This project combines nonwoven technology, biological technology and food waste management and seeks for this feasibility to use fungal microfiber (FM) as a binder for lyocell pro-duction and the characterizations for possible applications. Rhizopus delemar was cultivated apple pomace in liquid-state fermentation to obtain mycelia biomass. The biomass was later blended in a kitchen blender for one minute. The blended FM was later mixed with 6 mm lyocell fibre at different FM dry weight percentage and water to make nonwoven webs by wet-laid method. The feasibility of using fungal microfiber as a binder for lyocell nonwovens was confirmed in this study. It is not possible to make nonwoven webs using lyocell short fibre without any binder applied. With 5%_FM, the tensile strength of lyocell nonwoven webs reached 0.0989 MPa. A clear increasing tensile strength was recorded as the increasing of FM weight per-centage and resulted a highest tensile strength at 9.38 MPa when applying 60%_FM. The re-sult of water contact angle proved that the increasing FM could decrease the hydrophobicity of nonwoven samples. Abrasion test showed that FM could improve the abrasion resistance of the lyocell nonwoven samples. Porosity test showed that lyocell nonwoven samples with a higher FM ended up with smaller mean flow pore size diameter (MFP) that nonwoven samples with 65%_FM has an average MFP at 7.26 m m. The SEM images reviled that FM bonded nonwoven webs had a fibrous structure, which is due to binding effect of fungal microfiber on lyocell short fibers. These characterizations have demonstrated the mechanism of using fungal microfiber as a binder for lyocell nonwovens in this project. In this thesis project, FM bonded lyocell nonwoven webs showed a great potential on the application of nonwoven applications such as interior materials or filtration materials.

京都大学 / 0048 / 新制・課程博士 / 博士(理学) / 甲第21332号 / 理博第4428号 / 新制||理||1636(附属図書館) / 京都大学大学院理学研究科化学専攻 / (主査)教授 杉山 弘, 教授 秋山 芳展, 准教授 竹田 一旗 / 学位規則第4条第1項該当 / Doctor of Science / Kyoto University / DGAM

The mining industry is a major economic driver and job creator for many countries. However, mining is associated with geo-hazards and environmental issues, such as the disposal of large volumes of waste, acid mine drainage, and ground subsidence. As a result, efficient mining waste management is crucial for sustainable development. The geotechnical, economic, and environmental benefits of cemented paste backfill (CPB) have piqued the interest of researchers and academicians worldwide, making it an essential aspect of underground mining management. CPB is a thickened cementitious combination of dewatered tailings (70 - 85 wt.%), binders (usually 3 to 8% wt.%), and water used to backfill mine waste into underground mining stopes. Despite being used in small amounts, the cost of cement makes up to 80% of the cost of backfilling operations. In addition, clinker production accounts for 5-8% of global human created carbon dioxide (CO₂) emissions. This predicament necessitates the development of a viable alternative to cement. Partially substituting cement with supplementary cementitious materials like fly ash, blast furnace slag, natural pozzolans, and other materials has been increasingly prevalent in CPB. It is evident that the addition of slag to cement can increase the mechanical strength of CPB at the advanced ages but decreases the strength and suction development due to the slow reaction kinetics in the CPB at the early ages, which may negatively affect the mechanical stability of the CPB, mining cycle, and safety of mineworkers. Moreover, the supply of these materials is limited and may not be enough for the future needs of the industry. Furthermore, there has been a surge in interest in using limestone powder (LS) owing to its abundance, low cost, and lack of environmental costs which are associated with Portland cement - Type 1 (PCI). The addition of LS accelerates hydration at the early ages, thus resulting in high early strength, but the dilution effect can reduce the late strength. The combination of LS and slag in a ternary blended cement can be potentially used as a binder for CPB with acceptable strength development at the early and advanced ages while lowering the cost of the CPB and the carbon footprint of the mining industry. Nevertheless, the rheology, mechanical strength, and stability are important key performance quality criteria for CPB; however, the effect of ternary cement blends on these parameters is not well known. In this research program, the impact of the binary and ternary cement blends on (i) the fresh properties of CPB, such as the rheological properties (yield stress, viscosity) and setting time, and (ii) the strength and suction development of CPB are investigated. To understand the effect of substituting slag with LS in the binary binder in the first phase of the study, binary binders with two differ-ent PCI: Slag proportions of 50/50 and 80/20 are examined with no limestone, followed by replacing slag with an increasing amount of LS from 0 to 20 wt. % of the total binder, with a constant cement content, over a period of 4 hrs (0, 0.25, 1, 2, and 4 hrs) of curing at room temperature. In the second phase, the effect of a ternary binder (PCI-Slag- LS) with varying proportions on the suction development and the mechanical behavior of hardened CPB is investigated over a curing period of up to 90 days. The changes in strength of these binary and ternary binders on the CPB sample are tested for 1, 3, 7, 28, 60, and 90 days. An unconfined compression test (UCS) is conducted to evaluate the strength development. The microstructure of the mixes is examined through mercury intrusion porosimetry (MIP) for changes are validated through monitoring for the development of hydration and suction, electrical conductivity (EC), and temperature, which is carried out for up to 30 days. This is followed by a microstructure analysis with a thermogravimetric/differential thermogravimetric test on fresh and hardened samples. The results of the first phase show that an increase in the percentage of substituted cement in the binary binder (from PCI/Slag 80/20 to 50/50) increases the yield stress of the CPB but decreases the viscosity of the mix. However, the addition of LS as a substitution for slag shows a considerable decrease in the yield stress of the control mix with an increase in viscosity with increasing dosages of LS, thus indicating an improvement in the flowability of CPB. The second phase results indicate that the slow hydration kinetics of slag influences early age suction and strength changes in the binary sample with a high slag content (50/50); however, its latent hydraulic and pozzolanic properties enhance strength gain after 28 days. The addition of 5% limestone to the ternary blend increases the strength gain by up to 7 days compared to the binary control samples. Indeed, the presence of LS influences the rate of hydration of cement and slag through both physical (filler, nucleation, dilution) and chemical (hydrate) effects. However, substituting more than 10% LS for slag affects the mechanical performance at all ages. Overall, up to 50 wt.% slag and 10 wt.% limestone with cement as a ternary binder can be used without significant compressive strength loss. This study demonstrates that the partial substitution of ordinary Portland cement (OPC) with varying percentages of slag and LS is complementary, and overall, the interaction of slag and LS is observed. The optimal use of LS and slag in a ternary system may serve as a sustainable alternative to the commonly used OPC and PCI/Slag binders, thereby reducing the energy consumption and carbon footprint associated with cement. The findings of this study will ultimately help to develop a better understanding of the impact of ternary blends with increasing percentages of LS on the rheology and setting time of CPB mixes and mechanical strength changes in designing an efficient mixing plant, particularly its transport system.

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The master thesis at Sandvik Additive Manufacturing Division, Sandviken, aims at three things. The first step is to estimate the cost of a Binder jet Additive Manufacturing method and identify the key cost drivers in the manufacturing process, since cost estimation can help the organisation to understand the cost factors that are affecting the product's price. Also assisting the sales team to create a foundation to price quote their customers and raise profit margins. Hence the first part of the thesis emphasizes creating an easy-to-use template for the organization's production and sales teams. The second part of the thesis is to provide an Excel sheet that is simple to use for computing the yearly budgets so that it serves as a technique for forecasting impending outflows within the company. Hence, a quarterly and yearly budgeting template that the sales and production team can use at Sandvik AM division is designed. The final objective of this thesis is to establish the Binder Jet machine's Overall Equipment Efficiency key performance indicator. This is done by taking into account availability, performance, and quality. These three factors are tracked from the additive manufacturing machines using an automated OEE Key Performance Indicator calculator that collects data from the build reports into Excel using the power query tool. / Examensarbetet vid Sandvik Additive Manufacturing Division, Sandviken, syftar till tre saker. Det första steget är att uppskatta kostnaden för en Binder jet Additive Manufacturing-metod och identifiera de viktigaste kostnadsdrivkrafterna i tillverkningsprocessen, eftersom kostnadsuppskattning kan hjälpa organisationen att förstå de kostnadsfaktorer som påverkar produktens pris. Hjälper även säljteamet att skapa en grund för att prissätta sina kunder och höja vinstmarginalerna. Därför fokuserar den första delen av avhandlingen på att skapa en lättanvänd mall för organisationens produktions- och säljteam. Den andra delen av uppsatsen är att tillhandahålla ett Excel-ark som är enkelt att använda för att beräkna den årliga budgeten så att det fungerar som en teknik för att prognostisera förestående utflöden inom företaget. Därför utformas en mall för kvartalsvis och årlig budgetering som sälj- och produktionsteamet kan använda på Sandvik AM-divisionen. Det slutliga målet med denna avhandling är att fastställa Binder Jet-maskinens övergripande utrustningseffektivitets nyckelprestandaindikator. Detta görs genom att ta hänsyn till tillgänglighet, prestanda och kvalitet. Dessa tre faktorer spåras från de additiva tillverkningsmaskinerna med hjälp av en automatiserad OEE Key Performance Indicator-kalkylator som samlar in data från byggrapporterna till Excel med hjälp av kraftfrågeverktyget.

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During lithium-ion battery electrode fabrication, slurry drying conditions influence the resulting microstructure of electrodes. It has been found that the drying conditions can result in non-uniform cathode microstructures and material distributions. Accelerated drying, for example, is widely assumed to cause the binder in an electrode to migrate within the slurry, which can contribute to adhesion failure, and ultimately capacity fade and reduced battery life. While there are some conflicting studies regarding the aspects of accelerated drying that cause binder migration, there is not a widely used standard metric for measuring the gradient of binder across the thickness of an electrode. In this work, the vertical heterogeneity of electrodes, as measured using energy-dispersive X-ray spectroscopy (EDX), is correlated with different drying methods and rates. An improved metric for measuring the binder gradient in electrodes is proposed. For the electrodes in this study, binder migration is minimally affected by the drying method and the normalized binder gradient does not increase with increased drying rate. The results are compared to a drying physics model, and it is shown that further development of current models that predict binder gradient as a function of drying rate will need to be modified to more fully capture the physics of slurry drying.

WC cemented carbides are composites consisting of WC and a binder phase. WC/Co is widely used as cutting tools due to its excellent combination of hardness and toughness. This thesis work was performed at the R&D department of Sandvik Coromant and aimed to find the alternative binder phase to substitute cobalt. Several compositions of Fe-Ni and Fe-Ni-Co binder have been investigated in this study. The WC/Co reference samples were also prepared. The initial compositions were decided by the CALPHAD method. The samples were then produced by the means of powder metallurgy. The producing conditions, especially the sintering conditions, were manipulated to achieve full dense and uniform samples. The samples were analyzed by XRD, LOM, SEM, and EDS. Mechanical properties test has also been performed.The results showed that adjustment on carbon content is necessary to attain desirable structure. Increasing Fe content in the binder tends to make the materials harder. For Fe-Ni and Fe-Ni-Co, the martensitic transformation is essential to the mechanical performance. The induced “transformation toughening” in 72Fe28Ni and 82Fe18Ni binders significantly promoted the toughness. Furthermore, the grain growth inhibition by Fe was confirmed. The relations between sintering temperature, grain size and mechanical properties have been discussed. Compared with the WC/Co references, several compositions showed close and even superior mechanical performance which might provide solutions for the future alternative binder phase.

<p>Binder jet printing (BJP) is an additive manufacturing (AM) method which has the potential to be applied to high annual volumes in the automotive industry. Binder jet printing provides an excellent opportunity to innovate transmission valve body components. The three-layer design and complex hydraulic control system channels of valve body housing formulated a new electro-hydraulic system with the brand-new features inherited from BJP. For the valve body, the features of BJP brought a revolutionary new idea for both the valves and hydraulic channel design. The spool valve was housed with a sleeve that integrates orifices and port controls. The hydraulic channel layout of the valve body assembly was greatly simplified and space-saving. The support components had also been replaced with a lightweight design while maintaining the same functionality. Integrated design of Binder jet print produced hydraulic automatic valve system presented an entirely new design, whose static performance was compared to that of the conventional 948TE ZF9HP48 transmission valve body. Similar performance indicated that a valve body design featuring BJP would have great potential for various industrial applications.</p>