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.

The work presented in this thesis was conducted at Uppsala University and at Swerim AB. The study aims to broaden the knowledge about the corrosion of additively manufactured bioresorbable alloy WE43 in humanlike conditions for future applications. Biodegradable metal implants are implants meant to stay in the body and support the wounded bone for a certain time period, and then degrade as new, healthy bone forms in its place. Magnesium alloys have properties that are desired for these kind of implants as it is biodegradable, non-toxic and matches the mechanical properties of bone. Furthermore, magnesium alloy WE43, containing yttrium, neodymium and zirconium, already exist on the market as a powder extruded screw that treats Hallux valgus, thus proves the alloys compatibility as a bioresorbable implant. However, in order to optimize implants for specific situations, additive manufacturing can be a powerful tool. By utilizing the advantages of additive manufacturing, patient specific, complex designs implant can be manufactured rapidly in order to be used in a patient. On the other hand, additive manufacturing is a complex method with many aspects affecting the outcome. Therefore it is important to study the influence that different parameters have on the material's properties, especially the corrosion properties. This thesis aims to study different power settings on the laser in the manufacturing process and what effect it has on the microstructure as well as the corrosion properties of as built WE43 samples. Samples of three different parameters settings were manufactured with a Powder Bed Fusion-Laser Beam 3Dprinter. These samples were analyzed regarding surface roughness and microstructure with Light Optical Microscope, Scanning Electron Microscope, Energy Dispersive Spectroscopy, Electron Backscatter Diffraction and Alicona InfiniteFocus. Furthermore, the corrosion properties of the samples were investigated by collecting and measuring hydrogen gas that is released during the corrosion process. In addition, the electrolyte were examined regarding the change in ion concentration and electrochemical tests were performed. It was found that the samples did not differ substantially in microstructure as all three parameter settings exhibited a matrix of magnesium and precipitates of alloying elements. However, the sample manufactured at the lowest energy density had pores incorporated in the bulk. Despite the porous bulk this sample performed best in the immersion tests and exhibited the lowest corrosion rate over 28 days. The reason for this behavior is not determined, however possible causes are discussed and further studies are recommended.

This is a master thesis research on how to select the right components in a product, considering reducing the weight with topology optimization (TO) and adaption for additive manufacturing (AM). It is well established that manufacturing of complex structures can be achieved with AM, the possibility of integrating assembled components and improve features will therefore be investigated. The new component structure must still withstand the loads that it is subjected to during usage, to not permanently deform or break. In this research the studied product was a handheld Husqvarna chainsaw. Initially a feasibility study was conducted, where the product was disassembled and physically investigated for potential component cases. Additional knowledge was gathered with one semi structured interview per case, with experienced design engineers. Followed by one semi structured interview with AM experts, regarding available AM technique and similar material. Selection of case to continue with was based on the interviews information and Pughs decision matrix, with weighted criterions. TO were used for finding the optimal material distribution. The new component design was analyzed with linear finite element analysis to fulfill both the component and material stress requirements. Component orientation and support structure for AM was analyzed with computer aided engineering software. This resulted with integrating thirteen components for the engines cylinder into one component. The new design resulted in a weight reduction of 31%, while utilizing only 57% of the allowed stress limit. Also, the first 23 natural frequencies were improved with a new type of cooling fin structure, with an increased area of 15%. These results encourage the thesis workflow methodology usage for other products. In conclusion the established workflow of methods resulted in selecting a suitable case for integrating components with feature improvement and adaption of the new design with TO for AM, to reduce the weight.

Hot stamping of aluminium alloys allows for increased formability, decreased springback and the possibility of integrating age-hardening heat treatments into the process. However, it can be challenging due to the occurrence of material transfer of aluminium onto the tool, as aluminium is prone to adhesion even at low temperatures. Hence, lubrication is always necessary when forming aluminium, but lubricants can still fail, leading to direct interaction between tool and workpiece and thus material transfer. This phenomenon reduces the efficiency of the process, as interruptions are necessary for the refurbishment of the tools. Understanding of how material transfer takes place is important in order to find new or improved solutions, in terms of lubrication and surface engineering, to prevent adhesion. Nevertheless, current research in high temperature tribology of aluminium, mainly in terms of material transfer mechanisms, is very limited, as many of the works focus on lubricated conditions and do not look into the fundamental interactions between aluminium alloys and tool steels. In this context, the aim of this work is to investigate the mechanisms behind the occurrence of aluminium alloy transfer onto tool steel during sliding at high temperature and in dry conditions. A hot-strip drawing tribometer was used to perform tests at room temperature, 300°C, 400°C, and 500°C, directly after solubilizing the aluminium alloy at 520°C. Two different topographies for the tool steel were used: ground and polished. Material transfer characterization was performed mainly through scanning electron microscopy. It was found that grinding marks (ground tool steel) and carbides (polished tool steel) act as initiation sites for the transfer to occur. Temperature plays a role on the growth mechanisms of the transfer films during sliding, as thermal softening of the aluminium alloy is the dominant factor in determining the growth direction of the transfer layers. A growth towards the trailing edge (shearing and smearing of the transferred aluminium) or a growth towards the leading edge (build-up of transferred aluminium, leading to a thicker and more localized transfer material).

Práce je zaměřena na šíření únavových trhlin v módech II, III a II + III v prahové oblasti v kovových materiálech. Byly provedeny experimenty pro ARMCO železo, titan, nikl a austenitickou ocel na třech druzích vzorků pro zatěžování trhliny ve smykových módech. Byl použit zvláštní způsob vytváření iniciační trhliny, který eliminoval efekt zavírání trhliny na začátku smykového zatěžování. Ve všech zkoumaných materiálech byly efektivní prahové hodnoty v módu II přibližně 1,7 krát nižší než v módu III. Měřením úhlů lokálních odklonů a natočení lomových faset s použitím stereofotogrammetrie v SEM bylo usuzováno na tendenci trhliny k vyhýbání do lokálního módu I. Nejmenší úhly byly zjištěny u ARMCO železa pro trhliny v módech II i III, středně velké úhly u titanu a niklu a největší úhly (vyhnutí do čistého módu I) byly pozorovány u austenitické oceli. Tyto rozdíly lze vysvětlit různým počtem dostupných skluzových systémů v krystalových mřížkách daných materiálů. Poměry mezi naměřenými prahovými hodnotami v módu I, II a III byly srovnány s předpověďmi teoretických modelů. Byl navržen analytický vztah pro efektivní prahové hodnoty v módu II, který byl v dobré shodě s experimentálními výsledky. Pomocí efektivních prahových hodnot bylo vyčísleno kritérium pro vyhýbání do módu I, které vedlo ke kritickému úhlu odklonu 40° souvisejícímu s přechodem z lokálního smykového módu do otevíracího módu.

The use of recommended S-N curves, presented in current literature, to analyse and determine the fatigue life of a part is common practice in, inter alia, the construction industry.However, the recommended S-N curves are generally created for larger components used in mainly the construction industry. Hence, the use of S-N curves for the evaluation of smaller parts, may result in over-dimensioning of such parts. For this reason, evaluation and designing of smaller parts could benefit from the development of an in house S-N curve specific for the part. The purpose of this thesis is to generate and validate an in-house method for creating a S-N curve, for a specific part to be compared with recommended S-N curves in the literature. The specific part used for the generating of the method is a welded steel joint with the geometry of two steel pipes, welded together in a t-formation and which has been provided by Thule AB for the purpose of the thesis. The method presented uses the results from 1) physical fatigue tests using a fatigue testing machine and 2) static FEA to derive a S-N curve for the specific part using the least squares method. A fatigue testing rig enables the gathering of data of the number of cycles to failure when the part is subject to a given cyclic load. The rig uses pneumatics to control the forces applied onto the part with the use of a cylinder. Furthermore, the fatigue testing rig was designed to be controlled by the applied force, meaning, that the rig ensured a homogeneous load cycle by measuring the force from a load cell and alternating the direction of the cylinder with an electrically controlled pressure valve. The performance of static FEA evaluations aim at locating stresses in the part. For this thesis the stresses were evaluated using the hot spot method due to the part's welded geometry. The data gathered from the physical fatigue tests and the static FEA evaluations are subsequently combined deriving S-N curves applicable to the part. From the fatigue tests and FEA evaluations for the t-shaped welded steel part, four S-N curves were derived of which two curves showed the results of a linear fitted curve whereas the other curves used the recommended slope of $-1/3$. The results showed that the S-N curves derived, using a set slope, resulted in similar curves to the recommended S-N curve provided by the literature. However, the linear fitted S-N curve showed that the part, according to the S-N curve, had a higher fatigue resistance than recommended.  Due to limitations in the thesis work, the S-N curves derived within the framework of this thesis should be regarded as theoretical and have been strictly used to identify whether the method generated is applicable for deriving of S-N curves.

The lithium-ion battery (LIB) recycling industry is currently under development to improve the yields for critical metals. However, the organic components of LIBs must also be handled, which may result in harmful chemical emissions as by-products. Of particular concern are highly persistent and mobile per- and polyfluoroalkyl substances (PFAS) that could be released during LIB recycling since some of these compounds have been linked with adverse health effects. In this work, an extensive literature review was conducted to determine the presence of fluorinated materials in state-of-the-art LIBs and the recycling conditions which could lead to the release of problematic PFAS. This information was used to develop a new analytical approach to capture the broadest range of organic and inorganic fluorine species in samples taken in different stages of the recycling process. This new method is based on a sequential extraction procedure using different solvents, followed by combustion ion chromatography (CIC) to quantify the potential emission of fluorine-containing chemicals of different polarities. The results show that organofluorine compounds are formed during recycling, particularly for the cathodes, indicating that PFAS might be present. For other samples, such as the NiMnCo salt product of recycling, only low fluorine levels were detected which implies almost complete removal. Future work should further outline the emission paths of these processes. This study highlights the necessity to further investigate the emissions related to fluorinated materials during LIB recycling and indicates that post-treatments or changes in conditions might be necessary to avoid the formation and emission of PFAS.

This research extended the knowledge of the solid phase transformation and the resulting influence on impact toughness and pitting corrosion resistance in super austenitic stainless steel (SASS) SANICRO® 35. A time-temperature-transformation diagram (TTT diagram) was assembled by performing isothermal heat treatments in the temperature range of 650-1050 °C for different periods of time, ranging from 5 min to 500 min. Microstructural analysis via LOM-DIC, SEM-EDS shows that the nose temperature of dominating σ phase is located in between 900-950 °C. Minor nitrides including π phase and Cr2N with the nose temperature of 900 °C and 850 °C, respectively, were detected after prolonged heat treatment times. Area fraction of precipitates was calculated by analyzing micrographic images in the software ImageJ. Charpy impact tests indicate that the impact toughness degrades with increasing area fraction of precipitates but at a higher rate at the early stage of precipitation. Despite a much-lessened area fraction, fine precipitates decorating the grain boundaries in a continuous pattern impose significant negative effect on impact toughness. Pitting corrosion resistance was indicated by critical pitting temperature (CPT) as per ASTM G150mod (3M MgCl2). Pitting corrosion resistance deteriorated with increasing amount of σ phase due to the Cr- and Mo-depleted surrounding area, but it is more dependent on the distribution pattern of precipitates, as well as the secondary phase type. The lowest CPTs were measured after heat treatment for 500 min at 800 °C and 850 °C where nitrides including Cr2N and π phase were formed and the small precipitates were distributed on grain boundaries continuously. Auxiliary simulation of TTT diagram via TC PRISMA shows drastic variation from experimental results in regard of time scale. The enhancement pre-factor for the interfacial mobility and interfacial energy can be modified to approach the experimental results. / Detta arbete utfördes för att undersöka fasomvandlingar och dess inflytande på slagsegheten och gropfrätningsmotståndet för det superaustenitiska rostfria stålet (SASS) SANICRO® 35. Ett tid-temperatur-transformationsdiagram (TTT-diagram) har tagits fram genom att utföra isotermiska värmebehandlingar mellan 650-1050 °C med olika hålltider från 5-500 minuter. Mikrostrukturanalys genom LOM-DIC, SEM-EDS undersökning visar att nosen för den dominerande σ-fasen ligger mellan 900-950 °C. Mindre nitrider, som π-fas och Cr2N, med nosarna vid 900 °C respektive 850 °C observerades vid längre hålltider. Areafraktionen av utskiljningar beräknades genom analys av mikrobilder med programmet ImageJ. Slagprovning visade att slagsegheten minskar med ökande fraktion utskiljningar men med en tydligare försämring i början av fastransformationen. Trots att de utgör en betydligt mindre areafraktion så kan mindre utskiljningar som följer korngränserna också påverka materialet signifikant negativt. Gropfrätningsmotståndet testades genom att mäta Critical Pitting Temperature (CPT) enligt ASTM G150mod (3M MgCl2). CPT minskade med ökande andel σ-fas p.g.a. den Cr- och Mo-utarmade zon som omger de utskilda partiklarna. Det finns även en stark koppling mellan lägre CPT och distributionen av utskiljningarna samt andra typer av faser. Lägst CPT uppmättes efter 500 minuter vid 800 °C och 850 °C då små nitrider inklusive Cr2N och π-fas bildats längs med stora delar av korngränserna. Simulering av TTT-diagram i TC PRISMA visade en drastisk skillnad i tiden till utskiljning/mängden utskiljningar jämfört med de experimentella resultaten. Diffusionförstärkningsfaktorn (eng. “mobility enhancement pre-factor”) och ytenergin kan minskas för att bättre överensstämma med de experimentella resultaten.

Alloy 617 displays a ductility dip during straining at exactly 1000˚C, leading to brittle fracture. A sudden decrease in ductility appearing during Gleeble hot ductility tests of Ni-based superalloys is a well-known phenomenon, while its cause is unknown. Many mechanisms have been established as possible contributors to the issue, and in later years not one, but the simultaneous presence of several of these mechanisms were confirmed as the cause. The ductility dip leads to solid state cracking and a specific solid state cracking phenomenon known as ductility dip cracking is specifically common in Ni-based superalloys. Ductility dip cracking is identified by intergranular cracks and the occurrence of specific precipitates, among other things. This work investigates the possibility that the decreased ductility is due to ductility dip cracking. Furthermore, other possible explanations are investigated. Visual examination was conducted through LOM, SEM and chemical analysis using EDS technique. Combined with thermodynamic calculations, the existence of Cr-rich M23C6 carbides, Ti(N,C) and Mo-rich particles, most likely M3B2, were confirmed. Further, it is established that the ductility dip is related to the lack of dynamic recrystallization at 1000˚C. It is not confirmed that the ductility dip in alloy 617 is due to ductility dip cracking. / Nickelbaslegeringen 617 uppvisar en minskning i duktilitet under Gleeble-dragprovning vid exakt 1000˚C vilket leder till sprött brott. En plötslig sänkning av duktiliteten vid varmdragning av Ni-baserade superlegeringar är ett välkänt fenomen, dock är orsaken inte fastställd. Många mekanismer har bekräftats som bidrag till problemet och under de senaste åren har den simultana närvaron av fler av dessa mekanismer bekräftats som orsaken. Sänkningen i duktilitet leder till sprickbildning i fast fas och en specifik typ av sprickbildning känd som ”ductility dip cracking” är speciellt förekommande i Ni-bas legeringar. Denna identifieras bland annat genom intergranulära sprickor och närvaron av specifika utskiljningar. Detta arbete undersöker möjligheten att duktilitetssänkningen beror på  ”ductility dip cracking”. Dessutom undersöks fler tänkbara förklaringar. Visuell granskning genomfördes via LOM och SEM och analys av sammansättningar via EDS-analys. I kombination med termodynamiska simuleringar blev förekomsten av Cr-rika M23C6 karbider, Ti(N,C) och Mo-rika partiklar, troligtvis M3B2, bekräftad. Fortsatt är det bekräftat att duktilitetssänkningen är relaterat till avsaknaden av rekristallisation vid 1000˚C. Det är inte bekräftat i detta arbete att duktilitetssänkningen i legering 617 beror av ”ductility dip cracking”.

It is an established fact that segregation during casting affects the physical properties of carbon-based ferro alloys; this motivates the study of the segregation behaviour of carbon and carbide-forming solute elements. In this context, this thesis investigates two different situations: the effects of cooling rate and turbulence on the precipitation behaviour of the graphite nodules in nodular cast iron; the nature of carbide precipitation in a bearing steel grade and the effects of subsequent soaking on these carbides. The structures of boiling water reactor inserts cast by the uphill and downhill casting of nodular cast iron were examined. The samples were taken from representative locations in the top, middle and bottom cross sections of the castings. It was observed that in uphill-cast inserts the nodules were larger but fewer in number the bottom section, whereas in downhill-cast inserts the nodules in the bottom section were smaller, but greater in number. Variation in volume fraction of the graphite nodules across the inserts was also observed. The probable cause of this variation was the difference in cooling rate in different sections of the insert. Between the steel tubes located at the central part of the casting, the fraction of graphite was lower, which could be the result of carburization of the steel tubes. To study the effects of melt stirring during the solidification of nodular cast iron, several experiments were conducted at variable cooling rates and for different stirring times. Examination of the microstructure was conducted using Light Optical Microscope (LOM) and Scanning Electron Microscope (SEM). It was observed that during stirring the melt oxidized and oxide nuclei were formed. The number of nucleation sites for the precipitation of graphite nodules increased, which raised the nodule count and the fraction of the graphite precipitated. The matrix transformed from pearlite to ferrite, which could be due to the fact that more carbon had diffused out of the matrix. The segregation behaviour in hypereutectoid bearing steel produced by ingot casting was also studied. The effects of soaking on micro and macro segregation was investigated in samples taken from as cast and soaked ingots; emphasis was laid on the bulk matrix and A-segregation channels. Samples were also taken from ingots which were soaked and then hot worked. The micro and macro examination of the microstructure was conducted using LOM and SEM. Quantitative and qualitative composition analysis was performed using Energy-dispersive X-ray spectroscopy (EDX) and an electron micro probe analyzer (EMPA). It was observed that M3C, M2C and M6C had precipitated. The carbide morphology in the bulk matrix was different to that in the A-segregation channels. All the primary carbides in the bulk matrix were found to have dissolved after 4 hours of soaking at 1200oC. / Det är ett faktum att segringar som uppstår under gjutning påverkar materialegenskaperna hos kolbaserade järnlegeringar; detta utgör motivationen till studien av segringsuppträdandet hos kol och karbidbildande ämnen. Denna avhandling behandlar två olika aspekter inom ramen för detta ämne: påverkan av kylningshastighet och turbulens på kärnbildningen av grafitnoduler i nodulärt gjutjärn samt karbidbildning i kullagerstål och dess påverkan på den efterföljande värmebehandlingen av dessa karbider. Strukturen hos rör till vattenkokare som tillverkats av nodulärt gjutjärn som gjutits med fyllning från botten eller från toppen undersöktes. Prover togs från representativa tvärsnittspositioner från toppen, mitten och botten av de gjutna ämnena. Resultaten visade att användandet av bottenfyllda kokiller gav upphov till större men färre karbider i nedre delen av ämnet, medans användandet av toppfyllda kokiller gav upphov till mindre men fler karbider i nedre delen av ämnet. Variationer av volymfraktionen av grafitnoduler längs tvärsnitten observerades också. Den mest sannolika orsaken till denna variation var skillnaden i kylhastighet i de olika områdena av tvärsnitten. Hos rör tillverkade av det centrala delen av ämnet så var fraktionen grafit lägre, vilket kan bero på en uppkolning av rören. Ett flertal experiment utfördes med varierande kylningshastigheter och olika omrörningstider för att studera inverkan av omrörning av smältan på stelningen av nodulärt gjutjärn. Studier av mikrostrukturen genomfördes med ljusoptisk mikroskopi och svepelektronmikroskopi. Resultaten visade att smältan oxiderades under omrörningen, vilket resulterade i bildandet av oxider. Detta ledde till en ökning av kärnbildningsområden för grafitnoduler, vilket ledde till en ökning av antalet noduler samt fraktionen av grafit som fälldes ut. Strukturen omvandlades från perlit till ferrit, vilket troligen orsakades av att kol hade diffunderat ut från strukturen. Segringsbeteendet hos hypereutektoida kullagerstål tillverkade genom götgjutning undersöktes också. Effekten av värmebehandling på mikro- och makrosegringar undersöktes i prover tagna från gjutna och värmebehandlade ämnen. Fokus var på att studera strukturen i ämnena samt A-segringar. Dessutom togs prover från ämnen som först värmebehandlats och därefter varmbearbetats. Både mikro- och makroundersökningar av mikrostrukturen utfördes med ljusoptisk mikroskopi och svepelektronmikroskopi. Dessutom så genomfördes kvantitativa sammansättningsbestämningar med energidispersiv röntgenspektroskopi och elektronmikroprobsanalys. Resultaten visade att M3C, M2C och M6C karbider hade fällts ut. Karbidmorfologin i huvuddelen av strukturen skiljde sig från den som återfanns i A-segringar. Samtliga primära karbider i huvuddelen av strukturen hade lösts upp efter 4 timmars värmebehandling vid 1200oC. / <p>QC 20180523</p>