The separation of solids from biological wastewater treatment is an important step in the treatment process, as it has a significant impact on effluent water quality. The moving bed biofilm reactor (MBBR) technology is a proven upgrade or replacement wastewater treatment system for carbon and nitrogen removal. However, a challenge of this technology is the characteristics of the effluent solids that results in their poor settlement; with settling being the common method of solids removal. The main objective of this research is to understand and expand the current knowledge on the settling characteristics of MBBR produced solids and the parameters that influence them. In particular, in this dissertation, the impacts are studied of carrier types, biofilm thickness restraint design of carriers, and varying carbonaceous loading rates on MBBR performance, biofilm morphology, biofilm thickness, biofilm mass, biofilm density, biofilm detachment rate, solids production, particle size distribution (PSD) and particle settling velocity distribution (PSVD). With this aim, three MBBR reactors housing three different carrier types were operated with varying loading rates. In order to investigate the effect of carrier geometrical properties on the MBBR system, the conventional, cylindrically-shaped, flat AnoxK™ K5 carrier with protected voids was compared to two newly-designed, saddle-shaped Z-carriers with the fully exposed surface area. Moreover, the AnoxK™ Z-200 carrier was compared to the AnoxK™ Z-400 carrier to evaluate the biofilm thickness restraint design of these carriers, where the Z-200 carrier is designed for greater biofilm thickness-restraint. The Z-200 carrier is designed to limit the biofilm thickness to the level of 200 µm as opposed to 400 µm for the Z-400 carrier. Finally, to investigate the effects of varying carbonaceous loading rates on system removal performance, biofilm characteristics and solids characteristics, further analyses were performed at three different loading rates of 1.5 to 2.5 and 6.0 g-sBOD/m2·d in steady-state conditions. The PSD and the PSVD analyses were combined to relate these two properties. A settling velocity distribution analytical method, the ViCAs, was applied in combination with microscopy imaging and micro-flow imaging to investigate the relation of PSD and settling behaviour of MBBR produced particles. The obtained results have indicated that the carrier type significantly impacted the MBBR performance, biofilm, and particle characteristics. As such, the K5 carrier MBBR system demonstrated a statistically significantly higher carbonaceous removal rate and efficiency (3.8 ± 0.3 g-sBOD/m2·d and 59.9 ± 3.0% sBOD removal), higher biofilm thickness (281.1 ± 8.7 μm), higher biofilm mass per carrier (43.9 ± 1.0 mg), lower biofilm density (65.0 ± 1.5 kg/m3), lower biofilm detachment rate (1.7 ± 0.7 g-TSS/ m2·d) and hence lower solids production (0.7 ± 0.3 g-TSS/d) compared to the two Z-carriers. The Z-carriers' different shape exposes the biofilm to additional shear stress, which could explain why the Z-carriers have thinner and denser biofilm, resulting in higher solids production and lower system performance in comparison with K5. Moreover, the carrier type was also observed to impact the particle characteristics significantly. PSD analysis demonstrated a higher percentage of small particles in the Z-carrier system effluent and hence a significantly lower solids settling efficiency. Therefore, the solids produced in the K5 reactor have shown enhanced settling behaviour, consisting of larger particles with faster settling velocities compared to Z-carriers. This dissertation also investigated the effects of restraint biofilm thickness on MBBR performance by comparing the Z-200 biofilm thickness-restraint carrier to the Z-400 carrier. No significant difference was observed in removal efficiency, biofilm morphology, biofilm density, biofilm detachment rate, and solids production between the Z-200 to the Z-400 carriers. The PSD and the PSVD analyses did not illustrate any significant difference in the particles’ settling behaviour for these two biofilm thickness restraint carriers, indicating that the biofilm thickness-restraint carrier design was not a controlling factor in the settling potential of MBBR produced solids. Finally, this research studied the effect of varying loading rates and demonstrated a positive, strong linear correlation between the measured sBOD loading rate and the removal rate, indicating first-order BOD removal kinetics. The biofilm thickness, biofilm density and biofilm mass decreased when the surface area loading rate (SALR) was increased from 2.5 to 6.0 g-sBOD/m2·d. The solids retention time (SRT) was also shown to decrease by increasing the SALR, where the lowest SRT (1.7 ± 0.1 days) was observed at the highest SALR, with the highest cell viability (81.8 ± 1.7%). Significantly higher biofilm detachment rate and yield were observed at SALR 2.5, with the thickest biofilm and a higher percentage of dead cells. Consequently, a higher fraction of larger and rapidly settling particles was observed at SALR of 2.5 g-sBOD/m2·d, which leads to a significantly better settling behaviour of the MBBR effluent solids. This study expands the current knowledge of MBBR-produced particle characteristics and settling behaviour. A comprehensive understanding of the MBBR system performance and the potential influencing factors on the MBBR produced solids, particle characteristics, and their settleability will lead to optimized MBBR design for future pilot- and full-scale applications of the MBBR.

This thesis focuses on the topic of PBF-LB applied to titanium alloys. Of allalloys, an α + β is chosen, named Ti-6Al-4V. The selection of this particular alloy is driven by its current widespread use in many industrial applications where high strength coupled with low density are both desirable properties. For the last 50 years, parts made with this alloy have been cast or forged and then machined to achieve the final geometry. There is now an opportunity totransform this process chain by additive manufacturing, hence reducing material waste and achieving near net shape from powder feedstock. The process is summarised as follows: a laser selectively melts areas on a build plate where powder is pre-placed. Then a successive powder layer is spread and the process is repeated until completion. Upon removal of the part from the build plate, loose powder in the chamber is collected and recycled whenever possible. The design freedom provided by powder bed fusion methods enables production of intricate geometries and added functionality, despite the need for post-build consolidation and/or microstructural adjustments. Today’s fine and narrow powder cuts (e.g., 15-50μm) are designed to be coupled with low layer thicknesses (i.e., 30μm) to achieve smooth surfaces and high resolutions of small features e.g., internal cooling channels. However, costs associated with production of fine and narrow powder cuts are substantial as refinement of batches requires multiple sieving steps. In addition, resulting building times are considerably long (i.e., days), therefore a beneficial alternative could be that of exploring higher layer thicknesses together with wider and coarser powder cuts. The main idea of this work is to investigate the effects of employing a powder with a wider size distribution 15-90μm. The aim is to reduce the sievingrequired and consequently decrease the costs of developing and building parts made by PBF-LB. An extensive microstructural investigation is conducted on single tracks and cubes built with 27 different process parameter combinations, which also attempts to establish correlations between characteristics of tracks and responses measured in cubes. As a second step, the amount of residual porosity of asbuilt cubes is chosen as the discriminant for further mechanical testing of sub and super-β transus high-pressure heat treated material. / Den här avhandlingen fokuserar på additiv tillverkning av titanlegeringar med laser pulverbädd metoden. Den legering som främst är i fokus är Ti-6Al-4Vsom är en α+β legering. Anledningen till valet av denna titanlegering är att det är den vanligast förekommande titanlegeringen och att den används i ett antal olika industriella tillämpningar där hög styrka i kombination med låg vikt är önskvärda egenskaper. Under de senaste 50 åren har komponenter utav denna legering tillverkats med gjutning eller smide, följt av bearbetning till slutlig geometri. Med hjälp av additiv tillverkning finns nu en möjlighet att förändra tillverkningskedjan i vilket minskat materialspill och en mer nära-slutgeometri kan erhållas direkt genom användning av metallpulver som utgångsmaterial. Processen kan summeras enligt följande: en laser smälter ett förbestämt område på en byggplatta som täckts mer pulver. Därefter adderas ytterligare ett lager med metallpulver ovanpå, på vilket samma process sker igen, och igen osv, tills hela detaljen är färdigtillverkad. När detaljen ska tas loss ifrån byggplattan samlas det kvarvarande icke-smälta pulvret upp och återanvänds i så stor utsträckning som möjligt. Frihetsgraderna vid design i processen möjliggör tillverkning av komplexa geometrier och adderade funktionaliteter, även fast efterbehandling och/eller justeringar av mikrostrukturen kan behövas. Dagens smala pulverstorleksfördelning (tex 15-50μm) är avsedd att ge tunna lagertjocklekar (tex 30μm) för att åstadkomma en fin yta och hög upplösning av små geometrier, såsom exempelvis interna kylkanaler. Men kostnaderna som det innebär att framställa och sortera ut fina och smala kornstorleksfördelningarär avsevärd eftersom det innebär flera steg med silning. Vidare leder de tunnalagertjocklekarna till långa byggtider (typiskt dagar). Ett alternativ, som därför vore fördelaktigt, är att undersöka möjligheten med att bygga tjockare lager med en bredare och större pulverstorleksfördelning. Huvudfokuset i detta arbete fokuserar på att undersöka effekterna av att använda en bredare pulverpartikelstorleksfördelning 15-90μm, med syfte at minska silningsbehovet och därmed reducera kostnaden för att utveckla och tillverka detaljer med laser pulverbädd additiv tillverkning. En omfattande mikrostrukturundersökning har gjorts på enkelsträngar och kuber byggda med 27 olika processparameter-kombinationer, vilket samtidigt försöker identifiera korrelationer mellan enkelsträngarnas karaktäristik med resultaten uppmätta hos kuberna. I ett nästa steg har material, som tillverkats med processparametrar som renderade i minst/mest porer hos kuberna, mekaniskt provats efter att det högtrycksvärmebehandlats över- respektive under β-transus. / <p>Paper A is not included due to the copyright.</p><p>Paper B and C are to be submitted.</p>

The emphasis of this study is focusing on three-dimensional (3D) investigations of the manganese sulfide (MnS) inclusions characteristics in steels by using electrolytic extraction (EE). Two steel grades, 42CrMo4 and 157C, heat treated (HT) at 900 oC were investigated. 42CrMo4 steel samples were heat treated for 5, 10, 15 and 30 minutes while 157C steel samples were heat treated for 5 minutes. Samples of 42CrMo4 were taken from middle zone of an as-cast steel bar while that for grade 157C were taken from 3 different zones (centre, middle and surface). Inclusions were collected on film filters and analyzed by SEM for classification and determination of their characteristics including the size, number density (Nv), morphology and composition. The aspect ratio (AR) as well as particle size distribution (PSD) were also compared for steel samples conducted at various HT times. The result showed that EE is a reliable method of investigation inclusion characteristics. The inclusions were classified into 3 types according to their morphology and composition. Type I was elongated rod-like MnS, type II was coarsened sheet-like MnS and type III was spherical MnS inclusions. In addition, HT significantly reduced the Nv and fairly reduced AR but no significant reduction in size observed. The peak of PSD decreased with an increased HT time. The change of Nv, length, AR and PSD could be altered because of uneven inclusion distribution in filter and different sampling positions.