Laser Melting (LM) is an Additive Layer Manufacturing (ALM) process used to produce three-dimensional parts from metal powders by fusing the material in a layerby- layer manner controlled by a CAD model. During LM, rapid temperature cycles and steep temperature gradients occur in the scanned layers. Temperature gradients induce thermal stresses which remain in the part upon completion of the process (i.e. residual stresses). These residual stresses can be detrimental to the functionality and structural integrity of the built parts. The work presented in this thesis developed a finite element model for the purpose of investigating the development of the thermal and residual stresses in the laser melting of metal powders. ANSYS Mechanical software was utilised in performing coupled thermal-structural field analyses. The temperature history was predicted by modelling the interaction of the moving laser heat source with the metal powders and base platform. An innovative ‘element birth and death’ technique was employed to simulate the addition of layers with time. Temperature dependent material properties and strain hardening effects were also considered. The temperature field results were then used for the structural field analysis to predict the residual stresses and displacements. Experiments involving laser melting Ti-6Al-4V powder on a steel platform were performed. Surface topography analyses using a laser scanning confocal microscope were carried out to validate the numerically predicted displacements against surface measurements. The results showed that the material strain hardening model had a direct effect on the accuracy of the predicted displacement results. Using the numerical model, parametric studies were carried out to investigate the effects of a number of process variables on the magnitude of the residual stresses in the built layers. The studies showed that: (i) the average residual stresses increased with the number of melted powder layers, (ii) increasing the chamber temperature to 300°C halved the longitudinal stresses. At 300°C, compressive stresses appeared on the Ti64 surface layer, (iii) reducing the raster length from 1 mm to 0.5 mm reduced the average longitudinal stress in the top layer by 51 MPa (0.04σy), (iv) reducing the laser scan speed from 1200 mm/s to 800 mm/s increased the longitudinal stress by 57 MPa (0.05σy) but reduced the transverse stress by 46 MPa (0.04σy).

<p>There are today strong incentives for an increased understanding of material properties and manufacturing processes to facilitate the development of new technologies in the pharmaceutical industry. The purpose of this thesis was to suggest methods requiring a low sample amount for characterization of technical properties of powders.</p><p>Compression analysis was used to evaluate the formulation relevance of some compression equations. Using the mechanics of single granules to estimate powder functionality was part of this work. It was concluded that the formability of granular solids and the plasticity of single granules could be determined with compression analysis by using the Kawakita model for single components and binary mixtures of ductile granules.</p><p>Further on, the fragmentation propensity of solid particles could be estimated from compression analysis by using the Shapiro equation, enabling indicators of both the fragmentation and the deformation propensity of particles to be derived in one single compression test.</p><p>The interpretations of the compression parameters were only valid if the influence of particle rearrangement was negligible for the overall compression profile. An index indicating the extent of particle rearrangement was developed and a classification system of powders into groups dependent on the incidence of particle rearrangement was suggested as tools to enable rational interpretations of compression parameters.</p><p>The application of compression analysis was demonstrated by investigating the relevance of the mechanics of granular solids for their tableting abilities. The plasticity of single gran-ules was suggested to influence both the rate of compactibility and the mode of deformation, and consequently the maximal tablet strength. The degree of granule bed deformation was shown to be a potential in line process indicator to describe the tableting forming ability.</p><p>This thesis contributes to a scheme, suitable in formulation work and process control, to describe manufacturability of powders for an enhanced tablet formulation technology.</p>

No description available.

Electrostatic properties of formulation component materials and blends play an important role in dry powder inhalation (DPI) products, and that valid measurement of charge distribution will lead to more precise control of powder behavior in DPI manufacturing processes. Ultra-fine powders are known to be bipolarly charged, have non-spherical shapes and tend to be highly cohesive. Real time, non-invasive techniques need to be developed to obtain a precise and accurate time-history characteristic of electrically charged powders as they aerosolize from a DPI product, and how this measure relates to materials behavior throughout the various steps of a manufacturing process i.e. from drug micronisation, blending with lactose, through to filling dose units. A novel non-invasive technique for simultaneous measurement of size and charge of pharmaceutical powders is considered which employs the Phase Doppler Anemometry (PDA) system. Previous research demonstrated the advantages of this technique in measuring the bipolar charge distribution on a population of particles. These findings led to significant improvements in understanding performance of dry powder formulations, manufacturing processes and development of new platforms for inhaled drug delivery. The main aim of this research is to perform an investigation of electrostatic propertiesof pharmaceutical dry aerosols using the PDA system. The PDA technique was used to track the motion of charged particles in the presence of an electric field. The magnitude as well as the polarity of the particle charge can be obtained by solving the equation of particle motion in DC and AC fields combined with the simultaneous measurement of its size and velocity. The results show the capability of the technique to allow real-time size and charge distribution in the control of dry powder attributes that are critical to fully understanding manufacturing design space. The data obtained from initial investigations of electrical properties of pharmaceutical powders and bipolar charge measurements was used to perform an in-depth study of electrostatic properties of pharmaceutical aerosols dispensed by dry powder inhaler (DPI) devices. The delivery of a drug to the lungs can only be achieved by a combination of inhaler device and drug formulation which is capable of producing an aerosol of an aerodynamic diameter smaller than 5 μm and of appropriate charge. The aerosols generated by these devices are often bipolarly charged and can influence specific site deposition in human lung. By controlling the electrostatic charge generated by tribielectrification, it may be possible to achieve the desired drug deposition in the airways. Bipolary charged dispensed ultrafine particles are inhaled through the extrathoracic and tracheobronchial airways down into the alveolar region. Anatomically realistic respiratory airways and computation fluid dynamics (CFD) models have been created to study airflow structures and predict aerosol deposition within the human respiratory system using visible human data sets, human casts and morphometric data. Many theoretical studies of charged aerosol deposition in human respiratory systems have been developed, however getting real time, non-intrusive data of bipolar charge levels on aerosols dispensed from DPI’s within the human respiratory system represents a challenging issue. This research project presents a simplified human upper airway model which combined with the modified Phase Doppler Anemometry (PDA) system is able to provide real time bipolar charge distributions of aerosols delivered from several commercially available DPI devices. A three dimensional (3D) reconstruction of the upper respiratory system was performed from two dimensional (2D) images obtained from computerized tomography (CT), magnetic resonance imaging (MRI) and cryosectioned images available from Visible Human Server data set (Ecole Polytechnique Fédérale de Lausanne). The resulting dimensions of the model were consistent with morphometric data from the literature from which the simplified upper airway model consisting of two connected segments, i.e., the oral airways from the mouth to trachea (Generation G0), was created. The findings of this study provided a better understanding of the interaction between specific active ingredients and DPI devices. These results may be used in designing future generation DPI devices and a better understanding of aerosol transport and deposition efficiency within the human airways.

Três métodos de obtenção de pó de U3O8 de alta densidade foram estudados: trituração de pastilhas sInterizadas de U3O8; sinterização de grânulos de U3O8 calcinado; e sinterização de grânulos de diuranato de amônio (DUA). Testes foram conduzidos variando-se a temperatura e o tempo de calcinação do DUA, bem como o tempo de sinterização, resultando em dez lotes de U3O8. Os processos foram comparados em termos de características dos pós obtidos, rendimento granulométríco e número de etapas. O teor de impurezas, a área de superfície específica, a estequiometria, a morfologia, a densidade, a distribuição de porosidade e a identificação de fases foram considerados como parametros de caracterização dos pós. As principais conclusões mostraram que o segundo método (no qual o DUA foi calcinado a 600°C por 3h) forneceu os melhores resultados. Além disso, o terceiro método também produziu bons resultados, porém com dificuldades de manuseio do DUA. / Three preparation methods of high-density U3O8 powder have been studied: grinding of sintered U3O8 pellets, sintering of calcined U3O8 granules; and sintering of ammonium diuranate (ADU) granules. Experiments have been carried out varying ADU calcination time and temperature as well as sintering time, yielding ten U3O8 batches. Powder characteristics, granulometric yield, and number of process steps have been taken into account for comparison purposes. Impurity content, specific surface area, stoichiometry, morphology, density, porosity distribution and phase identification have been considered as parameters for powder characterization. The main conclusions show that the second method (following a 6000C/3h ADU calcination) gives the best results. Moreover, the third method gives also good results, but there were some difficulties with ADU handling.

Materiais cerâmicos obtidos a partir de pós nanocristalinos permitem a obtenção de excelentes propriedades após sinterização, devido à possibilidade de redução da temperatura final de sinterização com conseqüente refinamento microestrutural e excelente densificação. Nesse contexto, a zircônia tetragonal (ZrO2 (t)) tem um importante papel, pois suas características intrínsecas, tais como a transformação martensítica (ZrO2 (t-m)), permitem o desenvolvimento de excelentes propriedades, destacando-se a elevada tenacidade à fratura e resistência a flexão, tornando-a um material diferenciado visando aplicações nobres onde propriedades mecânicas e confiabilidade sejam pré-requisitos. Visando otimizar estas aplicações, se faz necessário conhecer as correlações entre as propriedades mecânicas e a microestrutura. Sendo assim, é de extrema importância promover a revelação microestrutural desses materiais, de forma padronizada e com representatividade estatística, o que exige cuidados nas técnicas de preparação ceramográfica. Nesse trabalho pretende-se caracterizar microestruturalmente cerâmicas a base de ZrO2(Y2O3) nanométrica, visando estudar os efeitos da temperatura e do tempo de sinterização na cinética de crescimento de grão. Foi definida uma rota de preparação e análise ceramográfica propondo seqüência de lixas e panos de polimento, assim como cargas e tempos em cada etapa. As amostras foram atacadas termicamente e micrografias foram obtidas. As micrografias foram processadas por rotinas de análise digital de imagens, visando definir padronizações para determinação de parâmetros microestruturais de interesse, tais como distribuição de tamanhos de grãos, densidade de grãos por unidade de área, razão de aspecto, etc. Foi estudado o efeito das condições de sinterização (temperatura final e tempo de isoterma) no crescimento de grãos. / Ceramic materials obtained from nanocrystalline powders enable the obtaining of excellent properties after sintering, due to the possibility of reducing the final sintering temperature with consequent microstructural refinement and excellent densification. In this context, tetragonal zirconia (ZrO2 (t)) has an important role, since their intrinsic characteristics, such as the martensitic transformation (ZrO2 (t-m)), allow the development of excellent properties, highlighting the high tenacity to fracture and resistance to bending, making it a differentiated material aiming noble applications where mechanical properties and reliability are prerequirements. In order to optimize these applications, it is necessary to know the correlations between the mechanical properties and microstructure. Thus, it is extremely important to promote the microstructural disclosure of these materials, in a standardized manner and with statistical representativeness, which requires care with the ceramographic preparation techniques. This work aims to microstructurally characterize ceramics based on nanometric ZrO2(Y2O3), looking for the study of the effects of the sintering temperature and time on the graingrowth kinetics. It was defined a route for ceramographic preparation and analysis proposing a sequence of sandpapers and polishing cloths, as well as loads and times at each stage. The samples were thermally etched and micrographs were obtained. The micrographs were processed through routines of digital image analysis, aiming the definition of standards for the determination of microstructural parameters of interest, such as distribution of grain sizes, density of grains per unit of area, aspect ration, and others. It was studied the effects of the sintering conditions (final temperature and time of isotherm) on the grain growth.

Dans les secteurs industriels tels que l’industrie chimique, pharmaceutique ou agro-alimentaire une faible aptitude à l’écoulement des poudres est souvent à l’origine du mauvais fonctionnement d’un procédé. Une mauvaise coulabilité peut ainsi entrainer le blocage de poudres dans un silo, des problématiques de dosages et de remplissage ou encore une détérioration de la qualité du produit final. Pour assurer un bon fonctionnement du procédé, il est donc nécessaire et essentiel d’évaluer la coulabilité de poudres utilisées. Pour cela, plusieurs techniques expérimentales telles que les dispositifs de mesure d’angle, les cellules de cisaillement, les dispositifs de tassement de poudre peuvent être utilisées. Des indices de coulabilité sont alors définis permettant de classer les poudres selon la qualité de l’écoulement. Des essais expérimentaux ont été menés sur plusieurs types de poudres et les premiers résultats ont montré que le passage d’une technique d’évaluation à une autre peut modifier, voire inverser le classement de la coulabilité des poudres. En effet, selon les techniques étudiées les poudres sont soumises à des sollicitations mécaniques différentes et donc le choix de la technique doit être adapté au cas réel d’étude. Dans ce travail, nous nous sommes intéressé plus particulièrement au cas de l’évaluation de l’écoulement de poudres à partir de dispositifs de compaction. Le travail réalisé a montré que les paramètres dynamiques (amplitude et fréquence de chocs) influencent énormément le classement de la coulabilité des poudres. A partir d’une approche énergétique, il a été montré qu’une évaluation et quantification de la coulabilité à partir du rapport d’Hausner ne peut être donnée par une technique de compaction que si celle-ci permet d’atteindre une valeur d’énergie nécessaire à l’obtention d’une compaction maximale des particules. Enfin, une étude de mise en œuvre des techniques d’évaluation de la coulabilité a été réalisée dans le domaine de la formulation en s’intéressant à l’évaluation quantitative de l’influence d’un agent d’écoulement / In industrial sectors, such as chemical, pharmaceutical or food industries, poor flowability of powders is often the causes of process malfunction. Poor flowability can lead to the blocking of powders in a silo, dosing and filling problems, or even bad quality on final product. To ensure proper process operation, it is therefore necessary and essential to evaluate the flowability of powders used. For this purpose, several experimental techniques such as angle of repose devices, shear cells or powder packing devices can be used. Flowability indices can then be defined in order to classify the powders according to the flow quality. Experimental tests have been carried out on several types of powders and the first results have shown that the transition from one technique to another can modify or even reverse the classification of the powder flowability. Indeed, according to the techniques studied, powders are subjected to different mechanical stresses and therefore the choice of the technique must be adapted to the real case of study. In this work, we were particularly interested to the evaluation of powders flowability from compaction devices. The work carried out has shown that the dynamic parameters (amplitude and frequency of taps) greatly influence the classification of powders flowability. From an energy approach, it has been shown that the evaluation of the flowability from Hausner ratio can be given by a compaction technique only if it achieves a value of energy required to obtain a maximal compaction of the particles. Finally, an implementation study of flowability evaluation techniques was carried out in the field of formulation by focusing on the quantitative evaluation of the influence of a glidant

Materiais cerâmicos obtidos a partir de pós nanocristalinos permitem a obtenção de excelentes propriedades após sinterização, devido à possibilidade de redução da temperatura final de sinterização com conseqüente refinamento microestrutural e excelente densificação. Nesse contexto, a zircônia tetragonal (ZrO2 (t)) tem um importante papel, pois suas características intrínsecas, tais como a transformação martensítica (ZrO2 (t-m)), permitem o desenvolvimento de excelentes propriedades, destacando-se a elevada tenacidade à fratura e resistência a flexão, tornando-a um material diferenciado visando aplicações nobres onde propriedades mecânicas e confiabilidade sejam pré-requisitos. Visando otimizar estas aplicações, se faz necessário conhecer as correlações entre as propriedades mecânicas e a microestrutura. Sendo assim, é de extrema importância promover a revelação microestrutural desses materiais, de forma padronizada e com representatividade estatística, o que exige cuidados nas técnicas de preparação ceramográfica. Nesse trabalho pretende-se caracterizar microestruturalmente cerâmicas a base de ZrO2(Y2O3) nanométrica, visando estudar os efeitos da temperatura e do tempo de sinterização na cinética de crescimento de grão. Foi definida uma rota de preparação e análise ceramográfica propondo seqüência de lixas e panos de polimento, assim como cargas e tempos em cada etapa. As amostras foram atacadas termicamente e micrografias foram obtidas. As micrografias foram processadas por rotinas de análise digital de imagens, visando definir padronizações para determinação de parâmetros microestruturais de interesse, tais como distribuição de tamanhos de grãos, densidade de grãos por unidade de área, razão de aspecto, etc. Foi estudado o efeito das condições de sinterização (temperatura final e tempo de isoterma) no crescimento de grãos. / Ceramic materials obtained from nanocrystalline powders enable the obtaining of excellent properties after sintering, due to the possibility of reducing the final sintering temperature with consequent microstructural refinement and excellent densification. In this context, tetragonal zirconia (ZrO2 (t)) has an important role, since their intrinsic characteristics, such as the martensitic transformation (ZrO2 (t-m)), allow the development of excellent properties, highlighting the high tenacity to fracture and resistance to bending, making it a differentiated material aiming noble applications where mechanical properties and reliability are prerequirements. In order to optimize these applications, it is necessary to know the correlations between the mechanical properties and microstructure. Thus, it is extremely important to promote the microstructural disclosure of these materials, in a standardized manner and with statistical representativeness, which requires care with the ceramographic preparation techniques. This work aims to microstructurally characterize ceramics based on nanometric ZrO2(Y2O3), looking for the study of the effects of the sintering temperature and time on the graingrowth kinetics. It was defined a route for ceramographic preparation and analysis proposing a sequence of sandpapers and polishing cloths, as well as loads and times at each stage. The samples were thermally etched and micrographs were obtained. The micrographs were processed through routines of digital image analysis, aiming the definition of standards for the determination of microstructural parameters of interest, such as distribution of grain sizes, density of grains per unit of area, aspect ration, and others. It was studied the effects of the sintering conditions (final temperature and time of isotherm) on the grain growth.

There are today strong incentives for an increased understanding of material properties and manufacturing processes to facilitate the development of new technologies in the pharmaceutical industry. The purpose of this thesis was to suggest methods requiring a low sample amount for characterization of technical properties of powders. Compression analysis was used to evaluate the formulation relevance of some compression equations. Using the mechanics of single granules to estimate powder functionality was part of this work. It was concluded that the formability of granular solids and the plasticity of single granules could be determined with compression analysis by using the Kawakita model for single components and binary mixtures of ductile granules. Further on, the fragmentation propensity of solid particles could be estimated from compression analysis by using the Shapiro equation, enabling indicators of both the fragmentation and the deformation propensity of particles to be derived in one single compression test. The interpretations of the compression parameters were only valid if the influence of particle rearrangement was negligible for the overall compression profile. An index indicating the extent of particle rearrangement was developed and a classification system of powders into groups dependent on the incidence of particle rearrangement was suggested as tools to enable rational interpretations of compression parameters. The application of compression analysis was demonstrated by investigating the relevance of the mechanics of granular solids for their tableting abilities. The plasticity of single gran-ules was suggested to influence both the rate of compactibility and the mode of deformation, and consequently the maximal tablet strength. The degree of granule bed deformation was shown to be a potential in line process indicator to describe the tableting forming ability. This thesis contributes to a scheme, suitable in formulation work and process control, to describe manufacturability of powders for an enhanced tablet formulation technology.

Compaction of polymer powders and polymer-based nanocomposites by uniaxial high-velocity cold compaction (HVC), by high-energy ball milling (HEBM) and using a novel technique, relaxation assists, was investigated with a focus on the process parameters, the compactibility characteristics, surface morphology and friction. The basic phenomena associated with HVC are explained and the general energy principle is introduced to explain the pull-out phenomenon, springback gradient, delay time, relative time of the pressure wave, and stick-slip phenomenon during the compaction process. Experimental results for different compaction profiles, different particle size distributions and different milling system for polymer-based nanocomposite are presented, showing the effect of varying the process parameters on the compacted material; the compactibility in the compacted bed, the uniformity of the compacted surface, the pull-out phenomenon, the springback gradient, the stick-slip phenomenon and the homogeneity of the dispersions of nanoparticles in the polymer powders in the solid state. It was found that the high-velocity compaction process is an interruption process and that the opposite velocity and pressure loss during the compaction process have a major influence on the quality of the compacted material. The relaxation assist device is a novel technique that has been successfully developed to improve the compaction process. The relaxation assists are parts of the piston and they are regarded as projectile supports. They are constructed of the same material as the piston, and the diameters are the same but the lengths are different. The relaxation assist device leads to an improvement in the compaction of powders, polymer powders and polymer-based nanocomposites by giving a more homogeneous opposite velocity and a better locking of the powder bed in the compacted form during the compaction process with less change in dimensions in the case of both homogeneous and heterogeneous materials. If the movement of the particles is restricted the powder bed attains a higher density and the total elastic springback is minimized. In addition, there is a more homogeneous dispersion of nanoparticles in the case of a heterogeneous material. A much better transfer of the pressure through the powder bed and a smaller loss of pressure lead to a more homogenous stick-slip of the particles and a higher sliding coefficient due to the overall friction during the compaction process. / QC 20100630