<p> This project will examine the effect of process parameters on the properties of a semi-crystalline cast film. The objective was to conduct the experiment on a commercial scale extruder. The process parameters studied were the chill roll temperature, annealing roll temperature, film thickness and line speed. The intent of this project was not to develop a deterministic model for the casting process, but only to investigate the effect of process parameters on the properties of cast films manufactured on a commercial extrusion line. </p> <p> The film properties evaluated were the tensile strength at break, Young's modulus, elongation at break, and haze. Only the properties in the machine direction (MD) were evaluated. The experimental data was first analyzed by plotting the average film properties against the average normalized process parameters. A second analysis was done with the experimental data by using multivariate data analysis (MVDA). Two multivariate data analysis (MVDA) projected methods were used, these were the partial projection to latent structure (PLS) by means of partial least squares, and the principal component analysis (PCA). The results from the first and second analysis showed that the changes in process parameters affected the properties of the cast films. It is conjectured that the effect of process parameters on semi-crystalline cast film properties are related to the percentage of crystallinity and crystal size. The manipulation of process parameters would change the percentage of crystallinity and crystal size, which in turn modify the properties of cast film. </p> / Thesis / Master of Engineering (ME)

In this thesis, friction stir channeling (FSC) and its process parameters influence on geometry, surface quality and productivity are explored. The probe of the friction stir processing (FSP) tool used to perform these tests was a modified submerged bobbin tool made of MP 159 Co-Ni alloy. The body was made from H13 tool steel. To find the optimal channel conditions for a targeted range of process parameters, multiple 6061 aluminum samples were prepared with a U shape guide to test the effects of different spindle speeds and feed rates. Using a gantry-type computer numerical control (CNC) friction stir welding (FSW) machine, the aluminum coupons were subjected to calibration experiments, force control tests, and an increased production rate to test these effects. It was found through experimentation that the programmed feed rates, spindle speeds and forces produced by the machine had an impact on the channel geometry. It was determined from the force-controlled setup that 8.46 mm/s at 750 RPM was the best combination of results for the four conditions tested on a CNC friction stir processing-machine. It was then tested at 10.58 mm/s at 800 RPM, which had comparable results with the best combination of input parameters from the force-controlled runs which demonstrates the utility of the process in high production settings. Finally, a proof-of-concept experiment was performed on a robotic arm outfitted with a FSW holder, showing acceptable results. This is a validation of its future implementation in the manufacturing of large parts for lightweight, aerospace, and automotive applications.

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This thesis summarizes the results concerning the manufacture of medical implants for bone replacement using electron beam melting (EBM) which is an additive manufacturing (AM) technology, and aims to satisfy the engineering needs for the medical functionality of manufacturing technology. This thesis has focused on some microscopic properties for surfaces and bone integration. The process parameters of EBM manufacturing were studied to ascertain whether they have impacts on surface appearance, as surface properties have impacts on bone integration and implant performance. EBM manufacturing uses an electron beam to melt metal powder onto each layer in a manner akin to welding. The electron beam is controlled by process parameters that may be altered to a certain extent by the operator. There are individual process parameters for every material, and new parameters are set when developing new materials. In this thesis, process parameters in default settings were altered to ascertain whether it was possible to specify process parameters for implant manufacturing. The blood chamber model was used for thromboinflammation validation, using human whole blood. The model is used to identify early reactions of coagulation and immunoreactions. The material used in this study was Ti6Al4V-ELI, which is corrosion resistant and has the same surface oxide layers as titanium, and CoCr-F75, which has high stiffness, is wear-resistant and is commonly used in articulating joints. The study shows that among the process parameters researched, a combination of speed and current have the most impact on surface roughness and an interaction of parameters were found using design of experiment (DOE). As-built EBM surfaces show thrombogenicity, which in previous studies has been associated with bone ingrowth. Surface structure of as-build EBM manufactured surfaces are similar to implants surfaces described by Pilliar (2005), but with superior material properties than those of implants with sintered metals beads. By altering the process parameters controlling the electron beam, surface roughness of as-build parts may be affected, and the rougher EBM manufactured surfaces tend to be more thrombogen than the finer EBM manufactured surfaces. As-build EBM manufactured surfaces in general show more thrombogenicity than conventional machined implants surfaces. / Denna avhandling behandlar tillverkning av medicinska implantat för integration i ben. I fokus är den additiva tillverkningstekniken ”elektronstrålesmältning” ( Electron Beam Melting –EBM), en av flera tekniker som populärt beskrivs med termen 3D-skrivare. Avhandlingen fokuserar på mikroskopiska ytegenskaper och dess inverkan på benintegration. Processparametrarna för EBM-tillverkning studerades för att fastställa hur de påverkar ytans utseende, efter som ytegenskaper har effekt på implantatens funktion. EBM-tillverkning använder en elektronstråle som likt svetsning smälter ihop metallpulver. Elektronstrålen styrs av processparametrar som till viss mån kan justeras av maskinoperatören. Det finns individuella processparametrar för varje material och nya parametrar utvecklas till varje ny legering. I denna avhandling har ”grundinställningarnas processparametrar” studerats för att ta reda på om det är möjligt att ställa in specifika parametrar till implantattillverkning. Med hjälp av blodkammarmetoden, som använder humant blod, har thromboinflammatoriska egenskaper undersökts. Metoden identifierar tidiga koagulations- och immunologiska reaktioner. Legeringarna som undersökts i denna studie var Ti6Al4V-ELI, som är korrosionsbeständigt med samma uppsättning oxider på ytan som titan har, och CoCr-F75, en legering som har hög styvhet, är slitstarkt och är vanligt förekommande i implantat för leder. Bland de undersökta processparametrarna visar en kombination av hastighet och ström ha mest inverkan på ytjämnhet och en interaktion mellan parametrar identifierades med hjälp av försöksplanering. EBM-tillverkade ytor visade på thrombogena egenskaper som i tidigare studier kan relateras till god integration i benvävnad. Ytstrukturen hos EBM-tillverkade ytor liknar de implantatytor som Pilliar (2005) beskriver, men materialegenskaperna är bättre än de materialegenskaper som implantat, med sintrad yta, har. Genom att ändra processparametrarna som styr elektronstrålen kan ytstrukturen påverkas. Grövre EBM-tillverkade ytor tenderar att vara mer thrombogena än de finare EBM-tillverkade ytorna är. Obehandlade EBM-tillverkade ytor i allmänhet är mer thrombogena än vad konventionellt framställda implantatytor är.

In this work, melt pool size in process mapped in power-velocity space for multiple processes and alloys. In the electron beam wire feed and laser powder feed processes, melt pool dimensions are then related to microstructure in the Ti-6Al-4V alloy. In the electron beam wire feed process, work by previous authors that related prior beta grain size to melt pool area is extended and a control scheme is suggested. In the laser powder feed process, in situ thermal imaging is used to monitor melt pool length. Real time melt pool length measurements are used in feedback control to manipulate the resulting microstructure. In laser and electron beam direct metal additive manufacturing, characteristics of the individual melt pool and the resulting final parts are a product of a variety of process parameters. Laser or electron beam spot size is an important input parameter that can affect the size and shape of a melt pool, and has a direct influence on the formation of lack-of-fusion and keyholing porosity. In this work, models are developed to gain a better understanding of the effects of spot size across different alloys and processes. Models are validated through experiments that also span multiple processes and alloys. Methods to expand the usable processing space are demonstrated in the ProX 200 laser powder bed fusion process. In depth knowledge of process parameters can reduce the occurrence of porosity and flaws throughout processing space and allow for the increased use of non-standard parameter sets. Knowledge of the effects of spot size and other process parameters can enable an operator to expand the usable processing space while avoiding the formation of some types of flaws. Based on simulation and experimental results, regions where potential problems may occur are identified and process parameter based solutions are suggested. Methods to expand the usable processing space are demonstrated in the ProX 200 laser powder bed fusion process. In depth knowledge of process parameters can reduce the occurrence of porosity and flaws throughout processing space and allow for the increased use of non-standard parameter sets.

The plastics industry is one of the fastest growing major industries in the world. There is an increase in the amount of plastic used for all types of products due to its light weight and ability to reprocess. For this reason, the reprocessing of thermoplastics and the usability of reprocessed materials are gaining significance, and it is important to produce and consume plastic materials in an environmentally friendly way. In addition, rising raw material cost linked to the increased oil prices encouraged for reusing of the plastic materials. The aim of this research was to study and optimize the injection moulding process parameters to achieve a trade-off between the product cost and product quality, measured through mechanical properties and geometry, based on using regrind ratios. The work was underpinned by a comprehensive study of multiple reprocessing effects in order to evaluate the effect of process parameters, material behaviour, reprocessing effects and possible links between the processing parameters and key properties. Experimental investigations were carried out, in particular, focused on the melt preparation phase to identify key process parameters and settings. Multiple reprocessing stages were carried out; using two types of PP material: unfilled and short glass filled. A series of tests were used to examine product quality (mass, colour and shrinkage) and physical properties (density, crystallinity, thermal stability, fibre length, molecular weight, in-line and off-line viscosity, tensile strength, modulus of elasticity, elongation (%) and flexural strength). This investigation showed that the mouldability of the filled and unfilled PP materials, through the successive reprocessing stages (using 100 % regrind), was observed to be relatively consistent. Given the link between the processing parameters and key product and material properties, it is possible to manufacture products with minimal loss to part quality and mechanical properties. The final phase of the work focused on process optimisation study for short glass fibre filled PP material and the identified key process parameters (melt temperature, screw rotational speed, holding pressure, holding time and injection rate). A response surface experiment was planned and carried out for three reprocessing stages (0 %, 25 % and 50 % regrind). The fitted response surface models were utilised to carry out the trade-off analysis between the operating cost (material cost, energy cost and labour cost) and product quality (dimensions and tensile strength) Based on the optimal moulding conditions, the operating cost was reduced (from stage I as a reference), by 24% and 30 % for stage II and stage III respectively. A small, perhaps undetectable, change in product dimensions was noted. In addition, a small reduction in tensile strength was noted (from stage I as a reference), by 0.4% and 0.1 % for stage II and stage III respectively. The same data was applied in other countries (Australia, USA, Brazil, Libya and China) to manufacture the same product; and it was observed that the cost was reduced with increasing of regrind ratio. But the significant reduction of the cost, essentially, depended on those countries which have low wage rates (e.g. Brazil, Libya and China). For example, the cost of moulded product manufactured in China is £ 0.025 (using 50% of regrind), while the cost of the same product produced in Australia is £ 0.12, hence giving a total saving of 79 % and making it a valuable issue to be considered in industry.

Este trabalho apresenta o desenvolvimento de compósitos estruturais de politetrafluoretileno (PTFE) com fibras de vidro contínuas e tem como objetivo a obtenção de um compósito com propriedades mecânicas que possibilite o uso em aplicações estruturais e que mantenham as características inerentes do PTFE sem reforços, tais como: baixo coeficiente de atrito, baixa interação química e elevada temperatura de trabalho. O PTFE é um polímero termoplástico, mas sua elevada viscosidade no estado fundido impede a utilização de moldagem por injeção. Componentes fabricados com PTFE são geralmente obtidos por compactação a frio do material granulado seguido de tratamento térmico. Neste estudo foi desenvolvida uma metodologia de fabricação de um laminado de PTFE e fibras contínuas, a partir do empilhamento, prensagem e tratamento térmico, de tecidos de fibra de vidro impregnados com PTFE. Foram estudadas as influências dos parâmetros de fabricação (prensagem e tratamento térmico) e de mecanismos que levam à degradação do laminado durante a fabricação, nas propriedades mecânicas finais dos compósitos. Foi também estudada a adição de uma quantidade complementar de PTFE ao laminado, com o intuito de se averiguar a possibilidade de se obter compósitos com revestimentos mais espessos de PTFE. O laminado foi avaliado por meio de ensaios de flexão 3-pontos e tração, para verificação dos ganhos na rigidez e resistência mecânica frente ao PTFE puro e por um ensaio de adesão fibra-matriz, baseado na norma ASTM D3167-03a. Como resultados, foram encontrados valores expressivos de resistência máxima aproximadamente 165 MPa e rigidez módulo de elasticidade de aproximadamente 14 GPa para valores adequados de processo de fabricação que minimizam efeitos de degradação dos laminados durante a fabricação. O trabalho mostrou a viabilidade de fabricação dos compósitos propostos e indicou uma rota a ser seguida para esta fabricação. / This work presents a study of the manufacturing of Polytetrafluoretylene (PTFE) composite with continuous fibres, which has the purpose of obtaining a composite with mechanical properties equivalent or better than that of engineering polymers, but that preserve the characteristics of PTFE products with no reinforcement (as low friction coefficient, low chemical interaction and high work temperature amplitude). The PTFE is a thermoplastic material, however its high molten viscosity prevents the use of melt injection techniques, and its components are obtained through cold compaction process followed by sintering. In this study it is proposed a methodology of PTFE laminate with continuous fibre manufacturing. The laminate was obtained by the pilling of PTFE-coated glass-fibre fabric in a metallic mold for the pressing and that were sinterised afterwards. The mechanisms that lead to degradation of the laminate and process parameters which influence the final mechanical properties of the product were speciafied. It was also studied the possibility of addition of a larger quantity of PTFE to the laminate in order to verify the possibility of making continuous laminate coating. The material was analysed through three-point bending test and tensile test applied to the manufactured test specimen to verify the gains of mechanical stiffness and strength in comparison to the pure PTFE and an adhesion test based on ASTM D3167-03a. The experimental results showed significant values of mechanical stiffness and strength for appropriate values of process parameters that minimize the effects of degradation of the laminate.

Este trabalho apresenta o desenvolvimento de compósitos estruturais de politetrafluoretileno (PTFE) com fibras de vidro contínuas e tem como objetivo a obtenção de um compósito com propriedades mecânicas que possibilite o uso em aplicações estruturais e que mantenham as características inerentes do PTFE sem reforços, tais como: baixo coeficiente de atrito, baixa interação química e elevada temperatura de trabalho. O PTFE é um polímero termoplástico, mas sua elevada viscosidade no estado fundido impede a utilização de moldagem por injeção. Componentes fabricados com PTFE são geralmente obtidos por compactação a frio do material granulado seguido de tratamento térmico. Neste estudo foi desenvolvida uma metodologia de fabricação de um laminado de PTFE e fibras contínuas, a partir do empilhamento, prensagem e tratamento térmico, de tecidos de fibra de vidro impregnados com PTFE. Foram estudadas as influências dos parâmetros de fabricação (prensagem e tratamento térmico) e de mecanismos que levam à degradação do laminado durante a fabricação, nas propriedades mecânicas finais dos compósitos. Foi também estudada a adição de uma quantidade complementar de PTFE ao laminado, com o intuito de se averiguar a possibilidade de se obter compósitos com revestimentos mais espessos de PTFE. O laminado foi avaliado por meio de ensaios de flexão 3-pontos e tração, para verificação dos ganhos na rigidez e resistência mecânica frente ao PTFE puro e por um ensaio de adesão fibra-matriz, baseado na norma ASTM D3167-03a. Como resultados, foram encontrados valores expressivos de resistência máxima aproximadamente 165 MPa e rigidez módulo de elasticidade de aproximadamente 14 GPa para valores adequados de processo de fabricação que minimizam efeitos de degradação dos laminados durante a fabricação. O trabalho mostrou a viabilidade de fabricação dos compósitos propostos e indicou uma rota a ser seguida para esta fabricação. / This work presents a study of the manufacturing of Polytetrafluoretylene (PTFE) composite with continuous fibres, which has the purpose of obtaining a composite with mechanical properties equivalent or better than that of engineering polymers, but that preserve the characteristics of PTFE products with no reinforcement (as low friction coefficient, low chemical interaction and high work temperature amplitude). The PTFE is a thermoplastic material, however its high molten viscosity prevents the use of melt injection techniques, and its components are obtained through cold compaction process followed by sintering. In this study it is proposed a methodology of PTFE laminate with continuous fibre manufacturing. The laminate was obtained by the pilling of PTFE-coated glass-fibre fabric in a metallic mold for the pressing and that were sinterised afterwards. The mechanisms that lead to degradation of the laminate and process parameters which influence the final mechanical properties of the product were speciafied. It was also studied the possibility of addition of a larger quantity of PTFE to the laminate in order to verify the possibility of making continuous laminate coating. The material was analysed through three-point bending test and tensile test applied to the manufactured test specimen to verify the gains of mechanical stiffness and strength in comparison to the pure PTFE and an adhesion test based on ASTM D3167-03a. The experimental results showed significant values of mechanical stiffness and strength for appropriate values of process parameters that minimize the effects of degradation of the laminate.

Hot tearing is a common and severe defect encountered in alloy castings and perhaps the pivotal issue defining an alloy's castability. Once it occurs, the casting has to be repaired or scraped, resulting in significant loss. Over the years many theories and models have been proposed and accordingly many tests have been developed. Unfortunately many of the tests that have been proposed are qualitative in nature; meanwhile, many of the prediction models are not satisfactory as they lack quantitative information, data and knowledge base. The need exists for a reliable and robust quantitative test to evaluate/characterize hot tearing in cast alloys. This work focused on developing an advanced test method and using it to study hot tearing in cast aluminum alloys. The objectives were to: 1) develop a reliable experimental methodology/setup to quantitatively measure and characterize hot tearing; and 2) quantify the mechanistic contributions of the process variables and investigate their effects on hot tearing tendency. The team at MPI in USA and CANMET-MTL in Canada has collaborated and developed such a testing setup. It consists mainly of a constrained rod mold and the load/displacement and temperature measuring system, which gives quantitative, simultaneous measurements of the real-time contraction force/displacement and temperature during solidification of casting. The data provide information about hot tearing formation and solidification characteristics, from which their quantitative relations are derived. Quantitative information such as tensile coherency, incipient crack refilling, crack initiation and propagation can be obtained. The method proves to be repeatable and reliable and has been used for studying the effects of various parameters (mold temperature, pouring temperature and grain refinement) on hot tearing of different cast aluminum alloys. In scientific sense this method can be used to study and reveal the nature of the hot tearing, for industry practice it provides a tool for production control. Moreover, the quantitative data and fundamental knowledge gained in this thesis can be used for validating and improving the existing hot tearing models.

<div>Fused deposition modeling (FDM) represents one of the most common techniques for rapid proto-typing in additive manufacturing (AM). This work applies image based thermography to monitor the FDM process in-situ. The nozzle temperature, print speed and print orientation were adjusted during the fabrication process of each specimen.</div><div>Experimental and numerical analysis were performed on the fabricated specimens. The combination of the layer wise temperature profile plot and temporal plot provide insights</div><div>for specimens fabricated in x, y and z-axis orientation. For the x-axis orientation build possessing 35 layers, Specimens B16 and B7 printed with nozzle temperature of 225 ➦C and</div><div>235 ➦C respectively, and at printing speed of 60 mm/s and 100 mm/s respectively with the former possessing the highest modulus, yield strength, and ultimate tensile strength. For the y-axis orientation build possessing 59 layers, Specimens B23, B14 and B8 printed with nozzle temperature of 215°C, 225°C and 235°C respectively, and at printing speed of 80 mm/s, 80 mm/s and 60 mm/s respectively with the former possessing the highest modulus and yield strength, while the latter the highest ultimate tensile strength. For the z-axis orientation build possessing 1256 layers, Specimens B6, B24 and B9 printed with nozzle temperature of 235°C, 235°C and 235°C respectively, and at printing speed of 80 mm/s, 80 mm/s and 60 mm/s respectively with the former possessing the highest modulus and ultimate tensile strength, while B24 had the highest yield strength and B9 the lowest modulus, yield strength and ultimate tensile strength. The results show that the prints oriented in the y-axis orientation perform relatively better than prints in the x-axis and z-axis orientation.</div>