Tungsten carbide (WC) based metallic matrix coatings sprayed using high velocity air fuel (HVAF) technique have attracted increasing attention as they show excellent tribological performance in various wear conditions. In the HVAF method, particles’ in-flight temperature and velocity can be influenced by the process variables including nozzle configuration as well as feedstock particle size range. On the other hand, the chemistry of metallic binder can also play a key role in determining both properties and performance of these coatings. In this thesis, characteristics and tribological behaviour of HVAF-sprayed WC-based coatings were investigated employing four different nozzle configurations (4L2, 4L4, 5L2and 5L4), and three different feedstock particle sizes of WC-CoCr feedstock powder (5/20, 5/30 and 15/45 μm). Also, characteristics and performance of coatings processed with four different WC-based feedstocks comprising alternative binders to traditionally used CoCr (namely CoCr, NiMoCrFeCo,FeNiCrMoCu and FeCrAl) were investigated. Characteristics of the coatings were explored by conducting scanning electron microscopy observations, microindentation testing and X-ray diffraction analysis. Performance of the coatings was evaluated by conducting sliding wear, dry jet erosion wear and sand rubber wheel abrasion wear testing. Moreover, material removal mechanisms in the coatings subjected to the above tests were investigated through post wear analysis. X-ray diffraction analysis showed that no considerable phase change compared to the starting feedstock was observed in any of the coatings sprayed by HVAF technique. It was revealed that decrease in powder particle size range can result in an improvement in microstructural characteristics, such as homogeneity and density, as well as hardness of the coatings. Besides, it can lead to a substantial improvement in wear performance of the coatings. It was shown that using various nozzle configurations does not result in any considerable change in characteristics or performance of the HVAF-sprayed WC-CoCr coatings. It was further shown that, by decreasing particle sizes from coarse to medium or fine, a significant difference can be observed. While wear mechanisms for medium and fine feedstock coatings were dominated by ploughing and fracture of individual carbide grains, for the coarse feedstock coatings ploughing and grooving along with the local removal of coating material were observed. Hardness values for all the four coatings with different binder chemistries were in a narrow range of 1100 – 1300 HV0.3. WC-NiMoCrFeCo and WC-FeNiCrMoCu coatings showed better or comparable sliding wear performance compared to WC-CoCr coating (as reference). WC-FeNiCrMoCu and WC-FeCrAl coatings showed comparable performance under erosion conditions while all the three binder alternatives yielded slightly inferior coating performance under abrasion wear, compared to the reference coating. While ploughing was the common wear mechanism in all the four coatings, pitting was noted in coatings with CoCr and FeNiCrMoCu binders in case of sliding wear. / Populärvetenskaplig Sammanfattning Cermet-beläggningar består av WC-partiklar inbäddade i ett metallbindemedel,sprutat med High Velocity Air Fuel (HVAF) uppvisar utmärkt tribologiskprestanda under olika slitage förhållanden. Med HVAF-tekniken kan partiklarnasflygtemperatur och hastighet påverkas av konfigurationen av den utrustning somanvänds såväl som partikelstorleksintervallet för råmaterialet. Därtill kan kemin hos det metalliska bindemedlet spela en nyckelroll för beläggningarnas egenskaper och prestanda. I denna avhandling undersöktes egenskaper och tribologiskt beteende hos HVAF-besprutade WC-baserade beläggningar. Undersökningen gjordes genom att använda fyra olika uppsättningar av ändra sprutparametrar förHVAF-processen där fyra olika munstyckskonfigurationer (4L2, 4L4, 5L2 och5L4) och tre olika partikelstorleksintervaller av WC-CoCr råvarupulver (5/20,5/30 och 15/45 μm). Studieegenskaper och prestanda för alla deponerade beläggningar, påverkan av processvariabler (olika munstyckskonfigurationer och olika partikelstorlekar) undersöktes. Dessutom undersöktes egenskaper och prestanda för tre olika WC-baserade råvaror med alternativa bindemedel till CoCr (NiMoCrFeCo, FeNiCrMoCu och FeCrAl) och jämfördes med WC-CoCrbeläggningsom referens. Beläggningens egenskaper undersöktes genom att genomföra SEM-analys, mikroindragningstest och röntgenanalys. Beläggningens prestanda utvärderades genom att utföra glidförslitning, erosionsslitage under torra förhållanden och test med torr sand/gummihjulanordning. Vidare undersöktes mekanismer för materialavlägsning i beläggningarna med ovanstående tester genom analys efter slitage. Ingen avsevärd fasförändring observerades för alla beläggningar som besprutades med HVAF-teknik. Det avslöjades att minskning av pulvrets genomsnittliga partikelstorlek resulterade i en förbättring av mikrostrukturella egenskaper, såsom homogenitet och densitet, samt beläggningarnas hårdhetsvärde. Dessutom leder det till en avsevärd förbättring av beläggningens slitageförmåga. Det visades att användning av olika munstycken till HVAF-processen inte resulterar i en avsevärd förändring i egenskaper eller prestanda hos WC-CoCr-beläggningarna. När det gäller förslitningsmekanismer visades det att genom att minska partikelstorleken från grov till medium eller fin sågs en avsevärd skillnad. För beläggningar besprutade med fina och medelstora partiklar dominerades förslitningsmekanismer av plöjningsslitage och sprickor av enskilda hårdmetallkorn. För grova beläggningar observerades plöjningsslitage och spårning tillsammans med avlägsnande av material. Ingen signifikant skillnad i mikrostruktur eller fasförändring observerades i alla beläggningar med alternativa bindemedel såväl som WC-CoCr som referensbeläggning. Hårdhetsvärdet för alla de fyra beläggningarna låg inom x intervallet 1100 - 1300 HV0.3. NiMoCrFeCo och FeNiCrMoCu visade bättre eller jämförbar glidförmåga med referensbeläggningen. FeNiCrMoCu och FeCrAl visade jämförbara prestanda under erosionsförhållanden och alla de tre undersökta beläggningsmaterialen visade något sämre prestanda under nötningsslitage jämfört med referensbeläggningen. Medan plöjningsslitage var den vanliga förslitningsmekanismen i alla de fyra beläggningarna noterades gropning i beläggningarna CoCr och FeNiCrMoCu vid glidförslitning.

This doctoral work was developed in the frame of bone tissue engineering, dealing with the fabrication of scaffolds for the regeneration of bones. At this purpose, calcium phosphates derived from natural sources are very interesting because they are more similar to the bone mineral and possess better bioactivity. Indeed, the bone mineral is different from synthetic hydroxyapatite as it is non-stoichiometric, nanosized, it presents a high degree of disorder and contains many additional ions and impurities such as CO32-, Mg2+, Sr2+, Na+, etc. These characteristics can be easily obtained by synthesizing hydroxyapatite from natural sources, such as corals, starfishes, seashells, animal bones, bird eggshells etc. The natural sources used in the present work are three types of biogenic calcium carbonate, i.e. calcium carbonate that is produced by living organisms in the form of aragonite or calcite. Among the different sources, three biogenic calcium carbonates were chosen: cuttlefish (Sepia Officinalis) bones, mussel (Mytilus Galloprovincialis) shells and chicken eggshells. Besides their abundance and availability, they were selected because of their different composition: aragonite in cuttlebones, calcite in eggshells and a mixture of aragonite and calcite in mussel shells. After the first chapter, which is a theoretical introduction, this thesis is divided into other five chapters. Chapter 2 contains a careful characterization of the three biogenic raw materials while Chapter 3 deals with the synthesis of hydroxyapatite starting from these natural sources. The process developed here takes place entirely at nearly room temperature, which allows the organic part of the biological materials to be preserved. This synthesis process is basically a wet mechanosynthesis followed by a mild heat treatment (up to 150°C). The study focuses on the influence of several process parameters on the synthesis efficiency: temperature, milling time, pH and raw material. The temperature used to dry the slurry after the wet ball-milling was found to be the most important parameter, the higher the temperature the faster the conversion of CaCO3 into hydroxyapatite. Moreover, aragonite was found to transform more easily into hydroxyapatite with respect to calcite, and also to follow a different reaction path. The synthesis process described in Chapter 3 allowed to produce different bio-derived powders that were found to be non-stoichiometric, nanosized, carbonated hydroxyapatites, containing also additional ions, especially Mg2+ in the eggshell-derived material and Sr2+ in the cuttlebone-derived one. These powders were then used as a starting point for the studies presented in the next three chapters. Chapter 4 shows a very preliminary evaluation of the interaction with human cells in vitro. First, the as-synthesized powders were consolidated by uniaxial pressing and sintering at temperatures between 900°C and 1100°C and their crystallographic composition was analyzed. Then, after having established the non-cytotoxicity of the sintered pellets, osteoblasts from human osteosarcoma cell line were seeded on the pellets and their behavior after 1, 3 and 5 days of culture was observed by confocal microscopy. In general, all materials promoted good cell adhesion and proliferation, especially the eggshell-derived one. At this point, the bio-derived materials were found to induce a good cellular response but, in order to foster the regeneration of bones, a scaffold must also contain a large amount of interconnected porosity. Among the numerous methods to fabricate porous structures, additive manufacturing is surely very attractive due many advantages, such as the possibility of customizing the shape based on tomography images from the patients, the fact that no mold is needed and the freedom of fully designing the porosity. Indeed, not only the size and the amount of porosity are important, but also the shape of the pores and their position and orientation have a deep effect on the interaction with the cells. Therefore, Chapter 5 and Chapter 6 deal with the fabrication of scaffolds by 3D printing, following two different approaches. In the study presented in Chapter 5, the powders synthesized from cuttlebones, mussel shells and eggshells were used in combination with a thermoplastic polymer (PCL, polycaprolactone) to obtain bioactive composites. Composite materials made of 85 wt% PCL and 15 wt% bio-derived hydroxyapatite were used to fabricate porous scaffolds by extrusion 3D printing. The biological in vitro tests showed that the composite scaffolds possess better bioactivity than the pure PCL ones, especially those containing mussel shell- and cuttlebone-derived powders, which promoted the best cell adhesion, proliferation and metabolic activity of human osteosarcoma cells after 7 days of culture. In addition, the elastic compressive modulus, which was found to be between 177-316 MPa, thus in the range of that of trabecular bone, was found to increase of about ∼50% with the addition of the bio-derived nanopowders. Finally, in Chapter 6, the cuttlebone-derived powder was used to fabricate porous bioceramic scaffolds by binder jetting 3D printing. Due to serious technical issues related to the printing of a nanosized powder, 10 wt% of bio-derived powder was mixed with a glass-ceramic powder with bigger particle size. Moreover, the organic part of the cuttlebone had to be previously eliminated by a heat treatment at 800°C. Thanks to the great freedom of design that is allowed by the binder jetting process, scaffolds with two different pore geometries were fabricated: with pores of uniform size and with a size-gradient. Indeed, natural bone possesses a gradient in porosity from the core to the surface, from porous trabecular bone to dense cortical bone. The sintered scaffolds showed a total porosity of ∼60% for the pure glass-ceramic and ∼70% for the glass-ceramic with 10 wt% of cuttlebone-derived nanoparticles, which most probably slowed down the densification by limiting the contact between the glassy particles. All the bioceramic scaffolds promoted good adhesion and proliferation of human bone marrow-derived mesenchymal stem cells in vitro, without any significant difference between the different samples. However, the scaffolds with the cuttlebone-derived powder and with gradient porosity showed the greatest decrease of metabolic activity after 10 days of culture, which could be accounted as a sign of differentiation of stem cells.

When laying up dry composite materials and aligning the fibers in the appropriate directions it can be a challenge due to the dryness of the fiber and mold design. Several commercial products are available to help fix plies to molds keeping the proper fiber orientation depending upon mold geometry. Prepreg and wet layups do not have this problem due to the inherent inclusion of a matrix in their manufacturing, dry materials have no added epoxy at the time of layup and are therefore in need of assistance maintain position. The purpose of this research is to determine if Super 77™ or EPON™ 2002 increases or decreases mechanical properties of the neat resin and composite laminates; if the increase or decrease is dependent upon the type of epoxy, and if the amount of applied tackifier can be optimized towards a high or low application quantity to minimize any detrimental effects to mechanical properties. Each tackification agent was applied in high and low concentrations to eight composite panels, with two control panels. The EPON™ was applied manually and set with heat exposure while the Super 77™ was sprayed from an aerosol can. The Super 77™ plies were stacked and pressed by hand while the EPON™ plies were stacked and ironed together to create panels, which were then infused with one of two room temperature infusion epoxies, MVS 610 or INF 114. The panels were then cut to specimen size for testing. Neat resin specimens were cast in silicone molds with high and low concentrations of tackifiers and allowed to cure for 12 hours at room temp, then heated to 60° C for 8 Both Super 77™ and EPON™ 2002 reduced the SBS for both epoxies, but Super 77™ reduced the short beam shear more than EPON™ 2002. The modulus of the neat resin cast specimens with high concentration were between 0 to 20% lower than neat resin with no tackifier; the tensile strength was increased for those specimens with Super 77™ and lower for those with EPON™ 2002. Similarly, the Charpy test resulted in higher values for Super 77™ than for EPON™ 2002. The effects of Super 77™ and EPON™ 2002 are complex and varied depending on application concentration, resin, and tackifier type; but the addition of any tackifier reduces mechanical properties from non-tackified laminates.

Additive manufacturing (AM) has experienced significant growth and development in recent years, owing to the ability to produce complex parts using a wide range of materials with relative ease. Powder bed-based metal AM has been at the forefront of this growth, even reaching the point where parts can be manufactured for end-use applications. Binder jetting (BJ) is one such technique where a liquid binder is selectively deposited on powder layers to create a green body which is then densified using sintering. The aim of this work was to use binder jetting to produce parts using Vanadis 4 Extra, a highly alloyed cold-work tool steel produced by Uddeholm AB for applications involving high demand on abrasive wear. Optimization of the densification parameters, which included debinding atmosphere, debinding temperature, sintering atmosphere, sintering temperature, and sintering time, to achieve full density parts was carried out as the first phase. It was found that the sintering atmosphere and time had the most significant impact on the density of the samples while the debinding atmosphere heavily impacted the C residue from the binder. In the second phase, samples were produced using the optimized parameters for mechanical analysis, which included analyses of the surface roughness and the wear resistance of the binder jetted samples against the conventionally produced samples. The surface roughness was in line with the data presented in literature for binder jetted samples. The binder jetted samples produced during this work exhibited better wear resistance than the conventionally produced samples, with the samples post-processed using hot isostatic pressing showing even better wear resistance. One possible explanation is the diffusion of N from the sintering atmosphere into the samples, leading to the conversion of carbides to carbonitrides and even nitrides. However, further investigation is needed in order to confirm this theory.

No description available.

This study aims to introduce a new qualification approach designed to enhance the overall integrity of complex cooling structures in gas turbine blades produced through 3D printing, with a focus on achieving maximum density. The primary objective is to present a comprehensive qualification and validation methodology tailored for components manufactured via binder jetting printing and non-selective laser melting (SLM) powder-based atomic diffusion additive manufacturing. This innovative qualification approach undergoes validation through stages encompassing design, printing, comprehension of thermal debinding and sintering processes, post-processing, optimization, and characterization, all aimed at achieving complex cooling structures with optimal density using stainless steel material and In718 as a case study. Subsequently, the material properties obtained are compared with those of IN718 produced via laser-based manufacturing. Thorough characterization is conducted before and after sintering to assess the impact of sintering on density enhancement. Experimental optimization employing the Taguchi matrix with an L9 orthogonal array involves the selection of three key parameters: sintering time, sintering temperature, and heat treatment. The procedural framework established in this research applies to high-temperature applications wherein components are fabricated using atomic diffusion additive manufacturing or binder jetting printing techniques. Testing and inspection procedures involve neutron scattering, radiography, and CT scanning methods, with a specific emphasis on neutron scattering measurements conducted under externally heated and internally cooled conditions to evaluate residual strains within the gas turbine environment. Understanding the interplay between residual stresses originating from manufacturing processes and thermal stresses provides valuable insights into the impact of additive manufacturing on component performance in thermal environments, thus contributing to the advancement of the proposed study.

Dissertation thesis is focused on rheological properties of asphalt binders and on changes of their performance during the lifetime in road structures. Aging processes of asphalt binders and methods of laboratory aging are described in the theoretical part of the thesis. Furthermore, basic rheological models and related test methods for the evaluation of asphalt binders are described. In the practical part, properties of asphalt binders are investigated after aging process and their performance is evaluated by empirical and functional test methods. The various methods of aging are compared with each other and a relationship between real conditions and laboratory aging is researched. In the next section, vacuum flashed cracked residue (VFCR) is added to the selected asphalt binders and their influence on rheological properties during description of aging of asphalt binders is investigated. The results were used in publication of two certified methodology under the title „The methodology for the evaluation of paving bitumen in terms of susceptibility to thermal oxidative aging“ and „The methodology describes laboratory aging of asphalt mixtures“. The results of the thesis are listed in the conclusion.

The aim of the diploma thesis is to verify and compare the properties of bituminous stone mastic asphalt, namely SMA 11S with modified PMB 45 / 80-55 asphalt binder or 50/70 road bitumen binder with rubber granulate. Comparison of properties is performed using functional tests. The thesis is divided into the theoretical and practical part. The theoretical part deals with the familiarization with the use of the SMA mixture, the selected concepts concerning recycling of non-leveled roads are described and described. Attention is paid especially to the recycling of roads in the Czech Republic with an emphasis on hot recycling on the incinerator, which allows increased dosing of Reclaimed Asphalt into asphalt mixtures. In the practical part, the results of the functional tests of the SMA 11S mixture, which have been taken from the test section, are processed and evaluated.

The subject of the thesis is to describe the effect of fluxing additives on the behaviour of asphalt binders. Emphasis will be placed on changes in rheological properties of asphalt binders at intermediate temperatures, stability during aging and influence of fluxing agents on their low-temperature properties. Theoretical part will deal with the principle of asphalt binders aging and it will summarize knowledge about fluxing additives. Further, empirical and functional tests will be described in order to evaluate asphalt binders. In the practical part, all laboratory tests will be evaluated and the effects of two different fluxing additives will be compared.

Diploma thesis deals with adding R - material to the wearing asphalt courses, specifically to the SMA 11S. It has two parts – theoretical and practical. The theoretical part describes using R - material in the recycling of roads, different types of recycling and how is this problem handled in the Czech Republic, the practical part deals with the design of three kinds of asphalt mixtures with different added ratios of R – material, describing empirical and functional tests on the bitumen binder and the designed asphalt mixtures and the results of those tests.