Process Safety Management (PSM) is concerned with the safe handling of products, safe production of products and the safe operation of the process as confirmed by Thrower (2013). The Occupational Safety and Health Administration (OSHA) (2012) promulgated the PSM standard in 1992, which incorporated fourteen elements, to decrease the occurrence of process safety incidents. Walt and Frank (2007) described the cracks in the implementation of PSM programs, emanating from major process safety incidents and compliance audits. This was confirmed by the decaying process safety performance observed in recent years. It was thus proposed that an analysis into the diverse process safety incident causes and its comparison against the implemented OSHA PSM program, would suggest its associated shortcomings. The aim of the study was to determine the most effective approach to implement and sustain PSM in an organisation to prevent and manage the occurrence of major industrial catastrophes. A semi-qualitative study was conducted through the employment of a survey questionnaire and published incident investigation reports. A total of fifty random process safety incidents were interpreted from published and accredited secondary literature. Most of the secondary literature was obtained from the Health and Safety Executive (HSE) and Centre for Chemical Process Safety (CCPS) databases. From the study findings, Mechanical Integrity (MI) failures were found to significantly and consistently contribute to process safety incidents. Further analysis specifically concluded that equipment or control failure was the significant cause. Employee Participation (EP) was found to statistically correlate with the other elements. The researcher found that literature agreed with the aforementioned findings and this study verified that the EP element was instrumental in the implementation of the other elements. The researcher used literature to confirm that safety culture and leadership commitment was crucial to effective and sustainable PSM programs. The case study analysis validated this observation. Therefore the most effective approach to implement and sustain PSM was to adopt the DuPont, Centre for Chemical Process Safety (CCPS), Risk Based PSM framework or Energy Institute (EI) models. To conclude, this study was effective as all the objectives and the aim was achieved. / MIng (Development and Management Engineering), North-West University, Potchefstroom Campus, 2014

Process Safety Management (PSM) is concerned with the safe handling of products, safe production of products and the safe operation of the process as confirmed by Thrower (2013). The Occupational Safety and Health Administration (OSHA) (2012) promulgated the PSM standard in 1992, which incorporated fourteen elements, to decrease the occurrence of process safety incidents. Walt and Frank (2007) described the cracks in the implementation of PSM programs, emanating from major process safety incidents and compliance audits. This was confirmed by the decaying process safety performance observed in recent years. It was thus proposed that an analysis into the diverse process safety incident causes and its comparison against the implemented OSHA PSM program, would suggest its associated shortcomings. The aim of the study was to determine the most effective approach to implement and sustain PSM in an organisation to prevent and manage the occurrence of major industrial catastrophes. A semi-qualitative study was conducted through the employment of a survey questionnaire and published incident investigation reports. A total of fifty random process safety incidents were interpreted from published and accredited secondary literature. Most of the secondary literature was obtained from the Health and Safety Executive (HSE) and Centre for Chemical Process Safety (CCPS) databases. From the study findings, Mechanical Integrity (MI) failures were found to significantly and consistently contribute to process safety incidents. Further analysis specifically concluded that equipment or control failure was the significant cause. Employee Participation (EP) was found to statistically correlate with the other elements. The researcher found that literature agreed with the aforementioned findings and this study verified that the EP element was instrumental in the implementation of the other elements. The researcher used literature to confirm that safety culture and leadership commitment was crucial to effective and sustainable PSM programs. The case study analysis validated this observation. Therefore the most effective approach to implement and sustain PSM was to adopt the DuPont, Centre for Chemical Process Safety (CCPS), Risk Based PSM framework or Energy Institute (EI) models. To conclude, this study was effective as all the objectives and the aim was achieved. / MIng (Development and Management Engineering), North-West University, Potchefstroom Campus, 2014

Le développement du marché des appareils de communication nomades, a nécessité l'intégration de composants passifs et actifs sur du silicium via des montages « hybrides ».Ceci a amené le LMP partenaire de l'entreprise STMicroelectronics à rechercher des solutions pour une intégration « monolithique ». Le silicium micro/mésoporeux est un candidat potentiel pour satisfaire les exigences de cette intégration. Ce travail traite de la réalisation de caissons profonds de silicium poreux sur silicium résistif de type P 30-50 Ω.cm et N 37-46Ω.cm. L'utilisation de l'acide acétique comme solvant industriellement compatible nous a permis de réaliser des structures micro/mésoporeuses. L'intégrité mécanique de nos échantillons a été étudiée via la mesure de la porosité en fonction de l'épaisseur. Ainsi des caissons poreux avec des épaisseurs de plus de 400 µm et 50 % de porosité ont été fabriqués.La réalisation d'une couche N⁺ sur du silicium type N 37-46 Ω.cm a permis la mise en œuvre de doubles couches composées d'une dizaine de micromètres de micro/mésoporeuse sur une couche de 200 µ.m de silicium macroporeux. Des changements importants ont été observés par addition d'une très faible quantité d'un tensioactif (triton X-I00®) a notre solution électrolytique et où des doubles couches ont été obtenues sur silicium type P 30-50 Ω.cm. / The rapid expansion of wireless devices caused a tremendous demand of the development of active and passive devices integration on silicon via « hybrid » systems. The search of a« monolithic » integration has led the LMP in partnership with STMicroelectronics to focus on this topic. Micro/Mesoporous silicon is a good candidate to fulfill the requirements to achieve this purpose. The present work deals with the realization of thick porous silicon layers on low doped P type (30-50 Ω.cm) and N type Si (37-46 Ω.cm). The use of a particular solution based on HF-H₂O and acetic acid allowed the implementation of micro/mesoporous Si structures. The mechanical integrity is studied via the porosity and the PS layer thickness.Thus layers with a thickness up to 400 µm have been implemented with a porosity of 50 % on P Type Si samples. Double layers with micro/mesoporous layer of tenth micrometers on a macroporous layer stack up to 200 µm have been realized on N-Type Si samples via the realization of an N⁺ layer by phosphorous implantation. Important changes occurred when a tiny amount of surfactant (triton X-I00®) has been introduced into our organic electrolyte and allowed the implementation of double layers on P type Si.

Electric vehicles contain hundreds of high-energy density lithium-ion batteries. The crashworthiness of these vehicles can be improved by better understanding the response of these batteries in an event of an accident or abusive loads. These loads can induce short-circuit and thermal runways in extreme cases. Therefore, an efficient finite element model of a battery that can precisely predict the coupled multi-physics behavior of a cell in a real-world application is desired. This investigation incorporates detailed and homogenized multi-physics modeling of various form factors of lithium-ion batteries. In the first two chapters of this thesis, a multi-physics homogenized model of a pouch cell was developed and validated in a wide range of multi-disciplines of the battery. In contrast to other similar models described in the literature, which are only applicable in certain scenarios, this model has a much broader range of applications due to the innovative techniques developed for material calibration and cell modeling. In addition, due to the homogenized nature and computational cost efficiency of this technique, the developed model has significance in the crashworthiness analysis of battery packs and electric vehicles where hundreds of these batteries exist. In the final chapter, a detailed layered model of an 18650 cylindrical cell was developed. Component and cell-level tests were performed on the cell to calibrate the material properties and extract the geometries of all the components of the cell. This model is the first of its kind that precisely predicts the load-displacement response and shape of deformation in various loading scenarios. This developed model has crucial importance in the safety assessment of the batteries by providing insight into the sequence of deformation of the internal layers and components and their interplay during mechanical abuse loadings. Overall, the two developed models in this thesis provide battery-related industries with a tool to improve the safety of future electrified industries. / Mechanical Engineering

This thesis presents a research into the solder interconnects made through the reactive bonding process based on the self-propagating reaction. A numerical study of soldering conditions in the heat affected zone (HAZ) during bonding was initially carried out in order to understand the self-propagating reactive bonding and the related influencing factors. This was subsequently followed by an extensive experimental work to evaluate the feasibility and reliability of the reactive bonding process to enable the optimisation of processing parameters, which had provided a detailed understanding in terms of interfacial characteristics and bonding strengths. In addition, by focusing on the microstructure of the bonds resulted from the self-propagating reactions, the interfacial reactions and microstructural evolution of the bonded structures and effects of high-temperature aging were studied in details and discussed accordingly. To study the soldering conditions, a 3D time-dependent model is established to describe the temperature and stress field induced during self-propagating reactions. The transient temperature and stress distribution at the critical locations are identified. This thus allows the prediction of the melting status of solder alloys and the stress concentration points (weak points) in the bond under certain soldering conditions, e.g. ambient temperature, pressure, dimension and type of solder materials. Experimentally, the characterisation of interconnects bonded using various materials under different technical conditions is carried out. This ultimately assists the understanding of the feasibility, reliability and failure modes of reactive bonding technique, as well as the criteria and optimisation to form robust joints. The formation of phases such as intermetallic compounds (IMCs) and mechanism of interfacial reactions during reactive bonding and subsequent aging are elaborated. The composition, dimension, distribution of phases have been examined through cross-sectional observations. The underlying temperature and stress profile determining the diffusion, crystallization and growth of phases are defined by numerical predictions. XXI Through the comparative analysis of the experimental and numerical results, the unique phases developed in the self-propagating joints are attributed to the solid-liquid-convective diffusion, directional solidification and non-equilibrium crystallization. The recrystallization and growth of phases during aging are revealed to be resulted from the solid-state diffusion and equilibration induced by the high-temperature heating. In conclusion, the interfacial reactions and microstructural evolution of interconnect developed through self-propagating reactive bonding are studied and correlated with the related influencing factors that has been obtained from these predictions and experiments. The results and findings enable the extensive uses of self-propagating reactive bonding technology for new design and assembly capable of various applications in electronic packaging. It also greatly contributes to the fundamentals of the crystallization and soldering mechanism of materials under the non-equilibrium conditions.

La production d’énergie avec des cellules photovoltaïques organiques (OPV) est une des applications les plus prometteuses des semi-conducteurs organiques, en raison de leur compatibilité avec les substrats flexibles permettant des produits légers, peu chers et décoratifs. Pendant longtemps, poly(3-hexylthiophène) (P3HT) a été le polymère de choix dans l’OPV combiné au [6,6]-phényl-C61-butanoate de méthyle (PC61BM) comme accepteur. Toutefois, des recherches récentes ont porté sur des polymères avec meilleures absorption et processabilité, qui peuvent assurer des rendements et des durées de vie plus élevés. Des rendements de conversion en puissance (PCE) au-dessus de 11% ont récemment été démontrés. Cette thèse rapporte sur la synthèse et la caractérisation de deux séries de polymères dits à faible bande interdite, LBGs "push-pull" (ou donneur-accepteur), constitués de l'unité donneuse 4,4-bis(2-ethylhexyl)-5,5'-dithieno[3,2-b:2',3'-d]silole (DTS) combinée au 3,6-dithiophén-2-yl-2,5-dihydro-pyrrolo[3,4-c]pyrrole-1,4-dione (DPP) ou au 5,7-di(thiényl)thiéno[3,4-b]pyrazines (DTP), comme unité acceptrice. Toutes les molécules et les polymères ont été caractérisés chimiquement et leur propriétés optoelectroniques, morphologiques et photovoltaïques ont été determinées. La série DTS-DPP a été choisie parce qu'elle est représentative d'un grand nombre de polymères LBG et a fourni un modèle facilement accessible pour évaluer l'importance de la chaîne latérale utilisée sur leur propriétés optoélectroniques et thermiques. Les premières études sur les dispositifs à base de DTS-DPP:PC61BM ont été menées, pour déterminer les propriétés photovoltaïques. Le meilleur dispositif permet d’obtenir un PCE de 1,7% avec JSC de 5,9 mA cm-2, VOC de 0,54 V et FF de 0,58. La série DTS-DTP a été choisie pour la stabilité chimique élevée des deux unités et pour la facilité de substitution des groupes latéraux. La polymérisation a partiellement abouti, en donnant seulement des oligomères. La caractérisation chimique a pu être effectuée, mais leur application dans l’OPV n'a pas été explorée. En termes de stabilité, les mécanismes de défaillance électrique des dispositifs OPV ont été étudiés, montrant une méconnaissance de leur stabilité mécanique. Les contraintes caractéristiques de chaque couche mince présentes dans les cellules solaires organiques constituent la force motrice à l’origine de la délamination des interfaces faibles ou même leur decohésion, causant une perte de l'intégrité et des performances du dispositif. Une technique pour sonder les couches ou les interfaces fragiles dans les cellules solaires polymère:fullerene est présentée. Elle a été développée par l'établissement d'un nouveau set-up pour le test pull-off, développé en utilisant un dispositif à géométrie inverse, de structure verre/ITO/ZnO/P3HT:PC61BM/PEDOT:PSS/Ag. Les dispositifs délaminés ont montré que le point le plus faible est localisé à l'interface AL/HTL, en bon accord avec la littérature. La technique a été étendue en variant les deux couches sensibles, en utilisant differents polymères LBG pour l’AL (PSBTBT et PDTSTzTz) en combinaison avec deux formulations de PEDOT:PSS, CleviosTM HTL Solar à base d'eau et un nouveau HTL Solar 2 à base de solvant organique. Une différence entre la contrainte à la rupture des dispositifs avec différentes combinaisons de AL et HTL est visible, suggérant différents chemins de fracture, tel que confirmé par la caractérisation de surface et qui pourrait être corrélée avec la différence de comportement de la couche active avec les deux formulations de PEDOT:PSS. Une autre voie adoptée, a été d’introduire une couche d’interface de copolymère à blocs amphiphile afin d'améliorer la compatibilité des deux couches. Cette stratégie n'a pas abouti et la nouvelle architecture présente une adhésion réduite. La poursuite de l’amélioration des procédés de fabrication de ces dispositifs pourrait faire de cette nouvelle architecture, une alternative viable. / Organic photovoltaic (OPV) devices are one of the most promising applications of organic semiconductors due to their compatibility with flexible plastic substrates resulting in light weight, inexpensive and decorative products. For a long time poly(3-hexylthiophene) (P3HT) has been the polymer of choice in OPV devices in combination with [6,6]-phenyl-C61-butyric acid methylester (PC61BM) as acceptor. However, recent research has focused on polymers with improved absorbance and processability that can ensure higher efficiencies and longer lifetimes (Low BandGap polymers (LBGs)). This has been fully demonstrated with a power conversion efficiency (PCE) above 11%. This thesis reports synthesis and characterization of two series of so-called “push-pull” (or donor-acceptor) LBGs based on the donor unit 4,4′-bis(2-ethylhexyl)-5,5’-dithieno[3,2-b:2′,3′-d]silole (DTS) and either 3,6-dithiophen-2-yl-2, 5-dihydropyrrolo[3,4-c]pyrrole-1,4-dione (DPP) or 5,7-di(thienyl)thieno[3,4-b]pyrazines (DTP), as acceptor unit. All π-conjugated molecules and polymers were characterized by chemical investigation and their optoelectronic, morphological, and photovoltaic properties are reported. The DTS-DPP series was chosen because representative of a large number of LBG polymers and provided an easily accessible and useful template to discover the importance of the type of side-chain used on the polymer optoelectronic and thermal properties. First studies on DTS-DPP:PC61BM devices have been conducted, in order to investigate any effect on their photovoltaic properties. The best device obtained had a PCE of 1.7% with JSC of 5.9 mA•cm-2, VOC of 0.54 V and FF of 0.58. The DTS-DTP series was chosen for the high stability of the two units and for the ease of substitution of the side-groups. The synthesis was partially successful and only oligomers were obtained. Nonetheless, chemical characterization was performed but their application in OPV was not explored. In terms of device stability, the electrical failure mechanisms in OPV devices have been investigated, while little is known about their mechanical stability. The characteristic thin film stresses of each layer present in organic solar cells, in combination with other possible fabrication, handling and operational stresses, provide the mechanical driving force for delamination of weak interfaces or even their de-cohesion, leading to a loss of device integrity and performance. A technique to probe weak layers or interfaces in inverted polymer:fullerene solar cells is presented. It was developed by establishing a new set-up for the pull-off test. The technique was developed using inverted device, with the structure glass/ITO/ZnO/P3HT:PC61BM/PEDOT:PSS/Ag. The delaminated devices showed that the weakest point was localized at the active layer/hole transporting layer interface, in good agreement with the literature. The technique was extended varying both sensitive layers, using different p-type low bandgap (co)polymers for the active layer (PSBTBT and PDTSTzTz) in combination with two different PEDOT:PSS formulations, the water based CleviosTM HTL Solar and a new organic solvent based HTL Solar 2. The half-devices produced upon destructive testing have been characterized by contact angle measurement, AFM and XPS to locate the fracture point. A difference in the stress at break for devices made with different combinations of active and hole transporting layers is visible, suggesting different fracture paths, as confirmed by surface characterization and could be correlated to the different behavior of the active layer with the two PEDOT:PSS formulations. Another solution adopted, it had been the introduction of amphiphilic block-copolymer interlayer to enhance the compatibility of the two layers. This strategy was not successful and the new architecture showed reduced adhesion strength. Further development of device processing could make this new architecture a viable alternative.