京都大学 / 0048 / 新制・課程博士 / 博士(理学) / 甲第19958号 / 理博第4225号 / 新制||理||1607(附属図書館) / 33054 / 京都大学大学院理学研究科化学専攻 / (主査)教授 杉山 弘, 教授 三木 邦夫, 教授 秋山 芳展 / 学位規則第4条第1項該当 / Doctor of Science / Kyoto University / DGAM

京都大学 / 0048 / 新制・課程博士 / 博士(理学) / 甲第20930号 / 理博第4382号 / 新制||理||1630(附属図書館) / 京都大学大学院理学研究科化学専攻 / (主査)教授 杉山 弘, 教授 三木 邦夫, 教授 秋山 芳展 / 学位規則第4条第1項該当 / Doctor of Science / Kyoto University / DGAM

京都大学 / 新制・課程博士 / 博士(理学) / 甲第24125号 / 理博第4853号 / 新制||理||1694(附属図書館) / 京都大学大学院理学研究科化学専攻 / (主査)准教授 板東 俊和, 教授 深井 周也, 教授 秋山 芳展 / 学位規則第4条第1項該当 / Doctor of Science / Kyoto University / DGAM

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Den additiva tillverkningsindustrin associeras ofta med en hållbar hushållning av resurser. Trots detta har denna industriavfall med stor potential till vidare användning. Detta kandidatexamensarbete undersöker möjligheten att använda Polyamid 12 (PA12) avfall från selektiv lasersintring (SLS) i formen av filament till en annan additiv tillverkningsmetod, friformsframställning. Avfall från olika delar av SLS-processen försågs av life science företaget Cytiva. Olika blandningar av avfallen extruderades till filament. Innan extrudering undersöktes innehåll samt de termiska egenskaperna hos avfallet med hjälp av differentiell skanningskalometri (DSC), termogravimetrisk analys och fourier transform infraröd spektroskopi. Filamenten analyserades med dragprovning, DSC och svepelektronmikroskopi. Rent obearbetat PA12 pulver och ett kommersiellt PA12 filament användes som referenser vid jämförelse. Blandningarna innehållande avfall från SLS-printerns automatiska rengöringsprocess var kontaminerade med glaspartiklar och blev därför spröda och erhöll en skrovlig yta. Dessa filament gick inte att 3D-printa eftersom glaspartiklar ansamlades i munstycket av printern. Flera filament fick en ojäm och liten diameter och kunde därför inte användas i 3D-printern. Ojämn och liten diameter blev resultatet av bekymmer med sensorn som mäter diametern av filamenten. Dessa filament gjordes av granulerade utskrivna prototyper, pulver nära utskrivna delar och silat pulver långt ifrån de utskrivna delarna. Filament gjorda på blandningar innehållande avfall från dammsugaren som används för att rengöra SLS-printern kunde med framgång skrivas ut i 3D-printern. Dessa filament hade en jämn diameter och innehöll inga större kontamineringar. Det är därför genomförbart att tillverka filament av avfall från alla delar av SLS-processen även om inte alla filament kunde 3D-printas. / Additive manufacturing is often associated with sustainable use of resources. However, this industry still has material waste with great potential for further use. This bachelor thesis examines the opportunity of using Polyamide 12 (PA12) waste from Selective laser sintering (SLS) in the form of filaments for another additive manufacturing method, fused filament fabrication. Waste from different parts of the SLS process were provided from the life science company Cytiva. Several blends of the waste were made into filaments. Prior extrusion, the thermal properties and content of the waste were examined with differential scanning calorimetry (DSC), thermogravimetric analysis and fourier transform infrared spectroscopy. The filaments were analyzed by tensile testing, DSC and scanning electron microscopy. Pure virgin powder of PA12 and a commercial PA12 filament were used as a reference for comparison. The blends containing waste from the SLS printer’s automatic blasting was contaminated with glass beads which resulted in brittle filaments with a rough surface. These filaments were not possible to 3D print with due to accumulation of glass beads in the nozzle of the printer. Several filaments got an uneven and small diameter and could therefore not be 3D printed with. The small and uneven diameter was a result of issues with the sensor measuring the diameter. This includes filaments made of granulated printed prototypes, powder close to the printed parts and sieved powder further away from printed parts. The filaments made of blends including waste from the vacuum cleaner used to clean the SLS printer could successfully be used in printing. These filaments had an even diameter and did not contain any larger contaminations. It is therefore possible to make filaments from waste from all parts of the SLS process although not all filaments could be 3D printed.

Novel solutions to offset thermal degradation of polyamide-6 (PA-6) and organoclay (organically modified layered silicates) nanocomposites during melt compounding have been investigated. In this research, a novel chain extender (Joncryl ADR 3400) has been used to improve thermal stability of PA-6 and PA- 6/organoclay nanocomposites during melt compounding. The materials were compounded using a linear twin extruder and various laboratory scale mixers. The effects of organoclay and chain extender were studied using both processing methods. In order to replicate large scale production used in industry, a comprehensive plan of experimental work was carried out under different processing conditions (extrusion temperature and screw speed), organoclay and chain extender loading using a linear twin screw extruder. Rheology, mechanical and thermal properties were analysed and selected samples were also characterised by TEM and FTIR. Process induced degradation of PA-6 during the melt compounding was found to have significant influence on the rheological and mechanical properties. Rheological and mechanical characterisation clearly showed showed that incorporation of the chain extender minimised thermal degradation of PA-6 and nanocomposites during melt processing. Visual analysis of selected nanocomposites using TEM confirmed that chain extender increased the dispersion of nanoclays in the PA- 6 matrix. The crystallinity of the PA-6 was slightly affected by addition of organoclay and chain extender. The samples obtained by linear twin screw extrusion showed higher rheological properties than the samples from laboratory scale mixers suggesting better mixing and less thermal degradation during extrusion. / Republic of Turkey, Ministry of National Education. / The full text was made available at the end of the embargo, 31st Dec 2019.

The use of carbon fibre-reinforced plastic technology is steadily gaining traction in the modern automotive industry as a lightweight alternative to conventional materials. The versatile chemical resistance of polyamide resins combined with the high strength properties of carbon fibre filler content aims to meet this growing need in the industry. By employing a number of accelerated and amplified ageing techniques, this work hopes to assess the resilience of carbon fibre-reinforced polyamide composites in a variety of foreseeable chemical, temperature, moisture, and stress environments. The resins included in this characterization study include polyamide-6 (PA6) and polyamide-6,6 (PA6/6). The carbon fibre-reinforced composite specimens are subject to long term immersion in commercial automotive fluids at room and elevated temperatures. Results show that the mechanical properties of both polyamide resins are sensitive to windshield washer fluid exposure, regardless of temperature. The significant drop in glass transition temperature and greater elongation at break confirmed a plasticization effect. The Young’s modulus and tensile strength experienced a loss of approximately 40% at saturation. Elevated temperatures resulted in increased fluid sorption rates of antifreeze and E-20 gasoline into the PA6 composite specimens. Likewise, a corresponding drop in PA6 composite mechanical properties was noted for the antifreeze and E-20 gasoline at elevated temperatures. The mechanical properties of the PA6/6 composite were largely retained in all tested automotive fluids, except windshield washer fluid, at elevated temperatures. The effect of absorbed fluid on mechanical properties tended to increase with higher fibre loadings for the PA6/6 composite and lower fibre loadings for the PA6 composite. Finally, a single parameter acoustic emission testing technique was employed to assess internal damage of stressed PA6 composite specimens exposed to different temperature and humidity levels. However, there was no discernible correlation between environmental stress conditions and internal damage for short term exposure times. / Thesis / Master of Applied Science (MASc) / The use of carbon fibre-reinforced plastic technology is steadily gaining traction in the modern automotive industry as a lightweight alternative to conventional materials. The versatile chemical resistance of polyamide resins combined with the high strength properties of carbon fibre filler content aims to meet this growing need in the industry. By employing a number of accelerated and amplified ageing techniques, this work assessed the resilience of carbon fibre-reinforced polyamide composites in a variety of foreseeable chemical, temperature, moisture, and stress environments. The composite only showed significant sensitivity to windshield wiper fluid in the tests.

Additive manufacturing methods has been prevailing for several decades and the recent technological advancements brings in the flexibility and consideration for large-scale production in the industries. The components manufactured with these methods have wide variety of applications and therefore, it is crucial to investigate the mechanical performance of the printed parts. There have been many researches done to investigate the mechanical behaviour of polymer material but the studies are limited when it comes to the fatigue performance of the polymer parts printed using multi-jet fusion technology. The aim of the master thesis is to investigate the fatigue behaviour of polyamide12 (PA12) material with the components manufactured using HP’s multi-jet fusion 3D printing machine. Fatigue life is influenced by several factors such as the loading condition, the topology of the specimen, material properties, print quality and the environmental conditions. It is therefore essential to consider all these factors when developing the experiments for fatigue life prediction. The master thesis work can be divided into three sections. The first section focuses on evaluating the mechanical properties of polyamide12. This includes the quasi-static test for determining the tensile properties of specimens with the geometrical influence, the difference in properties in relation to the print directions, the influence of humidity and porosity over the mechanical performance of the material and finally the effect of internal heat generation and the surrounding temperature. The results show that the temperature and the quality of the specimens are the two major factors affecting the mechanical and fatigue performance of PA12. That being said, the next section focuses on setting up the fatigue experiments based on the data obtained from the static tests. When carrying out the experiment, both the test frequency and the surrounding temperature were foundto have a greater impact over the fatigue results. High test frequency showed a dramatic increase in the temperature of the specimen which caused an early failure. Hence, the experiments were developed in such a way that the influence of the thermal fatigue can be ignored by controlling the temperature of the specimen through a compressed air cooling system. The final section presents the findings, the conclusions about the material behaviour and the development of a finite element model to predict the fatigue life of a topology optimised demonstrator part using the data gathered from the experiments. / Additiva tillverkningsmetoder har använts i flera decennier och de senaste tekniska framstegen möjliggör flexibilitet och storskaliga produktionsprocesser. Komponenter tillverkade med dessa metoder har många olika tillämpningar inom industrin och därför är det avgörande att undersöka de tillverkade materialens mekaniska prestanda. Det har gjorts många undersökningar av det mekaniska beteendet hosmaterial som metaller och polymerer, men studierna är begränsade när det gäller utmattnings prestandan hos detaljer som tillverkats med multi-jet fusionsteknik.  Syftet med examensarbetet är att undersöka utmattnings beteendet hos polyamid-12 (PA12) tillverkat med hjälp av HP multi-jet fusion 3D-utskriftsteknik. Utmattnings livslängden påverkas av flera parametrar såsom belastnings tillståndet, provets topologi, materialegenskaper, utskrifts kvalitet och miljöförhållanden. Det är därför viktigt att ta hänsyn till alla dessa faktorer när man utvecklar experimenten för utmattnings karakterisering. Examensarbetet kan delas in i tre avsnitt. Det första avsnittet fokuserar på att utvärdera de mekaniska egenskaperna hos PA12. Detta inkluderar kvasi statisk provning för att bestämma drag egenskaperna hos prover med olika geometrier, skillnaden i egenskaper i förhållande till utskrifts riktningarna, inverkan av fukt och porositet på materialets mekaniska prestanda och slutligen effekten av yttre temperatur. Resultaten visar att temperaturen och kvaliteten på proverna är de faktorer som har störst inverkan på den mekaniska prestandan hos PA12. Med detta som utgångspunkt fokuserar nästa avsnitt på att sätta upp utmattnings experimenten baserat på data som erhållits från de statiska testerna. Under utformningen av experimenten visade sig test frekvensen och den omgivande temperaturen ha en stor inverkan på utmattnings resultaten. Hög test frekvens bidrog till en dramatisk ökning av temperaturen hos provet vilket resulterade i tidigt brott. Experimenten utformades därför på ett sätt så att termisk inverkan kan undvikas, genom att kontrollera provets yttre temperatur med ett trycklufts kylsystem. Det sista avsnittet presenterar resultaten, slutsatser om materialets beteende och utvecklingen av en finita element modell för att förutsäga utmattnings livslängden för en topologioptimerad demonstratören med hjälp av data som samlats in från experimenten.

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