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Industry is constantly searching for improved materials for use in highly demanding applications. The materials chosen must withstand a wide range of temperatures and extended exposure in aggressive environments, including hydrogen gas. Because of the risk of catastrophe if brittle failure occurs, careful material selection is imperative. Austenitic stainless steels may be a likely choice for hydrogen service because their behavior in high pressure hydrogen ranges from no apparent damage to relevant, but generally small ductility loss (13). Because of this Variation in behavior, a single category cannot be established to encompass all austenitic steels and studies must be performed on each type of steel to determine its behavior under specific circumstances. Two steels being currently under consideration for use in hydrogen are Armco 21-6-9 and Tenelon, both are fully austenitic stainless steels which may be used over a wide range of temperatures, including service at liquid nitrogen temperature. / Master of Science / incomplete_metadata

Magister Scientiae - MSc / Amorphous silicon nitride (a-SiN:H) thin films has a multitude of applications, stemming from the tunability of the material properties. Plasma enhanced chemical vapour deposition (PECVD) is the industrial workhorse for production of device quality a-SiN:H. However, this technique has drawbacks in terms of film quality, rooting from ion bombardment, which then results in undesirable oxidation. Hot wire chemical vapour deposition (HWCVD) has shown to be a viable competitor to its more costly counterpart, PECVD. A thin film produced by HWCVD lacks ion bombardment due to the deposition taking place in the absence of plasma. This study will focus on optimising the MVsystems ® HWCVD chamber at The University of the Western Cape, for production of device quality a-SiN:H thin films at low processing parameters. The effect of these parameters on the structural, optical and morphological properties was investigated, for reduction of production costs. The films were probed by heavy ion elastic recoil detection, energy dispersive spectroscopy, Fourier transform infrared spectroscopy, atomic force microscopy, Xray diffraction, and ultraviolet visible spectroscopy. It was shown that silicon rich, device quality a-SiN:H thin films could be produced by HWCVD at wire temperatures as low as 1400 °C and the films showed considerable resistance to oxidation in the bulk.

Manufacturing of light-weight materials is associated with several types of casting defects during solidification. Porosity defects are common, especially in aluminum and its alloys, which initiate crack propagation and thereby cause drastic deterioration in the mechanical properties. These defects, classified as micro and macro defects (based on their sizes), are mainly governed by release of hydrogen into the liquid at the solid-liquid interface, which triggers the nucleation and growth of hydrogen bubbles in the melt. Subsequently, these bubbles interact with solidifying interfaces such as dendritic arms and eutectic fronts, leading to the formation of pores. Macroscopic defects in the form of voids are created due to solidification shrinkage. The primary focus of the present work is to develop phenomenological models for the evolution of microporosity and microstructures during solidification. The issues outlined above typically occur in multi-phase environments comprising of solid, liquid and gaseous phases, and over a range of length and time scales. Any phenomenological prediction would, therefore, require a multi-phase-scale approach. Principles of volume averaging are applied to equations of conservation to obtain single-field formulations. These are then solved with appropriate interface tracking techniques such as Enthalpy, Level-set, Volume-of-fluid and Immersed-boundary methods. The framework is built up on a standard pressure based incompressible fluid flow solver (SIMPLER algorithm) and coupled modeling strategies are proposed to address the interfacial dynamics. A two-dimensional framework is considered with a fixed-grid Cartesian co-ordinate system. Scaling analyses are performed to bring out the relative effects of various competing parameters in order to obtain further insights into this complex phenomenon. The numerical results and scaling predictions are validated against experimental observations published in literature. In literature, numerical predictions of microporosity mainly include criteria based models based on empirical relations and deterministic/stochastic models based on diffusion driven growth assuming spherical bubbles. The dynamic evolution of non-spherical bubble-metal interface in a three-phase system is yet to be captured. Moreover, several in-situ experiments have shown elongated bubble shapes during the engulfment phase, therefore a criterion to define the dependence on cooling rates and the resulting bubble morphology can possibly deliver further practical insights. We propose a numerical model for hydrogen bubble growth, its movement and subsequent engulfment by a solidifying front, combining the features of level-set and enthalpy methods for tracking bubble-metal and solid-liquid interfaces, respectively. The influx of hydrogen into heterogeneously nucleated bubbles results in growth of bubbles to sizes up to a few hundreds of microns. In the first part of this numerical study, a methodology based on the level-set approach is developed to simultaneously capture hydrogen bubble growth and movement in liquid aluminum. The solidification is first assumed to occur outside the micro-domain providing a specified hydrogen influx to the bubble-in-liquid system. The level-set equation is formulated in such a way as to account for simultaneous growth and movement of the bubble. The growth of a bubble with continuous and fixed hydrogen levels in the melt is studied. The rates of growth of bubble-liquid and solidifying interfaces are compared using an order of magnitude analysis. This scaling analysis explains the thought experiment proposed in the literature, where difference in bubble shapes was attributed to the cooling rate. Moreover, it shows explicit dependence on bubble radius and cooling rate leading to a new criterion for bubble elongation proposed in this thesis. This also highlights the comparison between solidification and hydrogen diffusion time-scales which primarily govern the competitive growth behavior. The bubble-in-liquid model is coupled with microscopic enthalpy method to incorporate effects of solidification and study the interaction of solid-liquid and bubble-liquid interfaces. The phenomena of bubble engulfment and elongation are successfully captured by the proposed model. A parametric study is carried out to estimate the bubble elongation based on different initial bubble sizes and varying cooling rates encountered in typical sand, permanent mold and die casting processes. Although simulation of microstructures has been extensively studied in the literature, very few models address the phenomena of simultaneous growth and movement of equiaxed dendrites. The presence of different flow environments and multiple dendrites are known to alter the position and shape of the dendrites. The proposed model combines the features of the following methods, namely, the Enthalpy method for modeling growth; the Immersed Boundary Method (IBM) for handling the rigid solid-liquid interfaces; and the Volume of Fluid (VOF) method for tracking the advection of the dendrite. The algorithm also performs explicit-implicit coupling between the techniques used. Validation with available literature is performed and dendrite growth in presence of rotational and buoyancy driven flow fields is studied. The expected transformation into globular microstructure in presence of stirring induced flows is successfully simulated. A simple order estimate for time required for stirring is performed which agrees with numerical predictions. In buoyancy driven environment of a settling dendrite, the arm tip speeds show expected higher velocity of the upstream tip compared to its counterpart. The model is extended to study thermal and hydrodynamic interactions between multiple dendrites with appropriate considerations for different orientations and velocities of the dendritic solid entities. The present model can be used for the prediction of grain sizes and shapes and to simulate morphological transformations due to different melt flow scenarios. In the final part, the methodology presented for growth and engulfment of hydrogen bubbles is extended to study the phenomenon of diffusion driven bubble growth occurring in direct foaming of metals. The source of hydrogen is determined by the rate of decomposition of the blowing agent. This is accounted for by a source term in the hydrogen species conservation equation, and growth rate of hydrogen bubbles is calculated on the basis of diffusive flux at the interface. The level-set method is used for tracking the bubble-liquid interface growth, and the macroscopic enthalpy model is used for obtaining heat transfer and solid front position. The model is validated with analytical solution by comparing the front position and the solidification time. The variation of foam density with a transient hydrogen generation source is studied and qualitatively compared with results reported in literature. The modeling strategies proposed in this work are generic and therefore have potential in simulating a variety of complex multi-phase problems.

Aluminas have had some form of chemical and industrial use throughout history. For little over a century corundum (α-Al2O3) has been the most widely used and known of the aluminas. The emerging metastable aluminas, including the γ, δ, η, θ, κ, β, and χ polymorphs, have been growing in importance. In particular, γ-Al2O3 has received wide attention, with established use as a catalyst and catalyst support, and growing application in wear abrasives, structural composites, and as part of burner systems in miniature power supplies. It is also growing in importance as part of the feedstock for aluminium production in order to affect both the adsorption of hydrogen fluoride and the feedstock solubility in the electrolytic solution. However, much ambiguity surrounds the precise structure of γ-Al2O3. Without proper knowledge of the structure, understanding the properties, dynamics and applications will always be less than optimal. The aim of this research was to contribute towards settling this ambiguity. This work was achieved through extensive computer simulations of the structure, based on interatomic potentials with refinements of promising structures using density functional theory (DFT), and a wide range of supporting experiments. In addition to providing a more realistic representation of the structure, this research has also served to advance knowledge of the evolution of the structure with changing temperature and make new insights regarding the location of hydrogen in γ-Al2O3. / Both the molecular modelling and Rietveld refinements of neutron diffraction data showed that the traditional cubic spinel-based structure models, based on m Fd3 space group symmetry, do not accurately describe the defect structure of γ-Al2O3. A more accurate description of the structure was provided using supercells of the cubic and tetragonal unit cells with a significant number of cations on c symmetry positions. These c symmetry based structures exhibited diffraction patterns that were characteristic of γ-Al2O3. The first three chapters of this Thesis provide a review of the literature. Chapter One provides a general introduction, describing the uses and importance of the aluminas and the problems associated with determining the structure of γ-Al2O3. Chapter Two details the research that has been conducted on the structure of vi γ-Al2O3 historically. Chapter Three describes the major principles behind the computational methods employed in this research. In Chapter Four, the specific experimental and computational techniques used to investigate the structure of γ-Al2O3 are described. All preparation conditions and parameters used are provided. Chapter Five describes the methodology employed in computational and experimental research. The examination of the ~ 1.47 billion spinel-based structural possibilities of γ-Al2O3, described using supercells, and the selection of ~ 122,000 candidates for computer simulation, is detailed. This chapter also contains a case study of the structure of κ-Al2O3, used to investigate the applicability of applying interatomic potentials to solving complex structures, where many possibilities are involved, and to develop a systematic procedure of computational investigation that could be applied to γ-Al2O3. Chapters Six to Nine present and discuss the results from the experimental studies. / Preliminary heating trials, performed to determine the appropriate preparation conditions for obtaining a highly crystalline boehmite precursor and an appropriate calcination procedure for the systematic study of γ-Al2O3, were presented in Chapter Six. Chapter Seven details the investigation of the structure from a singletemperature case. Several known structural models were investigated, including the possibility of a dual-phase model and the inclusion of hydrogen in the structure. It was demonstrated that an accurate structural model cannot be achieved for γ-Al2O3 if the cations are restricted to spinel positions. It was also found that electron diffraction patterns, typical for γ-Al2O3, could be indexed according to the I41/amd space group, which is a maximal subgroup of m Fd3 . Two models were presented which describe the structure more accurately; Cubic-16c, which describes cubic γ-Al2O3 and Tetragonal-8c, which describes tetragonal γ-Al2O3. The latter model was found to be a better description for the γ-Al2O3 samples studied. Chapter Eight describes the evolution of the structure with changing calcination temperature. Tetragonal γ-Al2O3 was found to be present between 450 and 750 °C. The structure showed a reduction in the tetragonal distortion with increasing temperature but at no stage was cubic γ-Al2O3 obtained. Examination of the progress of cation migration indicates the reduction in the tetragonal nature is due to ordering within inter-skeletal oxygen layers of the unit cell, left over from the breakdown of the hydroxide layers of boehmite when the transformation to γ-Al2O3 occurred. Above 750 °C, δ-Al2O3 was not observed, but a new phase was identified and designated γ.-Al2O3. / The structure of this phase was determined to be a triple cell of γ-Al2O3 and is herein described using the 2 4m P space group. Chapter Nine investigates the presence of hydrogen in the structure of γ-Al2O3. It was concluded that γ-Al2O3 derived from highly crystalline boehmite has a relatively well ordered bulk crystalline structure which contains no interstitial hydrogen and that hydrogen-containing species are located at the surface and within amorphous regions, which are located in the vicinity of pores. Expectedly, the specific surface area was found to decrease with increasing calcination temperature. This trend occurred concurrently with an increase in the mean pore and crystallite size and a reduction in the amount of hydrogen-containing species within the structure. It was also demonstrated that γ-Al2O3 derived from highly crystalline boehmite has a significantly higher surface area than expected, attributed to the presence of nano-pores and closed porosity. The results from the computational study are presented and discussed in Chapter Ten. Optimisation of the spinel-based structural models showed that structures with some non-spinel site occupancy were more energetically favourable. However, none of the structural models exhibited a configuration close to those determined from the experimental studies. Nor did any of the theoretical structures yield a diffraction pattern that was characteristic of γ-Al2O3. This discrepancy between the simulated and real structures means that the spinel-based starting structure models are not close enough to the true structure of γ-Al2O3 to facilitate the derivation of its representative configuration. / Large numbers of structures demonstrate migration of cations to c symmetry positions, providing strong evidence that c symmetry positions are inherent in the structure. This supports the Cubic-16c and Tetragonal-8c structure models presented in Chapter Seven and suggests that these models are universal for crystalline γ-Al2O3. Optimisation of c symmetry based structures, with starting configurations based on the experimental findings, resulted in simulated diffraction patterns that were characteristic of γ-Al2O3.