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Friction Stir Processing (FSP) has the potential for locally enhancing the properties of Al-Si alloy castings, for demanding applications within the automotive industry. In this thesis, the effect of FSP has been examined on three different cast Al-Si alloys:i) A Hypoeutectic Al-8.9wt%Si Alloyii) A Hypereutectic Al-12.1wt%Si Alloyiii) A Hypereutectic Al-12.1wt%Si-2.4wt%Ni AlloyThe influence of different processing parameters has been investigated at a fundamental level. Image analysis of particle size distributions and growth method of tessellation were used to quantify the level of particle refinement and the homogeneity of the second phase spatial distribution. Stop-action experiments were also carried out, to allow the microstructural changes around the tool during FSP to be studied. Two computer models have been explored, in order to predict the temperature distribution and the material flow behaviour. Furthermore, the stability of the microstructure of the friction stir processed material was studied after being heat treated at elevated temperatures. The changes in particle size and grain structure were examined, hardness measurements were taken across the PZ, and tensile testing were carried out at room and elevated temperatures.After FSP, the microstructure of the cast Al-Si alloys was greatly refined. However, differences in microstructure have been observed throughout the PZ, which tended to be better refined and distributed on the advancing side, than the retreating side of the PZ. Changing the processing parameters also influenced the size and spatial distribution of the second phase particles. By studying the changes in microstructure around the tool from the stop-action experiments, and comparing the results to the thermal distribution and material flow behaviour predicted by the computer models, it has been shown that the flow stress, pitch, and temperature of processing, all needed to be considered, when determining the effects that FSP have on the microstructure. FSP caused very little changes to the hardness of the material, while tensile properties were greatly improved, due to the elimination of porosity and refinement of large flawed particles. In terms of the stability of the microstructure after FSP, particle coarsening and abnormal grain growth has been observed during high temperatures heat treatment. Furthermore, the Al2Cu phase was found to dissolve into solid solution at elevated temperatures, so GPZs and solute clustering can then develop within the alloy during natural ageing.

In dieser Arbeit wurden zunächst zwei Charakterisierungsmethoden zur zerstörungsfreien Detektion von Voids in lokalen Rückseitenkontakten bei PERC Solarzellen vorgestellt, die akustische Mikroskopie und die Computertomografie. Beide Messmethoden wurden anhand von Proben mit unterschiedlichen Al-Pasten getestet und mit beiden Messmethoden können Voids sehr gut erkannt werden. Zur Vermeidung von Voidbildung konnte der positive Einfluss der Siliziumbeimischung in die Al-Paste bestätigt werden. Desweiteren konnte anhand unterschiedlicher RTP Feuerprofile gezeigt werden, dass durch eine verlangsamte Aufheizphase die Bildung von Voids deutlich reduziert werden kann, während die Abkühlphase nur einen geringen Einfluss auf die Voidbildung zeigt. Mithilfe eigens hergestellter Al-Pasten, mit unterschiedlichen Al-Partikelgrößen, wurde gezeigt, dass Al-Pasten mit einer Mischung aus kleinen und großen Al-Partikeln ebenfalls einen positiven Einfluss auf die Ausbildung von Voids haben können.

The world is ever increasing in its energy usage, making energy that is sustainable and secure harder to achieve. To fulfil the Paris agreement to limit global warming, the world needs to transition from fossil fuels toward more renewable energy sources, like wind and solar, but these sources have fluctuation in supply which often create a mismatch with demand. To combat this issue, thermal energy storage can be utilized, and one such technology is latent heat thermal energy storage. This study aimed to investigate the potential of latent heat thermal energy storage by developing a simple model of such a system and studying its impact on Rocklunda’s sport facilities. The model was developed by using MATLAB, primarily using the photovoltaic overproduction of the facilities to store as energy for the latent heat thermal energy storage. The implemented storage, based on the model’s result, had overall positive impact on the facilities. The optimized storage capacity was about 510 kWh, which throughout the storage’s lifetime would save ~4 989 MWh worth of heat by using the best performing phase change material: aluminium-silicon. The storage would also be able to utilize ~82% of the annual photovoltaic overproduction that would otherwise be unused/sold as well as reducing the heat demand by ~12% by using the heat stored via the storage. The implementation also proved to have beneficial effects on the environment as the saved heat was the equivalent of mitigating ~304 ton of CO2 emissions. Furthermore, there is a profit of ~236 000 SEK. / Reduction and Reuse of energy with interconnected Distribution and Demand (R2D2)

Diploma thesis examines the influence of the preparation and metallurgical treatment on the mechanical properties and structure of aluminium alloys Al-Si. The experimental part was carried out at MSR Engines s.r.o. This part describes the current (sodium modification) and newly proposed (strontium modification) state of preparation and metallurgical processing of melt. There is state the course of experimental melting processes, testing of samples, evaluation of tests and observation of the impact of individual modifiers on the structure.

To increase of bearing steels properties are research and development of surface modifications well above dedicated, in present. Basic requirements to the surface modifications are high wear resistance and good temperature resistance (origin by friction). Surface modifications can not negatively influence properties of bearing steels as a substrate. One of the possibilities can be used surface modifications used for high temperature applications. These are based on saturation of substrate surface layer by Al (and Si) elements. This work deals with preparing of Al and Al-Si diffusion layers from slurries on 100Cr6 bearing steel surface and study of elements interaction between coating and bearing steel as a substrate during proceeding of protective layers at high temperatures. To elements interaction study light microscopy, scanning electron microscopy equipped by energy dispersive microanalyses, glow discharge optical emission spectrometry and microhardness measurement methods were used. To the evaluation of layer thickness image analyses was used.

This thesis examines the influence of inoculation and modification on the internal structure and properties of aluminium-silicon alloys. The effect of inoculation by titanium and boron and modification by sodium and strontium is investigated in experimental part of the thesis. All these metallurgical interventions in the melt are tested on three types of hypoeutectic Al-Si alloys (AlSi10Mg(a), AlSi8Cu3, AlSi7Mg0,3). The experiment was carried out in cooperation with the foundry of non-ferrous metals, Aluminium Group, a.s. in Sloup.

The focus of this thesis is the critical review of Additive Printing (AP) or 3D-printing, and optimization strategies for the introduction of new materials. During the course of tenure, four classes of solids were investigated to determine the hurdles presented from each system. Specifically, the investigation developed techniques for optimization of ink production, green-film deposition, and laser sintering parameters surrounding the Optomec AJP system (AJP). In the assessment, statistical experimental design, analysis and material characterization techniques have been utilized. Final recommendations disseminate current best practices for new ink and material development, along with factor analysis of input variables for phase and material properties, along with insights for future research of these systems. The first chapter provides a general introduction to the field of AP. The second chapter focuses specifically on Optomec aerosol-jet process (AJP) techniques, and expands the discussion to process parameters, information concerning the fabrication/characterization procedure followed for each system, and includes: a detailed description of the materials investigated. This is important because printing parameters, optimization, and approach may be divergent for optimization within each strain; and is meant as an aid to resolve some technical issues for future investigators. The third chapter is fully dedicated to the results concerning the fabrication and the characterization of amorphous boron powder to film. Chapter four discusses future research options, ideas and directions. Appendices are provided for any which wish to investigate the orthogonal arrays used, or the combinatorial effects resulting in the attributes of the material system final products. / Master of Science

L’objectif de ce travail est d’établir des relations entre chimie d’interface et propriétés mécaniques dans les assemblages bimétalliques. Il met en évidence que les mécanismes qui contrôlent le développement d’une interface entre alliage Al-Si et renfort ferreux ou titane ont une influence majeure sur les propriétés mécaniques de cette interface. La caractérisation mécanique des interfaces est réalisée par un test de flexion 4 points sur des lames bimétallique élaborées par aluminiage au trempé sur lesquelles un raidisseur est rapporté par collage ou surmoulage. L’évolution de la chimie de la zone de réaction interfaciale est provoquée par un traitement thermique à 535°C à différents temps. La caractérisation des zones de réaction ainsi que des chemins de fissuration est réalisée par diffraction des rayons X et microsonde électronique. Pour les interfaces Fe/A-S7G03 brutes d’élaboration, avant traitement thermique, l’analyse des essais mécaniques conduit à l’obtention d’une valeur du taux de restitution d’énergie de 23 J/m2 qui correspond à la propagation d’une fissure dans la phase η−Al5Fe2(Si). En ce qui concerne les interfaces Ti/A-S7G03, leur force n’a pas permis la propagation d’une fissure dans les conditions de l’essai. A la suite d’un traitement thermique à 535°C, les interfaces Fe/A-S7G03 sont fragilisées par le mécanisme de croissance de la couche de réaction interfaciale qui conduit à l’apparition de porosités Kirkendall en son sein. A l’inverse, dans le cas des interfaces Ti/A-S7G03, aucun affaiblissement de l’interface n’est associé au traitement thermique en raison d’un mécanisme de croissance différent. / The objective of this work is to establish the relationships between interface chemistry and mechanical properties in bimetallic assemblies. It proves that the mechanisms which control the development of an interface between Al-Si alloy and titanium or ferrous reinforcement have a major influence on the mechanical properties of this interface. The mechanical characterization of these interfaces is performed by a 4-point bending test on the bimetallic plates elaborated by hot dip aluminizing on which a stiffener is joined by bonding or overmolding. The chemistry evolution of the interfacial reaction zone is induced by a heat treatment at 535 °C at different reaction times. The characterization of reaction zones and the crack paths is performed by X-ray diffraction and electron probe microanalysis. Before heat treatment, the analysis of mechanical tests performed on Fe/A-S7G03 interfaces leads to a value for the energy release rate of 23 J/m2 which corresponds to a crack propagation in the η- Al5Fe2 (Si) phase. As regards the Ti/A-S7G03 interfaces, their strength did not allow a crack propagation under the test conditions. After a heat treatment at 535°C, the Fe/A-S7G03 interfaces are weakened by the growth mechanism of interfacial reaction layer which leads to the appearance of Kirkendall voids within it. Conversely, in the case of Ti/A-S7G03 interfaces, the heat treatment is not associated with any weakening of the interfacial zone because of a different growth mechanism.

La micro fusion laser d'un lit de poudre (SLM) permet la réalisation de pièces complexes avec des microstructuresfines. Cette technologie présente de nombreux avantages mais se heurte encore à une faible disponibilité des poudres d'alliages. En SLM, la pièce est d'abord conçue par CAO (conception assistée par ordinateur), puis construite couche par couche avec un faisceau laser commandé par un ordinateur. Dans ce cadre, le travail effectué dans cette thèse a consisté à étudier et à développer une nouvelle méthode pour réaliser des pièces en alliages et en composites à partir de mélanges de poudres élémentaires, ouvrant ainsi la voie à une grande variété de compositions.Au niveau expérimental le choix s'est porté sur le système aluminium-silicium avec différentes teneurs en silicium (12, 18 et 50% en poids). L'effet de l'ajout d'un champ magnétique statique a aussi été proposé comme un outil supplémentaire de contrôle de la microstructure.Dans le processus de fabrication de pièces par SLM la puissance du laser et la vitesse de balayage déterminent au premier chef la densité, la microstructure, la composition des phases et les propriétés mécaniques du produit. Une analyse systématique de l'effet de ces paramètres sur l'alliage Al - Si fabriqué par SLM à partir de mélanges de poudres est présentée. Des alliages ont été ainsi obtenus pour plusieurs domaines de composition visés correspondant à des applications pratiques (structures légères, système tribologique, emballage électronique, ...).Les microstructures fines obtenues grâce à la solidification rapide des matériaux fondus conduit à des propriétés quise comparent de façon favorable à celles obtenues avec les techniques classiques d'élaboration et de mise en oeuvre. / As a new manufacturing technology, Selective laser melting (SLM) has a large potential in the manufacturing of complex parts with ultrafine microstructure.Selective laser melting has many significant advantages over traditional manufacturing methods but still faces a low availability of powder materials. With SLM, the part is firstly designed via 3D computer-aided design (CAD)), then built layer-by-layer with a high energy computer-controlled laser beam The work done in this study was therefore aiming at developing a new way to obtain alloys and composites directly from elemental powder mixtures with a large composition flexibility.Experimentally the choice was made of the aluminum-silicon system with several silicon contents (12, 18, 50 wt. %).Adding a static magnetic field was also considered as an additional way to control the microstructure. When parts are manufactured by SLM, laser power and scanning speed are the main parameters determining the density, microstructure, phase composition and mechanical properties. A systematic analysis of the role of these parameter on the manufacturing of Al - Si alloys by SLM from mixtures of powders was therefore conducted. Al - Si alloys with a very fine microstructure were thus obtained for several composition ranges corresponding to practical applications (lightweight structures, high wear resistance alloys, electronic packaging material, ...). The properties of the materials obtained in this way, according to the performed characterizations, compares favorably with those obtained via the conventional production technologies.