<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>

Li-ion batteries have enabled the widespread adoption of portable electronics and are becoming the technology of choice for electric vehicles and grid storage. One of the most promising ways to accommodate this demand is to increase the energy density and cycle life of battery electrode materials. Key strategies promoted in the literature include the use of nickel-rich cathodes as well as high-capacity anodes like silicon and lithium metal. While these materials enable a high energy density, this advantage is often counterbalanced with deficits such as poor stability and high cost. Multicomponent electrodes refer to strategies that try to leverage the relative advantages of different materials to offer an attractive compromise of energy density, cost, and cycle life. This thesis has investigated various aspects of multicomponent electrodes with a special emphasis on silicon-based anodes and high-entropy materials. Silicon (Si) is the second-most abundant element on earth and has one of the highest gravimetric capacities. However, silicon anodes are notorious for their poor cycle stability. Herein, improvements in the stability of silicon-based electrodes are achieved with multicomponent composite strategies involving the use of nanostructured spherical silicon. The nanosilicon is studied in high-fraction (80 wt% Si) and low-fraction (≤20 wt% Si) formulations to investigate both failure mechanisms and practical capacity retention, respectively. Composite strategies in which nanosilicon is encapsulated within a Li₄Ti₅O₁₂ ceramic or MOF-derived carbon matrix are shown to deliver superior capacity retention compared to simple composites of silicon and graphite. Considerable attention is given to the selection of a water-soluble binder and its role in electrochemical stability and electrode cohesion in high-loading silicon electrodes. It is found that unmodified high-molecular-weight sodium carboxymethyl cellulose offers better capacity retention compared to xanthan gum or low-molecular-weight binders. The high-entropy design strategy has created a diverse and largely unexplored set of multicomponent oxides and alloys with great potential as electrode materials. This strategy is applied to the family of layered cathodes, where the synthesis and electrochemical properties of the best-performing Li(NiCoMnTiFe)₁O₂ are reported. Despite the low Ni content, the cathode delivers a high initial capacity with unique overlithiation stability despite being charged to 4.4 V. Throughout the thesis, Operando XRD is used to reveal important insight into the lithiation mechanisms of the multicomponent electrodes including intercalation-based graphite, alloying-based silicon, and a novel organic azaacene.

The development of a process chain for Inconel 718 production utilizing Binder Jetting has been investigated. Different powder sources were compared by the effect they had on machine compatibility, powder bed packing, recyclability, green density, sintering parameters, final density, porosity, and mechanical properties. The three powder lots investigated originated from two different production sites. One of the three powder lots has a finer powder size distribution, due it being produced simultaneously with another powder lot with a coarser powder size distribution fraction. This synergy production results in a higher yield of the atomization process and thus is economically and environmentally beneficial. The compatibility between powder lots and Binder Jetting machine was investigated using new powder and recycled powder. By using recycled powder in the process an increase in green density by 5% could be achieved. Several temperature and hold time relations were tested to develop a sintering program with an acceptable final density above 94% of theoretical density. 1270◦C with a hold time of 4h generated the best results. Sintered samples did not reach acceptable strength properties. The elongation value was twice as high as required for one of the powder lots using recycled powder. Post heat treatment generated samples with an acceptable yield strength but highly reduced elongation properties.

Syftet med projektet var att utveckla en multiplexanalys för att detektera antigen från SARS-CoV-2, influensa och respiratoriskt syncytial virus genom att använda en masspektrometrisk metod som involverar antigenspecifika bindare. Bindarna klonades, renades och biotinylerades innan de användes i en analys utvecklad genom en målinriktad metod som involverade antigenerna. En slutsats som drog var att det var möjligt för Avi-märkta bindare att specifikt binda antigen-härledda peptidmål i multiplexanalysen. / The purpose of project was to develop a multiplex assay capable of detecting antigens from SARSCoV-2, influenza and respiratory syncytial virus by utilizing a mass spectrometric approach involving antigen-specific binders. Binders were cloned, purified and biotinylated before being employed in an assay developed by though a targeted method involving the antigens. It was concluded to be possible for Avi-tagged binders to specifically bind antigen-derived peptide targets in the multiplex assay.

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Additive manufacturing has gained considerable attention in recent years due to its capabilities of producing complex parts with tailormade mechanical properties. Because of its infancy state, additive manufacturing production chains are seldom optimized to the same extent as conventional manufacturing techniques. Companies with additive manufacturing production sitesusing powder as a building material often find themselves devoting a lot of resources towards depowdering, a post processing step that has potential of being a significant bottleneck.The purpose of this master thesis was to develop a de-powdering system that would function automatically, relieving operators from performing the process step manually. The following work has been conducted at Sandvik in Sandviken at the department for additive manufacturing.Results were acquired with high credibility due to a mixture of qualitative and quantitative gathering techniques that supplemented each other. Together with a literature review, empirical data gave rise to the possibility of developing a new de-powdering system for binder jetting technology.Optimization of the system indicated that larger inlets produced a higher removal efficiency. This was later confirmed with computational fluid dynamics, where smaller nozzles created a more turbulent air flow, making it difficult for powder particles to exit the system. Though final trials with green bodies revealed that the system, in its current state, did not have the capabilities of replacing manual de-powdering completely, it certainly displayed how efficient it can be with further development.

Yes / The Caleva UK single-screw Variable Density Extruder (VDE) is a continuous powder processing equipment known for spheronization and extrusion. Its suitability for granulation remains uncertain, a common challenge in powder processing industries that deal with granules, pellets, and tablets. This study investigates the VDE's potential for granulation, using 65 µm CaCO3 powder and PEG 4000 as a liquid binder. In order to replicate several experimental setups with varying binder concentrations and liquid-to-solid ratios (L/S) of 0.1 and 0.15, eight DEM simulations were run. Our results indicate that higher binder concentrations yield more consistent products with fewer fines, while lower concentrations result in inconsistent products with increased fines. Low L/S ratios produce fragile, fine-sized products with a broad particle size distribution (PSD). DEM simulations reveal a direct relationship between liquid binder content and contact forces. Analysis of bonds formed, and particle counts in simulations corroborates experimental observations of fines production. Additionally, granule strength appears to be directly proportional to contact force. / Special gratitude is given to Ghana Scholarship Secretariat for providing the necessary funding for this research. / The full-text of this article will be released for public view at the end of the publisher embargo on 23 Jan 2025.

A solid electrolyte is a crucial component of any solid state battery. Polymer gel electrolytes have received increasing attention in recent years due to their high ionic conductivity, flexibility, and improved safety. However, a general tradeoff usually exists between the mechanical properties and ionic conductivity in such materials. Molecular ionic composites (MICs) are a new type of rigid polymer gel electrolyte based on ionic liquids (ILs) and a double helical rigid-rod polyamide, poly(2,2′-disulfonyl-4,4′-benzidine terephthalamide) (PBDT). MICs have high ionic conductivity, high thermal and electrochemical stability, and widely tunable and high tensile modulus even at relatively low polymer content. MICs show great promise as solid electrolytes for solid state batteries. This dissertation describes the preparation and characterization of MIC electrolyte membranes. These transparent, flexible, and tough membranes are prepared through a convenient solvent casting process. A large variety of ILs, including both hydrophilic and hydrophobic examples, are suitable to prepare MIC electrolyte membranes by adjusting the solvents used in the casting process. The prepared membranes show a biphasic internal structure consisting of a PBDT-rich “bundle” phase and an IL-rich “puddle” (interconnected fluid) phase. Similar to the bulk MIC ingots prepared previously through an interfacial ion exchange process, the MIC membranes also have high ionic conductivity and tensile modulus at low polymer content. A MIC membrane composed of 1-butyl-1-methylpyrrolidinium bis(trifluoromethylsulfonyl)imide (Pyr₁₄TFSI), LiTFSI, and PBDT in a mass ratio of 8:1:1 is tested as a solid electrolyte for lithium metal batteries. This electrolyte membrane shows high ionic conductivity and high rigidity. The shear storage modulus of this MIC electrolyte membrane only decreases by 35% when heated to 200 °C from room temperature, suggesting great mechanical stability at high temperatures. The electrolyte membrane is successfully used as solid electrolyte for a Li/LiFePO₄ battery working over a large temperature range from 23 to 150 °C, and the discharge capacity retention of the cell is as high as 99% after 50 cycles at 150 °C. By replacing the IL in the MIC with a charge-neutral liquid, single-ion-conducting polymer gel electrolyte composed of PBDT and polyethylene glycol (PEG) oligomer are obtained. Similar to the MICs, these single-ion-conducting materials also have high Young’s modulus and biphasic internal structures. This study reveals that the counter ion (Li⁺ or Na⁺) of the PBDT has a major effect on both the ionic conductivity and modulus of the materials. Due to the stronger intermolecular interactions, LiPBDT-PEG demonstrates lower ionic conductivity but higher Young’s modulus. This dissertation also evaluates the viability of rigid PBDT as a polymer binder for electrodes. Aqueous solution-processed LiFePO₄ electrodes with only 3 wt% PBDT demonstrate stable cycling over 1000 cycles without obvious capacity decay, and the rate capacity of these aqueous solution-processed electrodes are comparable to the electrodes prepared with conventional poly(vinylidene difluoride) (PVDF) as the binder, suggesting PBDT can serve as a potential electrode binder for commercial applications. / A solid electrolyte is a crucial component of any solid state battery. Polymer gel electrolytes have received increasing attention in recent years due to their high ionic conductivity, flexibility, and improved safety. However, a general tradeoff usually exists between the mechanical properties and ionic conductivity in such materials. Molecular ionic composites (MICs) are a new type of rigid polymer gel electrolyte based on ionic liquids (ILs) and a double helical rigid-rod polyamide, poly(2,2′-disulfonyl-4,4′-benzidine terephthalamide) (PBDT). MICs have high ionic conductivity, high thermal and electrochemical stability, and widely tunable and high tensile modulus even at relatively low polymer content. MICs show great promise as solid electrolytes for solid state batteries. This dissertation describes the preparation and characterization of MIC electrolyte membranes. These transparent, flexible, and tough membranes are prepared through a convenient solvent casting process. A large variety of ILs, including both hydrophilic and hydrophobic examples, are suitable to prepare MIC electrolyte membranes by adjusting the solvents used in the casting process. The prepared membranes show a biphasic internal structure consisting of a PBDT-rich "bundle" phase and an IL-rich "puddle" (interconnected fluid) phase. Similar to the bulk MIC ingots prepared previously through an interfacial ion exchange process, the MIC membranes also have high ionic conductivity and tensile modulus at low polymer content. A MIC membrane composed of 1-butyl-1-methylpyrrolidinium bis(trifluoromethylsulfonyl)imide (Pyr14TFSI), LiTFSI, and PBDT in a mass ratio of 8:1:1 is tested as a solid electrolyte for lithium metal batteries. This electrolyte membrane shows high ionic conductivity and high rigidity. The shear storage modulus of this MIC electrolyte membrane only decreases by 35% when heated to 200 °C from room temperature, suggesting great mechanical stability at high temperatures. The electrolyte membrane is successfully used as solid electrolyte for a Li/LiFePO4 battery working over a large temperature range from 23 to 150 °C, and the discharge capacity retention of the cell is as high as 99% after 50 cycles at 150 °C. By replacing the IL in the MIC with a charge-neutral liquid, single-ion-conducting polymer gel electrolyte composed of PBDT and polyethylene glycol (PEG) oligomer are obtained. Similar to the MICs, these single-ion-conducting materials also have high Young's modulus and biphasic internal structures. This study reveals that the counter ion (Li+ or Na+) of the PBDT has a major effect on both the ionic conductivity and modulus of the materials. Due to the stronger intermolecular interactions, LiPBDT-PEG demonstrates lower ionic conductivity but higher Young's modulus. This dissertation also evaluates the viability of rigid PBDT as a polymer binder for electrodes. Aqueous solution-processed LiFePO4 electrodes with only 3 wt% PBDT demonstrate stable cycling over 1000 cycles without obvious capacity decay, and the rate capacity of these aqueous solution-processed electrodes are comparable to the electrodes prepared with conventional poly(vinylidene difluoride) (PVDF) as the binder, suggesting PBDT can serve as a potential electrode binder for commercial applications. / Doctor of Philosophy / Solid state batteries are widely considered as the pathway to next-generation high performance batteries. In a solid state lithium battery, the liquid organic carbonate electrolyte is replaced with a solid electrolyte. Polymer gel electrolytes are a type of potential solid electrolyte that have been widely studied in recent decades. This dissertation describes the application of a rigid polymer in preparing polymer gel electrolytes. This highly charged and rigid polymer is a water-soluble polyamide known as PBDT with a double helical structure akin to DNA. Through a modified solvent casting process, a new type of polymer gel electrolyte, known as molecular ionic composite (MIC), is prepared using PBDT and various ionic liquids. Extra salt (which can contain lithium) can also be incorporated into the MIC membrane. This type of new polymer gel electrolyte is rigid with high tensile modulus even at high temperatures and low polymer (PBDT) content. MIC membranes are used as solid electrolytes for lithium metal batteries working over a wide temperature range from 23 to 150 °C. A rigid polymer gel electrolyte can also be obtained by replacing the ionic liquids in MICs with polyethylene glycol. Besides the application in preparing solid electrolytes, PBDT is also evaluated as a polymer binder for aqueous processed electrodes. Preliminary study reveals that PBDT holds great potential for a range of commercial energy storage applications.