Solving of this diploma thesis is evaluation porosity in sequence on mechanical properties from different Al alloys. Castings were made by gravity casting to the iron-mould or gravity casting to the sand. Measurements (mechanical properties, porosity, DAS - dendrite arm spacing, shape factors and sphericity) were statistically analysed and dependencies which were detected were processed to the graphs.

Dendritic solidification has been the subject of continuous research, also because of its high importance in metal production. The challenge of predicting macroscopic material properties due to complex solidification processes is complicated by the multiple physical scales and phenomena involved. Practical modeling approaches are still subject to significant limitations due to remaining gaps in the systematic understanding of dendritic microstructure formation. The present work investigates some of these problems at the microscopic level of interfacial morphology using phase-field simulations. The employed phase-field models are implemented within a finite-element framework, allowing efficient and scalable computations on high-performance computing facilities. Particular emphasis is placed on the evolution and interaction of dendrite sidebranches in the broader context of dendrite fragmentation, varying and dynamical solidification conditions.

Für den Zylinderkopf ist das Schwerkraftgießen ein etabliertes Gießverfahren. Jedoch gehen die Gießereien in der Ausführung des Schwerkraftgusses unterschiedlich vor. Durch die mannigfaltigen Anschnittsysteme und die sich dadurch ergebenden Vor- bzw. Nachteile bei der Herstellung entstehen Unterschiede bei Qualität und Kosten. Ziel dieser Arbeit ist es, Standards und Vereinheitlichungen während der Produktentstehung eines Zylinderkopfes zu etablieren, um eine gleichbleibende Qualität der Zylinderköpfe in den Gießereien zu gewährleisten. Dazu sind vielfältige Ansatzpunkte zu verfolgen. Eine Möglichkeit ist die geometrische Beurteilung des Zylinderkopfs, wie z.B. Wandstärken, Speisungswege und die Außengeometrien. Die nach Lastenheftvorgaben zu erfüllenden Eigenschaften spielen gleichermaßen eine Rolle und haben Einfluss auf die Wahl des Gießverfahrens. Mit Hilfe von speziellen Entscheidungsmethoden ist eine Vorauswahl für ein Gießverfahren möglich. Des Weiteren werden mittels experimentellen Untersuchungen die Entscheidungen gestützt. Die Gießsimulation ist als zusätzliches Auslegungswerkzeug einzusetzen. Hierbei sind Gussfehler im Bauteil zu lokalisieren und zu vermeiden. Unzureichende Speisungswege oder zu geringe Wandstärken durch komplizierte Kerngeometrien sind zu ermitteln. Des Weiteren sind Vorhersagen zu Dendritenarmabständen und Materialausnutzung (Speiserdimensionierung) möglich, die direkt mit der Wahl des Gießverfahrens zusammenhängen. Die Verzahnung von Geometrie- und Metallurgiefaktoren führt idealerweise zur Definition von Standardisierungsaspekten zur Auswahl der Gießtechnologie bei der Zylinderkopfentwicklung. Durch eine parallele Produkt- und Prozessentwicklung ist eine Verkürzung des Produktentstehungsprozesses erreichbar.

Additive manufacturing can bring several advantages in tooling applications especially hot working tooling as high pressure die casting. Printing of conformal cooling channels can lead to improved cooling and faster solidification, which, in turn, can possibly result in better quality of the cast part. However, few studies on advantages of additive manufactured tools in high pressure die casting are published.The aim of this study was to investigate and quantify the effect of conformal cooling on microstructure and mechanical properties of high pressure die cast aluminum alloy. Two tools each consisting of two die inserts were produced with and without conformal channels using additive manufacturing. Both tools were used in die casting of aluminum alloy. Aluminum specimens were then characterized microstructurally in light optical microscope for secondary arm spacing measurements and subjected to tensile and hardness testing. Cooling behavior of different inserts was studied with a thermal camera and by monitoring the temperature change of cooling oil during casting. Surface roughness of die inserts was measured with profilometer before and after casting.Thermal imaging of temperature as a function of time and temperature change of oil during casting cycle indicated that conformal insert had faster cooling and lower temperature compared to conventional insert. However, thermal imaging of temperature after each shot in a certain point of time showed higher maximum and minimum temperature on conformal die surface but no significant difference in normalized temperature gradient compared to the conventional insert.The average secondary dendrite arm spacing values were fairly similar for samples from conventional and conformal inserts, while more specimens from conventional insert demonstrated coarser structure. Slower cooling in conventional insert could result in the coarser secondary dendrite arm spacing.Tensile strength and hardness testing revealed no significant difference in mechanical properties of the specimens cast in conventional and conformal die inserts. However, reduced deviations in hardness was observed for samples cast with conformal insert. This is in agreement with secondary dendrite arm spacing measurements indicating improved cooling with conformal insert.Surface roughness measurement showed small wear of the inserts. More castings are needed to observe a possible difference in wear between the conventional and conformal inserts.Small observed differences in cooling rate and secondary arm spacing did not result in evident difference in mechanical properties of the aluminum alloy but the variation in properties were reduced for samples cast with conformal cooling. Future work may include more accurate measurement of cooling behavior with a thermocouple printed into the die insert, casting of thicker specimen for porosity evaluation and fatigue testing and longer casting series to evaluate the influence of conformal cooling on tool wear.

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Ce manuscrit décrit analytiquement et numériquement les instabilités d'un fluide magnétique dans une cellule de Hele-Shaw. On considère l'interface entre un fluide magnétique et un autre fluide non magnétique, miscible ou non, soumise à un champ magnétique homogène normal à la cellule ou à l'interface. Le champ démagnétisant est inhomogène à cette interface et génère un mouvement convectif des fluides. Dans la première partie, nous avons utilisé une analyse linéaire de stabilité entre deux liquides miscibles pour une distribution donnée de concentration à l'interface. Les résultats s'appliquent aussi à la stabilité d'un réseau de concentration induit par une expérience de Rayleigh forcé. Nous avons démontré que l'équation de Brinkman décrit mieux la dissipation visqueuse dans une cellule de Hele-Shaw que celle de Darcy. Nous avons trouvé que la viscosité (et non la diffusion massique) donnait à l'écoulement une échelle de longueur de l'ordre de l'épaisseur de la cellule dans le cas des forçages élevés. Dans la seconde partie de notre étude, nous avons modélisé la dynamique non linéaire de l'interface avec une tension superficielle par la méthode des intégrales de frontière. Nous avons décrit la modification des doigts de Saffman–Taylor par les forces magnétostatiques. Nous avons obtenu des structures dendritiques proches de celles observées expérimentalement et analysé quelques aspects de la formation des motifs.

The thesis describes the synthesis of PbS nano-, micro-structures by colloidal and hydrothermal techniques. Size and morphology dependent luminescence studies were carried out in detail. Application oriented studies like ion sensing and modulation of luminescence are carried out on colloidal PbS QDs. Photoelectrical studies are carried out on various morphologies of PbS microstructures. We observe the persistent photoconductivity, growth and quenching of photocurrent, and a few novel phenomena in flower shaped PbS microstructures. This work is presented in eight chapters inclusive of summary and directions for future work. CHAPTER 1 provides a brief introduction to optical and photoelectrical properties of semiconductor quantum dots and hydrothermal technique in preparation of quantum structures. A review of PbS nanostructures and its technological applications are discussed. CHAPTER 2 provides the experimental techniques used in this work. First, the synthesis of PbS nano-, micro-structures by various methods, and characterization tools used in this work are briefly presented. CHAPTER 3 deals with the synthesis of PbS quantum dots in poly vinyl alcohol with various precursor concentrations to identify the surface states by temperature dependent photoluminescence (PL) measurements. Average bandgap value calculated from absorption measurements was 2.1 eV. We have observed that high-energy PL bands (>1.3 eV) are due to electron traps (Pb dangling bonds) and low-energy bands (<1 eV) are due to hole traps (S dangling bonds). By capping with thiol compounds (mercaptoethanol-C2 H5OSH), absence of the 1.67 eV band indicates the passivation of Pb dangling bonds. To explain above observed results, we propose a band diagram with distributed shallow to deep states and attributed them to the specific surface related defects (Pb or S). CHAPTER 4 discusses the ion sensing applications of PbS quantum dots. We found that the sulfur related dangling bonds are quite sensitive to different metallic ions (since mercaptoethanol passivates only Pb atoms). Sulfur related PL band (~ 1 eV) have shown an order of magnitude improvement in its intensity for Hg, Ag ions and relatively low enhancement for Zn, Cd ions at 1 µmol concentrations. However Cu quenches the luminescence. An important distinction may have to be made between PbS and Cd related quantum structures. The PbS QDs can distinguish between Cu & Hg, however Cd related QDs couldn’t distinguish between these two ions. Photo-brightening and photo-darkening is an interesting phenomena indicative of photo-induced ionic migration that either helps in enhancing the emission of sulfur related defect emission or degrades the emission properties depending on the ion concentration. This report is the first of its kind in ion sensing applications using PbS QDs. CHAPTER 5 discusses the results of duel beam excitation on trap luminescence of PbS QDs. By using different lasers simultaneously (514 nm and 670 nm), we have observed the reversible luminescence quenching of trap emission. The high-energy PL band (1.67 eV) has double the quenching effect compared to low-energy PL band (1.1 eV). The luminescence quenching mechanism is attributed to the re-emission of the charge carriers from the traps (photo-ionization) due to the simultaneous excitation with the second beam. The dependence of the temperature, the effect of two beam excitation intensities and modulation frequency dependent quenching mechanism are primarily focused in this chapter. The quenching mechanism is considered to be quite useful in the optical modulation devices. CHAPTER 6 discusses the PL results on various morphologies of PbS nano-, microstructures. Interestingly, after protecting the surface with organic ligands such as mercaptoethanol (C2 H5OSH), dendrite structures have shown high-energy bands (~ 1.0 eV) in the PL spectra, which indicate the existence of various quantum confinement regimes in different branches of dendrites. The anomalous temperature dependent behavior of PL intensity is attributed to the size distribution. CHAPTER 7 discusses the results of photoconductivity measurements on various morphologies of PbS nano-, micro-structures. Flower shaped structures have shown persistent photoconductivity (PPC). This observed PPC is attributed to the presence of potential barriers, which are created by the different confinement regimes or due to the lattice relaxation, which occurs due to the carrier trapping at surfaces. In PPC, the estimated time constants of both build up and decay transients using the stretched exponentials are of the order of few tens of seconds. In PPC measurements, we observe the PC quenching below 40 K and growth above this temperature. PC quenching is attributed to the transfer of photo-excited carriers to a metastable state. The presence of metastable state is supported by the dark conductivity measurements in flower shaped structures. CHAPTER 8 presents the summary and directions for the future work.

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