<p dir="ltr">Current industrial processes are energy and carbon emission intensive. Amidst the growing demand for decarbonization, it is critical to utilize alternate sources of energy and innovative technologies that could improve efficiency and reduce power consumption. In this context, twin-screw compressors are used extensively in commercial and industrial applications. Profile optimization and capacity modulation solutions (e.g., slide valves, variable-speed, etc.) are continuously investigated to improve the performance and operation of the compressors. This study focuses on an exploratory investigation of an additively manufactured twin-screw compressor with internal cooling channels to achieve a near isothermal compression process by evaluating both the potential compressor performance improvement and the structural integrity by means of rotordynamics and fatigue analyses.</p><p dir="ltr">To predict the compressor performance, complex coupling between compression process and heat transfer during the operation of the compressor must be investigated. The interactions between solid (i.e., rotors) and fluid phases (i.e., air and coolant) were modeled using a transient 3D CFD model with conjugated heat transfer (CHT). The CFD model predicted compressor performance parameters such as isentropic efficiency, heat transfer rate, work input and compression forces on the rotors. The performance of the twin-screw compressor with internal cooling channels has been compared with a conventional twin-screw compressor for which experimental data was available. Further investigations have been conducted at different operating conditions, including various pressure ratios, rotational speeds, and mass flow rates to improve the compressor efficiency. The results of the CFD model were used to quantify compression loads, assess the characteristics of the heat transfer processes, and optimize the internal flow through the cooling channels. As the rotors can be affected by stress accumulation and deformations due to their hollowness and reduced wall thickness over time, this study also established a detailed rotordynamic simulation model and a fatigue model using the actual compression forces obtained from previous CFD studies. Both hollow and solid rotors have been analyzed and compared. The bearing loads have been verified against Campbell diagrams whereas the fatigue results have been compared with experimental testing. With the validated model, the hollow rotor compressor durability was analyzed and compared with the conventional rotors. Lastly, a general mechanistic model to better understand bearing loads and frictional losses in a twin-screw compressor is also established and studied.</p><p dir="ltr">The CHT study concluded that the hollow rotor with single-phase internal cooling yielded to an increase in isentropic efficiency of 1% for the higher pressure ratio and 2% for lower pressure ratio at 19,000 RPM. More importantly, the hollow rotors also showed a decrease of 40 K and 20 K in discharge temperatures for the two operating conditions respectively, thereby arriving closer to isothermal conditions and reducing the thermal stresses on the rotors. The rotordynamic study revealed that the male rotor would endure highest amount of von Misses stress reaching up to 338 MPa for the pressure ratio of 3.29 bar and 19,000 RPM. Because of this, a maximum fatigue factor of safety of 5 occurs on the male rotor. From the analyses, the rotors were deemed to be safe and optimized for the designed operating conditions and proof of concept rotors were additively manufacturers with an Inconel alloy through Direct Metal Laser Sintering.</p>

<div>Defects are unavoidable, life-limiting and dominant sites of damage and subsequent failure in a material. Ni-based superalloys are commonly used in high temperature applications and inevitably found to have defects in the form of inclusions, voids and microscopic cracks which are below the resolution of standard inspection techniques. A mechanistic understanding of the role of defects in such industrially relevant bulk polycrystalline material is essential for philosophies of design and durability to follow and ensure structural integrity of components in the inevitable presence of such defects. The current understanding of defect-mediated damage, in bulk Ni superalloys, is limited by experimental techniques that can capture the local micromechanical state of the material surrounding the defect. In this work, we combine mechanical testing with in-situ, non-destructive 3-D X-ray characterization techniques to obtain rich multi-modal datasets at the microscale to interrogate complex defect-microstructure interactions and elucidate the mechanisms of failure around defects. The attenuated X-ray beam, after passage through the material, is utilized through computed micro-tomography to characterize the defects owing to its sensitivity to density differences in the material. The diffracted X-ray beam, after illuminating the material, is employed through high energy diffraction microscopy in various modes to interrogate the evolving micromechanical state around the discovered defects.</div><div>Three case studies are performed with specimens made of a Ni-based superalloy specially designed and fabricated to have internal defects in the form of: (i) an inclusion, (ii) a microscopic crack, and (iii) voids. In each case, the grain scale information is investigated to reveal heterogeneity in the local micromechanical state of the material as a precursor for the onset of failure. Models and simulations based on finite element or crystal plasticity are utilized, wherever necessary, to assess the factors essential to the underlying mechanism of failure. In the first case study, the detrimental effects of an inclusion in initiating a crack upon cyclic loading is interrogated and the state of bonding, residual stresses, and geometrical stress concentrations around the inclusion are demonstrated to be of utmost importance. In the second case study, the propagation of a short fatigue crack through the microstructure is examined to reveal the crystallographic nature of crack growth through the (i) alignment of the crack plane with the most active slip system, (ii) the correlation between the crack growth rate and the maximum resolved shear stresses, and (iii) the dependence of the crack growth direction on microplasticity within grains ahead of the crack front. In the third case study, the role of voids in ductile failure under tensile loading is explored to illuminate the activation and operation of distinct mechanisms of inter-void shear and necking under the control of the local state of stress triaxiality and the local plasticity within the grains at critical sites of fracture.</div><div>In summary, a grain scale description of the micromechanical state has been unambiguously determined through experiments to examine the heterogeneity around defects in the material. It has enabled us to identify and isolate the nature of factors essential to the activation of specific mechanisms at the onset failure. The grain scale thus provides an ideal physical basis to understand the fundamentals of defect mediated damage and failure instilling trust in the predictive capabilities of models that incorporate the response of the grain structure. The generated datasets can be used to instantiate and calibrate such models at the grain level for higher fidelity. </div>

Les tubes GV des centrales nucléaires REP (alliages 600, 690 et 800) sont protégés contre la corrosion par une couche d'oxyde. Le relâchement, dans le milieu primaire, de produits de corrosion qui, activés, augmentent la radioactivité, est limité par cette couche. La rupture localisée de la couche peut conduire à la corrosion sous contrainte de l'alliage. L'objectif de cette étude est de comprendre les phénomènes régissant les stades initiaux de la formation des couches d'oxydes sur ces alliages. Un système d'oxydation (micro-autoclave) a été développé, permettant de réaliser des essais d'oxydation dans l'eau à 325°C de quelques secondes à ~10 min. Les surfaces ont été caractérisées par XPS, NRA, STM et MEB, et un modèle de croissance a été proposé pour l'alliage 600. Des essais plus longs ont été effectués (400 h). Les cinétiques à temps longs ont pu être reliées à celles des temps courts, confirmant le rôle crucial des stades initiaux dans la croissance des couches d'oxyde.

Les composants des industries de l'aéronautique, du spatial ou de l'énergie sont souvent en fonctionnement dans des environnements sévères où les températures et les pressions peuvent atteindre des valeurs importantes. Les matériaux traditionnels sont alors remplacés par des superalliages dits réfractaires, l'Inconel 718 est un de ces matériaux. Ils sont en particulier caractérisés par la conservation de leurs propriétés mécaniques à hautes températures. L'Inconel 718 est un alliage à base nickel, réputé comme difficile à usiner. Cette difficulté de mise en forme, liée à ses caractéristiques physiques et mécaniques, impose généralement une utilisation très importante de fluides de coupe ; ceux-ci représentent une fraction significative du coût de la pièce usinée. L'objectif est alors de migrer vers l'usinage à sec et grande vitesse. Cependant, du fait des caractéristiques mécaniques et du caractère réfractaire de l'Inconel 718, les surfaces générées peuvent être affectées thermiquement durant l'opération d'usinage avec la mise en place de contraintes résiduelles en traction néfastes pour la tenue en service des pièces usinées. Au travers des travaux présentés, nous nous proposons de montrer la faisabilité de l'usinage à sec de l'Inconel 718 et ses conséquences sur l'intégrité des surfaces réalisées. Des essais de tournage sous lubrification et à sec ont été réalisés dans des conditions de semi-finition avec un outil en carbure de tungstène revêtu. Les surfaces et sous surfaces ont été observées et qualifiées par un ensemble de moyens : microscope à interférométrie, microscope électronique à balayage, microduromètre, goniomètre rayons X pour l'analyse des contraintes résiduelles. L'analyse de l'intégrité des surfaces a permis de mettre en évidence les principaux facteurs influents. La qualité des surfaces produites dépendant de la maîtrise de la température de coupe, une technique de mesure des températures a alors été développée pour une opération de fraisage ; elle est basée sur la technologie des thermocouples. Les essais menés ont permis de déterminer la température en surface et en sous surface ; ces informations sont des éléments importants de validation d'un modèle thermique de la coupe. Enfin, à la suite d'essais de fraisage périphérique et de la mesure des efforts pour différentes conditions de coupe, nous présentons une comparaison entre ces résultats expérimentaux et une modélisation du procédé. La modélisation correspond à une approche thermomécanique de la coupe. En termes d'efforts, la comparaison est tout à fait satisfaisante ; un prolongement de cette approche pour valider l'aspect thermique, est toutefois envisagé.

Fundação de Amparo a Pesquisa do Estado de Minas Gerais / The nickel-based superalloys have a high mechanical strength which remains at elevated temperature, high creep and fatigue resistances and excellent oxidation resistance. This makes these alloys highly recommended for use in high temperature working environments such as mechanical components for the aerospace industry. However, these characteristics are major problems when machining them, as it promotes high heat generation in the flow zone, resulting in the development of high wear rates on the cutting tools. In order to reduce the problems caused by the high temperatures generated, the application of a cutting fluid, when possible, is essential to reduce friction at the chip-tool-workpiece interfaces and lower the temperatures in the cutting zone. Seeking to further increase in the efficiency of cutting fluids during machining of nickel alloys, this work presents a study of the influence of solid lubricants, graphite and molybdenum disulphide (MoS2) mixed to a vegetal based cutting fluid, applied by conventional method (flooding) and minimal quantity of fluid - MQF in turning of Inconel 718 with carbide and ceramic (mixed, whisker and SiAlON) tools. When turning with cemented carbide tools the addition of graphite to the cutting fluid provided the best results, while with ceramic tools MoS2 presented the best performance. The life of the carbide tool had an average increase above 200% in conventional flooding application of cutting fluid when compared to MQF, regardless the addition of solid lubricant. The addition of solid lubricants promoted an increase in the life of whisker and SiAlON tools. The flank wear was dominant for cemented carbide tools and SiAlON ceramics, while for whisker and mixed ceramics the notch wear was predominant. Attrition and diffusion wear mechanism were observed in all evaluated conditions. The addition of solid lubricant to the cutting fluid provided significant improvements in the surface roughness values for most of the evaluated conditions. However, there were no significant changes in the machining forces and cutting temperature. The residual stress was tensile and compression, depending on the fluid application method. Overall, the addition of solid lubricant showed no significant differences. / As superligas à base de níquel apresentam alta resistência mecânica que se mantém em elevadas temperaturas, altas resistência à fluência e à fadiga e excelente resistência a oxidação. Isso torna estas ligas altamente recomendadas para utilização em ambientes que trabalham a altas temperaturas, como por exemplo na fabricação de componentes mecânicos para a indústria aeroespacial. Entretanto, esta característica representa um grande problema quando elas são usinadas, pois promove elevada geração de calor na zona de fluxo, implicando no desenvolvimento de altas taxas de desgaste da ferramenta de corte. A fim de reduzir os problemas causados pelas altas temperaturas geradas, a aplicação de um fluido de corte, quando possível, é essencial, proporcionando redução do atrito na interface cavaco-ferramenta-peça e menores temperaturas na zona de corte. Na busca de aumentar ainda mais a eficiência dos fluidos de corte na complexa usinagem das ligas de níquel, este trabalho apresenta um estudo da influência dos lubrificantes sólidos grafite e bissulfeto de molibdênio (MoS2) misturado a um fluido de corte de base vegetal, aplicados pelo método convencional (jorro) e mínima quantidade de fluído MQF, no torneamento do Inconel 718, com ferramentas de metal duro e cerâmicas (mista, whisker e SiAlON). No torneamento com ferramentas de metal duro a adição de grafite ao fluido de corte proporcionou os melhores resultados, enquanto que no torneamento com ferramentas cerâmicas, foi o MoS2 que apresentou melhor desempenho. A vida da ferramenta de metal duro teve um incremento acima de 200% na usinagem convencional (jorro) quando comparado com a usinagem por MQF, sem considerar a adição do lubrificante sólido. A adição de lubrificantes sólidos promoveu um incremento na vida das ferramentas whisker e SiAlON. O desgaste de flanco foi predominante para as ferramentas de metal duro e cerâmica SiAlON, enquanto que nas cerâmicas whisker e mista o desgaste de entalhe foi predominante. Os mecanismo de desgaste de attrition e difusão foram observados em todas as condições avaliadas. A adição de lubrificante sólido ao fluido de corte proporcionou melhorias significativas nos valores da rugosidade para a maioria das condições avaliadas. No entanto, não se observou mudanças significativas nas forças e temperatura de usinagem. As tensões residuais foram de tração e compressão, dependendo do método de aplicação do fluido. No geral, a adição do lubrificante sólido não apresentou diferenças significativas. / Doutor em Engenharia Mecânica

The aerospace industry is constantly striving to becoming more economical and environmentally friendly. One of many efforts to achieve this is the Lightcam project which in this case is evaluating the use of additive manufacturing in the form of electron beam melting in conjunction with the nickel-based superalloy, Alloy 718. This combination is not fully explored and examined. For this purpose, a demonstrator vane was produced and it was subsequently evaluated in this thesis. The evaluation was performed in as-built condition and was divided in non-destructive testing, evaluation of these methods and metallographic review to confirm the results, and potentially revealing more properties. The non-destructive testing was performed using conventional radiography and computed tomography. Both methods struggled to deliver complete and reliable results, for varying reasons. Radiography could deliver results of the whole vane, but these were impossible to evaluate due to the rough surface created by the electron beam melting process. The computed tomography on the other hand was not affected by the rough surface and produced usable, though not complete, results of the vane. The reason for the computed tomography’s inability to deliver complete results was the material, varying thickness and complex geometry of the vane. As a complement and to verify the results from the non-destructive testing, a metallographic examination was conducted. These tests were conducted with the aim of answering the following three questions:  What non-destructive testing methods are suitable to evaluate Alloy 718 components manufactured with electron beam melting? - Neither radiography nor computed tomography are suitable as a sole evaluation method, for various reasons. All surface dependent methods were deemed unsuitable without testing due to the rough surface. What types of defects and in what quantity can they be found in the produced vane? - Defects found are: Porosity and lack of fusion, both found as internal and partially external and in varying sizes. Where are the defects located? - Pores are mainly found in the center of sections modeled to a 3mm thickness. Lack of fusion was found between build layers in all thicknesses. Apart from these results, hardness was found to vary depending on build height, increasing from the bottom towards the top. Microstructure was also found to vary with the build height, but always consisting of either equiaxed or columnar grains. / Lightcam

No description available.

Internal Combustion Engine (ICE) exhaust components are exposed to extreme operating temperatures. Thus, it is necessary that they are designed with materials that can sustain thermal and vibrational stresses. This study investigates the wear mechanisms and tribological performance of the exhaust manifold joint in Scania CV diesel trucks, focusing on the lip seal ring between the exhaust and turbo manifolds. The joint is prone to wear due to thermal and vibrational stresses, impacting its service life and raising environmental concerns. The manifold material, ductile cast iron SiMo51, offers good thermal resistance, while the lip seal ring, made of Inconel 718c, provides excellent thermal fatigue and corrosion resistance, coated with AlTiN for wear and oxidation resistance. However, the tribological performance of this joint and material combination remains unknown, necessitating further research.  This work aims to understand wear initiation mechanisms and their relationship with temperature. Test setups were established using an oscillating cylinder on disc configuration in the SRV 3 tribometer. SiMo51 uncoated/coated with Tribaloy 400 and Inconel 718c uncoated/coated with AlTiN were tested against each other to identify the best material pair. Analysis involved coefficient of friction, visual inspection, wear volume measurements, SEM micrographs, and EDS for surface chemical composition. Results indicated that friction behaviour is temperature-dependent, with oxide layer formation reducing the coefficient of friction when the manifold is uncoated, while the opposite occurs when coated with Tribaloy 400. Wear behaviour varied based on material combinations and temperature. Uncoated manifold exhibited dominant adhesion (galling) accompanied by tribo-oxidation at higher temperatures, with maximum wear volumes at room temperature. Introduction of T-400 on the manifold initiated galling on the lip seal, leading to abrasion on the manifold surface, accompanied by tribo-oxidation at elevated temperatures. Wear increased until 500°C, followed by a decrease at 700°C. Further explanations of T-400 wear behaviour are lacking in the literature.

No description available.

No description available.