This thesis is deals with the suitability of Ag-Sn-Sb alloy for extrusion and selection of suitable materiál for the extruder nozzle. The theoretical part of this thesis deals with the general possibilities of 3D metal printing, especially the metal printing in the semi-solid phase and with it‘s problems. The experimental part describes the development of semi-solid alloys testing device and the research od the alloy and its interactions with solid materials in mutual motion. Analyzis of mechanical and chemical influence between alloy and solid material were performed by visual investigation and analysis of elements by EDS detector. The results of these analyzes led to the choise of nozzle material suitable for extrusion of Ag-Sn-Sb alloy.

This diploma thesis solves the 3D printing problematics for non-commercial printers. Firstly possibilities of its using, heat diffusion and printing materials are described. Next part of thesis is focused on heating pads and printing nozzles for which 3D models in SolidWorks software are created. The temperature analyzes are tested with these models and then comparing of results is done. Working models for SolidWorks Plastics and SolidWorks Simulation software is created in following part. Thanks to this software tools printing model is simulated and deformation creating in printing process is observed. The most suitable solutions are chosen from gained solutions.

The aim of diploma thesis is design and lay-out of high pressure pumping station with plunger pumps for splash of scales from slabs of hot-rolled. Theoretic (introduction) part of this thesis contain description of formation of scales and description of ways how it is possible remove these scales. And this part contains also explication of effect of water jet on solid material. The practical part of diploma thesis is focused on design of pumping station including of dimensioning of machinery. Part of this work is also technical documentation for proposed pumping station and specification of main machines and devices.

This master´s thesis deals with issues of tube furnaces in the process industries, especially with a design of a transfer pipeline, which is one of the main parts of the furnace. According to the requirements, designed pipeline is stress analyzed using the two pipeline programs Japar and Caesar II, that are briefly described. In addition to this design several variants of analysis are performed and the results are compared. Comparison helps to explain the diversity of the programs. For example, the effect of elbows on the stress analysis. The master´s thesis also describes the factors that affect the working life of the furnace.

Cette thèse, initiée par un programme de coopération franco-britannique entre la DGA et la DSTL, est consacrée à l’étude des phénomènes de décollement de jet au sein des tuyères propulsives sur-détendu. L’aérothermodynamique des systèmes propulsifs (missile, avion supersonique ou lanceur) est un des domaines de la mécanique des fluides où des progrès décisifs restent à réaliser pour améliorer les performances des ensembles moteurs, en terme de bilan de poussée, de stabilité, de fiabilité et de réduction de nuisances (bruit, émission de polluants, etc.). Les conditions de vols et la complexité des phénomènes caractéristiques n’étant pas reproductibles sur bancs d’essais à l’aide des outils expérimentaux actuelles, l’utilisation de simulation numérique permettrait une étude approfondie et précise des phénomènes mis en jeu. Le besoin d’informations concernant l’instationnarité de l’écoulement s’affirmant de plus en plus, notamment sur les phénomènes basse fréquence dû aux décollements de jets, l’utilisation des simulations numériques aux grandes échelles (LES) permettrait de faire face au coût prohibitif des simulations directes (DNS). Les tuyères sur-détendu souffrent de charges latérales, caractérisées par des forces instationnaires orthogonales à la direction de l’écoulement. Ils sont causés par le décollement de la couche limite se développant le long de la paroi, provoquant des excursions de chocs importants, parfois asymétrique. Ces phénomènes instationnaires ont déjà été observés expérimentalement et numériquement. Ces instationnarités émergent d’une combinaison de phénomène complexe, tels que les interactions choc/couche limite sur la paroi de la tuyère, les couches de mélange décollées ou les zones de recirculation en aval du décollement, toutes produisant des modes énergétiques à différente fréquence caractéristique et tout particulièrement dans la plage de basse fréquence. Capturer le phénomène de décollement est un véritable défi dû à la nécessité de résoudre plusieurs échelles spatiales et temporelles. L’utilisation des simulations directes (DNS) ou résolu proche paroi (WR-LES) devient difficile compte tenu des ressources en calcul numérique actuelles. Pour parer ce problème, l’utilisation d’une stratégie de modélisation proche paroi est nécessaire. Le modèle de paroi développé par Kawai & Larsson (2013) est intégré à la simulation LES, combiné au modèle de viscosité de Duprat et al. (2011) afin de tenir compte des gradients de pression rencontré tout au long de la tuyère. Le développement d’un code curviligne a également permis de réduire le coût de calcul des simulations cylindriques en utilisant un maillage raffiné proche paroi. Les résultats obtenus à partir des simulations modélisés (WM-LES) permettent de bien mettre en évidence les phénomènes d’instationnarité menant au problème de charge latérale. Le coût de calcul étant réduit de 40 fois comparé à une simulation résolu proche paroi WR-LES, la production d’une base de donnée basse fréquence devient possible. La comparaison des calculs modélisés aux calculs résolus et aux données expérimentales confirme la bonne implémentation du modèle pour des simulations LES de tuyère propulsive. La caractérisation des différents phénomènes est faite à l’aide d’analyses spectrales effectuées sur la base de donnée permettant de mettre en avant le phénomène basse fréquence rencontré dans les tuyères sur-détendu. / The present thesis, sponsored by a Franco-British cooperation program between the DGA and the DSTL, is devoted to the study of separation phenomenon in over-expanded nozzle. The aerothermodynamic of propulsion systems (missile, supersonic aircraft or launcher) is one the fields of fluid mechanics where important progress remains to be made in order to improve the performance of the engine, in terms of thrust, stability, reliability and pollutant (noise reduction, pollutant emissions, etc.). Since the flight conditions and the complexity of the characteristic phenomena are not reproducible on experimental benches, the use of numerical simulation would allow a thorough and precise study of the phenomena involved. The instationnarity observed in the separation of the boundary layer is becoming a main concern nowadays, especially the low-frequency phenomenon observed in some experiments, the use of large scale simulations (LES) would fit perfectly the computational power allocated on supercomputer compared to the prohibitive cost of direct simulations (DNS). Over-expanded nozzles are known to suffer from side loads, characterized by undesired unsteady forces orthogonal to the flow direction. They are caused by boundary-layer separation that causes significant and asymmetrical shock excursions within the nozzle. These phenomena have been studied experimentally and numerically. They emerge from a combination of complex unsteady flow phenomena, not yet fully understood, such as shock/boundary-layer interactions at the nozzle walls, detached mixing layers, and large regions of recirculating flow, all producing energetic motions at frequencies one or two orders of magnitudes lower than the characteristic frequency of the incoming turbulence. Capturing the phenomenon is a real challenge due to the need to resolve at least four decades of time scales, from the energetic scales of the incoming turbulence. This makes both direct (DNS) and wall-resolved large-eddy simulations (WR-LES) rather impractical. Instead, a wall-modelled LES (WM-LES) strategy is employed here, following the approach of Kawai & Larsson (2013) together with the eddy-viscosity modification of Duprat et al. (2011) so as to account for pressure gradients. The WM-LES is found to accurately reproduce the flow topology, as well as the spectral content obtained by a reference WR-LES. The development of a curvilinear code has allowed us to decrease the cost of computation of the simulations by using a stretched mesh close to the wall. The results obtained from the wall-modeled simulations (WM-LES) allowed us to capture and study the phenomena of instationnarity leading to the problem of side-loads. The WM-LES being about 40 times cheaper, the low-frequency motions may be statistically converged, enabling the study of the very low frequencies. The comparison of the modeled simulations with the resolved simulations and the experimental data confirms the good implementation of the model for LES computations of over-expanded nozzle flow. The characterization of the different phenomena is done through spectral analyses, carried out on the LES database allowing the highlight of the low-frequency phenomenon encountered in the over-expanded nozzle flow.

Turbochargers are becoming an essential device in internal combustion engines as they boost the intake air with more pressure in order to increase the power output. These devices are normally designed for a single steady design point but the pulsating flow delivered from the internal combustion engine is everything but steady. The efficiency drop experienced in the off-design points by the fixed geometry turbochargers have made some research groups to look into new variable geometry solutions for turbocharging. A nozzle ring is a device which normally achieves a higher performance under design conditions, but the efficiency rapidly drops at off-design conditions. In this paper, a variable angle nozzle ring is designed and implemented in the model of a radial turbine of a turbocharger in order to study its potential when working under real internal combustion engine cycles. To understand the profit margin the turbine performance is compared with two turbines with the same impeller geometry: one without nozzle ring and one with a nozzle ring with a fixed angle. The results show that the maximum efficiency angle function calculated for the variable angle nozzle ring achieves an improvement in the total efficiency of 5 % when comparing with a turbine with a fixed angle and 18 % when comparing with a vaneless turbine. The improved guidance achieved due to the variable blade angle leads to less turbine losses and therefore more mechanical energy can be extracted from the exhaust mass flow throughout all the combustion cycle but a further study should be made in order to match all the engine operations points. Notably, taking the pulsating boundary conditions into consideration, a remarkable improvement is achieved already for the fixed angle nozzle ring.

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.

No description available.

The ever increasing demands on today's engine performance and emissions control is forcing the automotive industry to make use of innovative solutions. One of these is to apply the technology of VNT turbos on commercial petrol vehicles. When using a VNT turbo, the aspect ratio of the turbine can be altered while driving to suit the current operating window. In order to actually gain performance while using a VNT, the vanes have to be properly controlled using a suitable control strategy. In this project, direct collocation have been utilized through the usage of YOP which is an adaptation of CasADi in MATLAB to solve non-linear optimization problems. Comprehensive models of the turbocharger and the cylinders have been built and validated to properly represent a VEP4 LP engine from AUROBAY. The models are implemented in YOP to create and simulate different OCPs using the turbo speed as state and position of the vanes as control signal. With this model in YOP together with the air mass flow per second as reference, a good reference following together with decent values for relevant parameters can be accomplished. Other objective functions such as minimum time and maximal volumetric efficiency are also investigated in the project which yield likewise results. From the results it can be concluded that this type of model and control strategy can be used with success when studying optimal control of a VNT turbo.

Gas atomization is regarded as a reliable method for creating high-quality metal powders from molten metal. The liquid metal is fed into the chamber as a free-falling stream through a nozzle, where it is impinged by high-velocity gas jets, causing degeneration and production of metal droplets, which solidify to create metal powders. As the metal droplets fall lower towards the collection hoopers, the solidification process begins. As a result, having a strong handle on the process parameters helps to produce metal powders that are fine, spheroidized, and have good characteristics. A free fall atomizer with twelve discrete nozzles, having a cylindrical internal profile, arranged in two different levels has been employed to introduce high-velocity gas jets into the chamber, for the current study. A cross-sectional sketch created by Uddeholm AB provided the geometric dimensions, and CFD was used to generate a simulation experiment for the system. Fluent setup input values were derived from literature data. The primary objective of the study is to analyze the influence of varying inlet pressure and the number of discrete gas jet nozzles, on the flow behavior of the atomizing gas. Additionally, the Discrete Phase Model approach was adopted to study the interaction of particles with the gas flow. The simulation model was validated by carrying out the visualization experiment, Schlieren imaging. From the study, it was realized that the results of the numerical model showed a mismatch relative to the experimental value. This can be attributed to the discretization technique, input parameters and the numerical model employed in this study. However, the parametric study provided a qualitative analysis regarding the influence of input parameters on flow behavior. It was studied that with increasing the inlet pressure and number of discrete nozzles there is a subsequent increase in the maximum velocity attained by the atomizing gas, resulting in a decrease in velocity of melt introduced into the system. Additionally, a radial pressure gradient was observed to be present that increased in accordance with the parameters, resulting in reduction of the melt film thickness produced during pre-filming mechanism. However, the Discrete Phase Model provided evidence that with increment in the gas to melt ratio, the number of particles that get dispersed to make collision with the domain wall increased. Thus, a subsequent increase in downstream velocity was required to maintain the particles within the domain walls as the study parameters were increased. / Gasatomisering betraktas vara en tillförlitlig metod för att skapa högkvalitativt metallpulver från smält metall. Den flytande metallen matas in i en kammare som en fri fallande ström genom ett munstycke, där den trycks in av höghastighetsstrålar. Vilket skapar en degeneration och en bildandet av metalldroppar som stelnar till att metallpulver kan skapas. Stelningsprocessen börjar när metalldropparna faller emot uppsamlingsbågarna. Ett fint och sfärisk metall metallpulver med goda egenskaper kan produceras genom att ha en god kontroll på processparametrarna. I denna studie har en ”Free Fall Atomizer” med tolv diskreta munstycken med en cylindrisk profil arrangerade i två olika nivåer använts för att introducera höghastighetsstrålar i kammaren. De geometriska dimensionerna var försedda från en ritning i tvärsnitt skapad av Uddeholms AB och samt användes en CFD för att generera ett simulationsexperiment av systemet. Ingångsvärden för inställningarna av flödena härleddes från litteraturdata. Huvudsyftet med studien var att studera flödesbeteendet av den atomiserande gasen genom att analysera inflytandet av att variera ingångstrycket och antalet diskreta gasstrålmunstycken. Dessutom togs det till en diskret fasmodell för att studera partiklarnas interaktion med gasflödet. Simulationsmodellen validerades genom att utföra ett visualiseringsexperiment genom Schlierenfotografering. Det framgick i studien att den numeriska modellens resultat inte stämde överens med det experimentella värdet. Detta kan attribueras till diskretiseringstekniken, inmatningsparametrarna och den numeriska modellen som användes i studien. Hur som helst försedde den parametriska studien en kvalitativ analys angående inflytandet av inmatningsparametrarna på flödesbeteendet. Det framgick att en ökning av ingångstrycket och av antalet av diskreta munstycken gav en påföljande ökning i den maximala hastigheten som den atomiserande gasen kan erhålla. Vilket resulterar till en sänkning av hastigheten av smältan som introduceras till systemet. Dessutom observerades en radiell tryckgradient vara närvarande som ökade i enlighet med parametrarna. Det resulterade i en reduktion av smältfilmtjockleken som producerades under förfilmingsmekaniskmen. Trots det visade den diskreta fasmodellen att en ökning av gas till smältförhållandet också ökade antalet partiklar som sprids vidare för att kollidera med domänväggen. Således krävdes en påföljande ökning av nedströmningshastigheten för att bibehålla partiklarna inom domänväggar när studiens parametrar ökade.