det kan komma att finnas möjligheter att implementera tekniken i fler branscher och företag. Detta skulle innebära en bredare marknad för AM. Syftet med examensarbetet var att undersöka vilka möjligheter och hinder som finns för ökad användning av AM i Sverige. Studien genomfördes genom kvalitativa intervjuer med åtta olika verksamheter tillhörande den svenska industrin och en litteraturgenomgång för att presentera nuläget för AM i svensk industriell marknad. Resultatet av datainsamlingen analyserades med modellerna PEST, 4P och slutligen SWOT. De fördelar som har setts med användningen av AM har varit minskade ledtider, minskade kostnader för tillverkning av produkter och verktyg, minskat materialspill och en optimal designprocess med ökad kreativitet. De begränsningar som finns i tekniken i dagsläget är att priset för material och maskiner är dyrt. Vidare anses även kvalitet på slutdetalj, begränsad byggvolym och opålitliga processer vara problematiska. De möjligheter som finns beror huvudsakligen på den forskning som görs. Förutsättningarna för AM i svensk industri kommer att bero på hur tekniken kommer att utvecklas. De hinder som finns är kopplat till kompetensbrist och att det inte finns befintliga standarder för material eller process inom AM. / Within the industrial sector, an increased interest and usage of Additive Manufacturing (AM) throughout the decade has been formed. The layer-upon-layer building technology has been seen and recognized as one of the next industrial revolutionizing methods of production. As the technology is still in the trending and uprising phase it should be considered that its full potential has not yet been achieved, as large opportunities for implementation of AM exist and that new companies and markets have a growing interest in this technology. Through this study a market research was conducted to identify and present what opportunities and obstacles there are for an increased usage of AM in Sweden. A literature study on the Swedish market has been made to present the market as of today. Eight qualitative interviews have also been conducted with companies within the industrial sector to identify the areas of use within AM for production. The concepts and models used to analyze these questions was PEST, Marketing Mix and SWOT. The concluded results for advantages in using AM are shortened lead times, reduced costs of production of components and tools, reduced material waste and optimization of design processes with increased creativity. The concluded challenges are expensive materials and machine, the quality of finished components, limited printing volume due to the 3D-printers and reliability of printing processes. The finalized opportunities that are presented in this work are that AM is dependent on how much research on the subject and factors around it is done. How AM will be applied in the coming future revolves around the advancement in the technology. The obstacles that are found in this study are lack of competence and lack of standard for materials and processes within AM.

The advantages of Topology Optimization (TO) are realized to a large extent due to the manufacturing freedom that Additive Manufacturing (AM) offer, compared to more conventional manufacturing methods. AM has the advantage of manufacturing shallow and complex structures previously not possible, and consequently opens up a whole new design spectrum. This thesis investigates the possibilities of using Topology Optimization as a tool to find stronger and lighter designs for the inlet turbine manifold in the rocket engine demonstrator Prometheus. The manifold is optimized by giving it more mass, subjecting it to load cases and pushing the topology optimization to make the manifold meet the weight requirement without exceeding the yield strength. Result validation indicates that the pressure and thermal loadings are the most prominent. The current topology optimization tools in ANSYS do not support optimization due to thermal features and thus optimization in the presented work has only been able to consider static structural loads. Nevertheless, it is possible to optimize the manifold due to static structural loads and achieve a manifold which satisfies the weight requirement. However, optimization tools due to thermal loading would be a desirable feature in the future.

Submitted by BRUNO FONTOURA DA SILVA COLMAN (brunocolman@hotmail.com) on 2018-05-03T15:19:22Z No. of bitstreams: 1 Dissertação de Mestrado - Bruno Colman Rev.36_03-05-2018.pdf: 5215084 bytes, checksum: 2152650458ee3ee274744cb5b222bb3c (MD5) / Approved for entry into archive by Cristina Alexandra de Godoy null (cristina@adm.feis.unesp.br) on 2018-05-03T17:05:09Z (GMT) No. of bitstreams: 1 colman_bfs_me_ilha.pdf: 5215084 bytes, checksum: 2152650458ee3ee274744cb5b222bb3c (MD5) / Made available in DSpace on 2018-05-03T17:05:09Z (GMT). No. of bitstreams: 1 colman_bfs_me_ilha.pdf: 5215084 bytes, checksum: 2152650458ee3ee274744cb5b222bb3c (MD5) Previous issue date: 2018-03-05 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / Esse trabalho tem a finalidade de projetar, com base em levantamento bibliográfico, uma prótese de disco intervertebral de Ti6Al4V pelo processo DMLS. Os sistemas de imagem de tomografias computadorizadas e ressonâncias magnéticas trabalham de maneira semelhante. Imagens em 3D de dados dos pacientes são construídas através da combinação de fatias 2D tomadas a partir de sistemas de sensores e da interpolação entre eles. A distância entre as fatias desses sistemas de imagens é grosseira comparada com a tecnologia da manufatura aditiva, portanto, esses processos combinam as imagens das fatias dentro de um software para criar um modelo 3D sobrepondo camadas, devido a essa sinergia entre os dois tipos de sistema, pesquisadores de todo o mundo tentam melhorar e inventar próteses para substituir o disco intervertebral através da ciência. Os resultados mostraram que a fabricação de uma prótese de disco com junta esférica pelo processo de manufatura aditiva é viável, porém nos segmentos menores, como na cervical ainda são difíceis de produzir devido à altura do disco intervertebral e ao limite da dimensão das camadas da manufatura aditiva, que atualmente estão por volta dos 20μm, por isso requerem tratamentos superficiais após sua fabricação. Espera-se que este trabalho possa ajudar futuros pesquisadores da área de biomecânica da coluna vertebral. / This work has the purpose of designing, based on a bibliographical survey, an intervertebral disc prosthesis of Ti6Al4V by the DMLS process. Computed tomography (CT) imaging systems and MRIs work similarly. 3D images of patients data are constructed by combining 2D slices taken from sensor systems and interpolating between them. The distance between the slices of these imaging systems is rough compared to the additive manufacturing technology, so these processes combine the slice images within a software to create a 3D model overlapping layers because of this synergy between the two system types, researchers around the world try to improve and devise prostheses to replace the intervertebral disc through science. The results showed that the manufacture of a disc prosthesis with spherical joint by the additive manufacturing process is feasible, but in the smaller segments, such as in the cervical still difficult to produce due to the height of the intervertebral disc and to the limit of the size of the layers of the manufacture additives, which are currently around 20μm, so they require surface treatments after their manufacture. It is hoped that this work may help future researchers in the area of spinal biomechanics. / CAPES - PROPG

Metal Additive Manufacturing (AM) promises an era of highly flexible part production, replete with unprecedented levels of design freedom and inherently short supply chains. But as AM transitions from a technology primarily used for prototyping to a viable manufacturing method, many challenges must first be met before these dreams can become reality. In order for machine users to continue pushing the design envelope, process space must be expanded beyond the limits currently recommended by the machine manufacturers. Furthermore, as usable process space expands and demands for reduced operator burden and mission-critical parts increase, in-situ monitoring of the processes will become a greater necessity. Processing space includes both the parameters (e.g. laser beam power and travel velocity) and the feedstock used to build a part. The correlation between process parameters and process outcomes such as melt pool geometry, melt pool variability, and defects should be understood by machine users to allow for increased design freedom and ensure part quality. In this work, an investigation of the AlSi10Mg alloy in a Laser Powder Bed Fusion (L-PBF) process is used as a case study to address this challenge. Increasing the range (processing space) of available feedstocks beyond those vetted by the machine manufacturers has the potential to reduce costs and reassure industries sensitive to volatile global supply chains. In this work, four non-standard metal powders are successfully used to build parts in an L-PBF process. The build quality is compared to that of a standard powder (supplied by the machine manufacturer), and correlations are found between the mean powder particle diameters and as-built part quality. As user-custom parameters and feedstocks proliferate, an increased degree of process outcome variability can be expected, further increasing the need for non-destructive quality assurance and the implementation of closed-loop control schema. This work presents two Machine Learning-based Computer Vision algorithms capable of autonomously detecting and classifying anomalies during the powder spreading stage of L-PBF processes. While initially developed to serve as the monitoring component in a feedback control system, the final algorithm is also a powerful data analytics tool – enabling the study of build failures and the effects of fusion processing parameters on powder spreading. Importantly, many troubling defects (such as porosity) in AM parts are too small to be detected by monitoring the entire powder bed; for this reason, an autonomous method for detecting changes in melt pool morphology via a high speed camera is presented. Finally, Machine Learning techniques are applied to the in-situ melt pool morphology data to enable the study of melt pool behavior during fusion of non-bulk part geometries.

The ability to accurately quantify the performance an additively manufactured (AM) product is important for a widespread industry adoption of AM as the design is required to: (1) satisfy geometrical constraints, (2) satisfy structural constraints dictated by its intended function, and (3) be cost effective compared to traditional manufacturing methods. Optimization techniques offer design aids in creating cost-effective structures that meet the prescribed structural objectives. The fundamental problem in existing approaches lies in the difficulty to quantify the structural performance as each unique design leads to a new set of analyses to determine the structural robustness and such analyses can be very costly due to the complexity of in-use forces experienced by the structure. This work develops computationally tractable methods tailored to maximize the structural performance of AM products. A geometry preserving build orientation optimization method as well as data-driven shape optimization approaches to structural design are presented. Proposed methods greatly enhance the value of AM technology by taking advantage of the design space enabled by it for a broad class of problems involving complex in-use loads.