Applications involving high electrical conduction require complex components that are difficult to be manufactured by conventional processes. Laser sintering (LS) is an additive manufacturing technique that overcomes these drawbacks by offering design flexibility. This study focuses upon optimizing the process of laser sintering to manufacture functional prototypes of components used in high electrical conduction applications. Specifically, components for two systems – high current sliding electrical contacts and fuel cells – were designed, manufactured and tested. C-asperity rails were made by LS and tested in a high current sliding electrical setup. Corrugated flow field plates were created by LS and their performance in a direct methanol fuel cell (DMFC) was tested. This is the first experimental attempt at using laser sintering for manufacturing such complex components for use in high electrical conduction applications. The second part of this study involves optimization the laser sintering process. Towards this, efforts were made to improve the green strength of parts made by LS. Particle size of graphite/ phenolic resin and addition of nylon/11 and wax were tested for their effect upon green strength. Of these, significant improvement of green strength was observed by altering the particle size of the graphite/ phenolic resin system. New methods of improving green strength by employing fast cure phenolic resins with carbon fiber additions were successfully demonstrated. This study also identified a binder system and process parameters for indirect LS of stainless steel –for bipolar plate compression/ injection mold tooling. All the experimental results of this study lead us to believe that laser sintering can be developed as a robust and efficient process for the manufacture of specialized components used in advanced electrical conduction systems. / text

The thesis deals with the development of self-leveling cement screed with compensated shrinkage. It is a ternary binder system with the majority of portland cement, that in the beginning of setting and hardening form an expandable folder ettringite. At first there was a background research of volume changes of hydrating cement composites and methods for measuring these changes. Various sort of expansion additives were also introduced, the main emphasis was on concepts of calculated formation of ettringite, which are typical for self-leveling underlayment. Background research included the issues of formation of ettringite, influences on it’s nucleation and it’s stability. The practical development of the screed began by measuring volume changes of different pastes on a ternary composition. Selected formulations suitable for use are verified together with additives to semi-application tests. After the final configuration of the screed mixture, there was a test in real application of an representative area. Individual formulations were tested in terms of long-term stability of ettringite in dry and moist environments.

This thesis aims to optimize self-levelling floor screeds and thin layer screeds based on ternary binder system containing portland cement, calcium aluminate cement and gypsum with intentional ettringite formation. It also studies the influence of designed mixtures, chemical admixtures and aggregate granulometry on achieved technological characteristics required by standard.

The project elaborated in frame of engineering studies branch M2332-00. The project is submitting the study of binder systems for technology Warm box. Pursuant to the literary pursuit a problem of the technology Warm box these binders was tested: binder systems based of the Na-silicates, biogenous binders – proteins, polysacharides and fenol resins. Fenol resins and biogenous binders (K2 and Hide glue) showed to be optimal for core making technology Warm box. Biogenous binders are ecologically unexceptionable.

This dissertation thesis deals with interactions on the interface core - melt by casting of cylinder heads from Al alloys in semi-permanent moulds and solves a specific problem with sticky sand after decoring of a diesel cylinder head casting. It describes in detail the process of core production using the Cold-Box method and process of casting using the progressive technology Rotacast. It theoretically analyses the reaction on the interface core-melt and presents a classification of surface defects by Al castings produced by gravity casting into semi-permanent moulds. It also states the results of technological tests of binders, core mixtures and cores (Cogas analysis). By solution of a problem with sticky sand in intake and exhaust ports of diesel cylinder head casting is used methodology for problem solving DMAIC. All experimental tests are solved in laboratory and production conditions of an international company dealing with casting of cylinder heads from Al alloys in semi-permanent moulds.