Significant efforts have been made in the last decades to decrease the world’s dependency to fossil fuels. One of the fronts which has shown major improvement is gas turbine efficiency. To this end, components such as recuperators have been developed to recover heat that is usually trapped and wasted in the exhaust gases of combustion processes. Brayton Energy Canada has recently developed a promising compact heat exchanger that could be used as a recuperator in gas turbines. Nevertheless, this novel type of wire mesh heat exchanger still has room for improvement, especially regarding the way that its fin arrays are manufactured due to the fact that the technique presently used is time consuming and consequently costly. The present research aims to manufacture near-net shaped pin fin arrays using cold gas dynamic spray as an additive manufacturing technique by selectively covering the substrate by the means of a mask. Moreover, this research work studies the feasibility of using CGDS as an additive manufacturing technique to produce pin fin arrays, the thermal and hydrodynamic performances of this new type of pin fin created, the effect of geometric parameters such as fin density and height on the performances, the viability of the sprayed pin fins in a real environment by means of finding mechanical properties such as adhesion strength, the possibility of producing a streamwise material anisotropic fin arrays, and finally the different adhesion mechanisms by means of numerical modeling of the relevant impact physics.

Within the framework of an Institutional Partnership of the Alexander von Humboldt Foundation, the Budker Institute of Nuclear Physics Novisibirsk (BINP) and Forschungszentrum Dresden-Rossendorf worked together in a joint project devoted to the research at the coupled GDT-SHIP facility of the BINP with the focus on the study of plasma phenomena within the SHIP mirror section. The project began at July 1st, 2005 and ended on August 30th, 2008. It included work packages of significant theoretical, computational and analyzing investigations. The focus of this final report is on the presentation of results achieved whereas the work that was done is described briefly only. Chapter 2 illustrates the GDT-SHIP facility and describes shortly the planned topics of the SHIP plasma research. Chapter 3 explains the main extensions and modifications of the Integrated Transport Code System (ITCS) which were necessary for the calculations of the fast ion and neutral gas particle fields in SHIP, describes briefly the scheme of computations and presents significant results of pre-calculations from which conclusions were drawn regarding the experimental program of SHIP. In chapter 4, the theoretical and computational investigations of self-organizing processes in two-component plasmas of the GDT-SHIP device are explained and the results hitherto achieved are presented. In chapter 5, significant results of several experiments with moderate and with enhanced plasma parameters are presented and compared with computational results obtained with the ITCS. Preparing neutron measurements which are planned for neutron producing experiments with deuterium injection, Monte Carlo neutron transport calculations with the MCNP code were also carried out. The results are presented. Finally, from the results obtained within the joint research project important conclusions are drawn in chapter 6.

L'objectif de cette thèse est de développer un nouveau schéma numérique du type volumes finis pour la dynamique des gaz. Dans deux articles, F.Berthelin, T.Goudon et S.Minjeaud proposent de résoudre le système des équations d'Euler barotrope en dimension 1 d'espace, avec un schéma d'ordre 1 fonctionnant sur grilles décalées et dont la conception des flux est inspirée des schémas cinétiques. Nous proposons d'enrichir ce schéma afin qu'il puisse résoudre le système des équations d'Euler barotrope ou complet, en dimension 2 d'espace sur maillage cartésien ou non structuré, possiblement à l'ordre 2 et le cas échéant à bas nombres de Mach. Nous commencerons par développer une version 2D du schéma sur grilles cartésiennes (ou MAC) à l’ordre 2 via une méthode de type MUSCL, d'abord pour les équations barotropes puis pour les équations complètes. Ces dernières demandent de traiter une équation d’énergie supplémentaire et l’un des problèmes -résolu- est de trouver une définition discrète convenable de l’énergie totale telle qu'elle satisfasse une équation conservative locale. Dans un troisième chapitre nous étudierons le passage à la limite du compressible vers l'incompressible et nous verrons comment utiliser les atouts de notre schéma afin de le modifier et d'en faire un schéma Asymptotic Preserving pour des écoulements à bas nombres de Mach. Dans un quatrième temps nous proposerons une adaptation du schéma sur des maillages non structurés. Notre approche sera fortement inspirée des méthodes DDFV et pourra présenter des avantages dans les régimes à faibles nombres de Mach. Cette thèse se termine par un cinquième chapitre issu d’une collaboration lors du CEMRACS 2017, où le point de vue considéré n’est plus macroscopique mais microscopique. Nous commencerons par étudier un modèle micro/macro idéalisé auquel un processus stochastique a été ajouté puis nous tenterons d'en déduire un modèle à grande échelle pour un système fortement couplé, qui soit consistant avec la description micro/macro sous-jacente du problème physique. / The objective of this thesis is to develop a new numerical scheme of finite volume type for gas dynamics. In two articles, F.Berthelin, T.Goudon and S.Minjeaud propose to solve the barotropic Euler system in dimension 1 of space, with a first order scheme that works on staggered grids and of which fluxes are inspired by kinetic schemes. We propose to enhance this scheme so that it can solve the barotropic or complete Euler systems, in dimension 2 of space on Cartesian or unstructured grids, possibly at order 2 and at Low Mach numbers where appropriate. We begin with the development of a 2D version of the scheme on Cartesian (or MAC) grids, at order 2 via a MUSCL type method, for the barotropic equations at first and then for the complete equations. The latter require to handle with an additional energy equation and one of the -solved- problems is to find a suitable discrete definition of the total energy such that it satisfies a local conservative equation. In a third chapter we study the transition from the compressible case to the incompressible limit and we shall see how to use the advantages of our initial scheme in order to make it an Asymptotic Preserving scheme at low Mach numbers. In a fourth chapter we propose an adaptation of the scheme on unstructured meshes. Our approach is strongly inspired by the DDFV methods and may have advantages in low-Mach regimes.This thesis ends with a fifth chapter issued from a collaboration during CEMRACS 2017, where the considered point of view is no longer macroscopic but microscopic. We begin by studying a simplified micro/macro model with an added stochastic process and then we attempt to deduce a large-scale model for a strongly coupled system which has to be consistent with the underlying micro / macro description of the physical problem.

Aluminum alloys have been used for decades in aircraft as they offer a wide range of properties explicitly developed to provide a set of characteristics adapted to structural and non-structural components. However, aircraft components inevitably undergo degradation during service due to their extensive use and exposure to harsh environments. Typical repair methods are either not efficient for large scale repairs due to their low material growth rate, not suitable for field repair or involve the use of high process temperatures. The present research aims at evaluating the cold gas dynamic spray (CGDS) as a potential repair technology to restore Al7075-T6 nose landing gear steering actuator threads found on the Boeing 757 aircraft. Moreover, it studies the suitability of using cold spray to deposit Al2024 material. The influence of process parameters and substrate surface preparation on the material deposition efficiency and resulting microstructural and mechanical repair properties is also evaluated.

Carbon fibre reinforced composites are known for their high specific strength-to-weight ratio and are of great interest to the aerospace industry. Incorporating these materials into the fuselage, like in Boeing's 787 "Dreamliner", offers considerable weight reduction which increases flying efficiency, and reduces the cost of flying. In flight, aircraft are often subject to lightning strikes which, in the case of composites, can result in localized melting given the high resistive nature of the material. Aerospace carbon fibre composites often incorporate a metallic mesh or foil within the composite layers to dissipate the electrical charge through the large aircraft. The damage to the aircraft is minimized but not always eliminated. This research aims to elaborate a practical technique to deposit thin layers of conductive material on the surface of aerospace grade composites. Using Cold Gas Dynamic Spray (CGDS), such coatings could be used to repair damaged components. An experimental research approach was used to develop metallic coated composites. Using the CGDS equipment of Centerline (SST-P), specific parameters (such as gas temperature and stagnation pressure) were determined for each type of metallic coating (tin-based & copper-based). The use of bond coats was explored in order to attain the desired coatings. Once optimized, these coatings were evaluated with respect to their corrosive, adhesive, and electrical properties following industry standards.

The purpose of this research work was to develop a nozzle capable of depositing dense CoNiCrAlY coatings via cold gas dynamic spray (CGDS) as well as compare the oxidation performance of bond coats manufactured by CGDS, high-velocity oxy-fuel (HVOF) and air plasma spray (APS) at temperatures of 1000°C and 1100°C. The work was divided in two sections, the design and manufacturing of a CGDS nozzle with an optimal profile for the deposition of CoNiCrAlY powders and the comparison of the oxidation performance of CoNiCrAlY bond coats. Throughout this work, it was shown that the quality of coatings deposited via CGDS can be increased by the use of a nozzle of optimal profile and that early formation of protective α-Al2O3 due to an oxidation temperature of 1100°C as opposed to 1000°C is beneficial to the overall oxidation performance of CoNiCrAlY coatings.

The purpose of this research work was to develop a nozzle capable of depositing dense CoNiCrAlY coatings via cold gas dynamic spray (CGDS) as well as compare the oxidation performance of bond coats manufactured by CGDS, high-velocity oxy-fuel (HVOF) and air plasma spray (APS) at temperatures of 1000°C and 1100°C. The work was divided in two sections, the design and manufacturing of a CGDS nozzle with an optimal profile for the deposition of CoNiCrAlY powders and the comparison of the oxidation performance of CoNiCrAlY bond coats. Throughout this work, it was shown that the quality of coatings deposited via CGDS can be increased by the use of a nozzle of optimal profile and that early formation of protective α-Al2O3 due to an oxidation temperature of 1100°C as opposed to 1000°C is beneficial to the overall oxidation performance of CoNiCrAlY coatings.

The purpose of this research work was to develop a nozzle capable of depositing dense CoNiCrAlY coatings via cold gas dynamic spray (CGDS) as well as compare the oxidation performance of bond coats manufactured by CGDS, high-velocity oxy-fuel (HVOF) and air plasma spray (APS) at temperatures of 1000°C and 1100°C. The work was divided in two sections, the design and manufacturing of a CGDS nozzle with an optimal profile for the deposition of CoNiCrAlY powders and the comparison of the oxidation performance of CoNiCrAlY bond coats. Throughout this work, it was shown that the quality of coatings deposited via CGDS can be increased by the use of a nozzle of optimal profile and that early formation of protective α-Al2O3 due to an oxidation temperature of 1100°C as opposed to 1000°C is beneficial to the overall oxidation performance of CoNiCrAlY coatings.

The cold gas dynamic spray process developed in the middle of the 80’s reached the industrial stage in development. Even so, many scientific investigations still go on. The nature of the bond between the coating and the substrate is the subject of some controversy. The development of the process will be improved by understanding how the properties of the powder and the mechanical properties of the substrate influence the bonding process. This study analyses the basic dynamics of the process when copper is sprayed.<p>• The one dimensional isentropic model of the gas behaviour in a Laval type nozzle allows evaluating the effect of the gas stagnation pressure P0 and temperature T0 on the impact velocity and temperature of the powder particle.<p>• The analysis of single splats on two substrates (aluminium and steel) shows the influence of the substrate on the deformation of single particles and the influence of the impact speed on the impact shape.<p>• Coatings are made of with powders with a specific size distribution. Two copper powders with a different size distribution are compared based on the deposition efficiency (D.E.) and the mechanical properties of the coating. The mechanical properties tested are the microhardness, the bond strength and the nanohardness.<p>• X-ray diffraction will show that the two powders have an initial very different microstructure. The consequence of this is a different deformation mechanism during the coating build up.<p>• An Auger analysis of the interface has shown the presence of diffusion zone when copper was sprayed on the Al and TA6V substrate.<p>It appears that the size distribution will determine the final impact conditions of the powder. The microstructure of the powder and the oxide content of the powder yield different deformation processes and may explain the differences in D.E. and mechanical properties. The Auger analysis of the interface has yielded diffusion zone that were not expected but some mechanisms under impact loading can explain their presence./<p>Le procédé de projection thermique à froid a été développé dans le milieu des années 80 et il arrive au stade industriel. Néanmoins, plusieurs développements scientifiques sont encore en cours. La nature du lien entre la poudre et le substrat est toujours l’objet de certaines controverses. Le développement futur du procédé nécessite une bonne compréhension de l’influence de la poudre et des propriétés du substrat sur le mécanisme d’adhérence. Cette étude va mettre en évidence les principaux facteurs influençant la projection de cuivre.<p>• Le modèle unidimensionnel isentropique du gaz parfait dans une buse convergente/ divergente permet de déterminer l’influence de la pression de stagnation et de la température de stagnation sur la vitesse et la température d’impact des particules de poudre.<p>• L’analyse d’impact unique sur les substrats d’acier et d’alliage d’Al (AA2014) montre l’influence du substrat sur la déformation des particules de poudre. La vitesse d’impact a une conséquence importante sur la forme d’une particule projetée sur une surface. <p>• Les revêtements sont fabriqués à partir de poudre avec une granulométrie donnée. Deux poudres avec une distribution de taille différente sont comparées par leur rendement de déposition et les propriétés mécaniques des revêtements obtenus. Les propriétés mécaniques testées sont la microdureté, l’adhérence et la nanodureté.<p>• La diffraction par rayons-X montre que les deux poudres ont initialement une microstructure très différente. Lors de l’impact, les deux poudres vont se déformer de manière différente et ceci se traduit dans la microstructure.<p>• La spectroscopie Auger montre qu’une zone de diffusion s’est formée à l’interface entre le cuivre et les deux substrats d’Al et de TA6V.<p>La distribution de taille des poudres a une influence considérable sur la vitesse et la température d’impact des particules de poudres mais il apparaît que d’autres facteurs ont aussi énormément d’influence. Le taux d’oxyde dans la poudre a une influence très importante sur le rendement et l’adhérence du dépôt. Les deux poudres projetées ont une microstructure initiale très différente et ceci se traduit par une déformation différente des particules de poudre dans le revêtement.<p> / Doctorat en Sciences de l'ingénieur / info:eu-repo/semantics/nonPublished

The purpose of this research work was to develop a nozzle capable of depositing dense CoNiCrAlY coatings via cold gas dynamic spray (CGDS) as well as compare the oxidation performance of bond coats manufactured by CGDS, high-velocity oxy-fuel (HVOF) and air plasma spray (APS) at temperatures of 1000°C and 1100°C. The work was divided in two sections, the design and manufacturing of a CGDS nozzle with an optimal profile for the deposition of CoNiCrAlY powders and the comparison of the oxidation performance of CoNiCrAlY bond coats. Throughout this work, it was shown that the quality of coatings deposited via CGDS can be increased by the use of a nozzle of optimal profile and that early formation of protective α-Al2O3 due to an oxidation temperature of 1100°C as opposed to 1000°C is beneficial to the overall oxidation performance of CoNiCrAlY coatings.