This thesis addresses the development, evaluation and modelling of an anti-segregation system ("AS-System") for.use in larger silos handling alumina in the aluminium smelting industry. This work is unlike much of what has gone before because it is much more grounded in the technical and economic consequences of segregation for a particular manufacturing process. Segregation of particulates, i.e. separation of components due to differences in properties such as size, density etc., has an extensive literature going back as far as 1915, but this focuses mainly on the segregation process itself and largely ignores the context and the consequences. The consequence of segregation is loss of homogeneity; the impact that has on any given process, is generally not addressed very deeply. Surveying the literature on segregation, and studying the total processes of aluminium production, creates a basis for understanding the importance of segregation for aluminium production, as well as the importance of powder technology in general for this industry. A method for quantification of segregation in this production process, based on sampling, has been established. This was intended to give the fundamental information necessary for measuring the extent of the problem and the degree of improvement achieved. By placing sampling points along the logistic chain for the alumina, and by sampling these points for a long enough period, information about the influence of the various handling steps on the bulk solids can be identified. Segregation by particle size is the main type of influence, although the work has shown that attrition is another. Standardised statistical expressions have been used for analysing the bottlenecks of the logistic loops, and study of the results has led to a useful way of expressing the level of segregation, the change of segregation level in a handling step (silo filling and discharge), and improvements in this change. The degree of segregation when handling alumina has proven to be quite considerable in terms of effects on the production process. The effects on the efficiency of the aluminium smelting process, and the environment, have both been evaluated. Variations in the alumina due to segregation have been found to correlate with both dust concentration in the smelter pot room, and anode effects (an unwanted upset in the smelting process). An economical evaluation of an investment in anti segregation systems has been made. This evaluation has shown significant economic consequences, clearly justifying both the investigations of segregation, and the implementation of anti segregation measures. To remedy the effects of air current segregation in the aluminium industry, a complete Anti Segregation System (AS-System) based around Anti Segregation Tubes (AST) utilising a special inlet configuration has been developed. In a number of full size installations, this solution has proved itself capable of handling the variations and transients of process conditions which occur in the industry, with a large operational capacity range, due to the special inlet configuration. The effect of the full scale installed anti segregation systems have been measured, and compared to other systems. The AS-System clearly demonstrated a homogenising effect no matter how low the ingoing variations in particle size were. Other commercial systems which have been evaluated have turned out to be no more than Segregation Effect Damping Systems, since they only seem to reduce the segregation effect after it has happened, instead of trying to eliminate the problem by directly attacking the segregation mechanism itself which is what the AS-System does. A new scaled down test rig for the AS-System was developed, consisting of three ASTs fed from a central distributor. To test the potential effect of the AS-System, to determine its efficiency in countering segregation, tests with repeated filling and emptying of a scale silo were carried out. The results clearly showed that the AS-System very much reduced segregation, compared to conventional filling, even in a small-scale silo. Improved models have been developed for the function of the AST and these have been verified against measurements from the new test rig. The early version of the test rig for the AST used only one centre-mounted tube, with one pressure measurement in the top of the tube. The first models were based on the assumption of the pressure being linear, and assumed full dispersion of the falling material inside the tube; and calibrated from the single pressure measurement inside at the top of the tube. Although this simple model calculated very conservative values of the negative pressure, the model was used for the initial development and design of the AST, and later the ASSystem (Anti Segregation System). A second model was derived, where the material velocity was calculated based on free fall. This model was also based on the idea of full dispersion, but was in better agreement with measured values during further tests, which showed a considerable deviation from the original assumption of a linear pressure distribution once intermediate pressure measurements were available. When using the multi-phase-flow-simulation-program-code FLUENT to simulate the pressure distribution of the AST, the results were quite disappointing, however the FLUENT program was able to identify an initial positive pressure generated by the flow from the inlet box to the tube. Implementing this initial pressure into the simple non-linear model above, both the trend and values correspond quite well with the measured values. A single particle drag model was tried, but dismissed after calculating the maximum possible capacity for known tubes and finding the predictions to be unrealistically low. A new approach was introduced, modelling the fall of the powder in a continuous layer along the inner wall of the tube on one side, creating skin drag along the surface between the falling solid powder and the air. The length of the tube and the width of the chosen AST profile define this surface. This approach assumes that the powder falls like a layer along the tube wall. Previous theory for pressure drop in pneumatic conveying inspired this approach, but it had not previously been used for gravity flow in vertical tubes, and as a result the novel Solid Surface Body Drag Model (SSBDM) was developed. This analytical model gives very good correspondence with the measured data for the pressure distribution inside the AST, yet is extremely simple to use. When comparing the model with measured data, the SSBDM was able to predict the pressure distribution within the error boundaries of the test measurements. A method for design of the AST was derived from the SSBDM, using a dimensionless parameter function determined for the pressure drop model. The models giving the design indicate that the capacity is more than proportional to the cross sectional area of a chosen tube profile, which is in agreement with observations. The model suggests that the capacity is proportional to the cross sectional area in the power of 1.25. This model allowed the study of the effect of tube shape, which revealed that a square profile for the AST does not seem to be the optimum design; rather, a rectangular profile should be chosen for maximum capacity. The model suggests that the capacity is proportional to the width of the side of the tube along which the powder layer is falling, but proportional to the perpendicular side in a rectangular profile in the power of 1.5. The model gives an equation for pressure drop which can also be utilised to place the first valve on the tube. It also shows that for high capacities, and large silos, a system consisting of several ASTs should be chosen (AS-System). Predictions from the model have been tested against the measured capacities of full scale installed systems and give good agreement. Overall, the AS-System has been shown to be cost-effective in reducing segregation; results measured from the full scale installations show a homogenising factor (reduction in variation of the material being handled) of 1-1.5. As a result of these verifications and the simplicity of the model presented in this thesis, the plant engineer can confidently design a system which will function correctly and make a positive, predictable improvement in the homogeneity of the alumina in his plant.

Roman military equipment has traditionally been studied from a typological perspective based on a linear concept of change. Whilst Roman alloys have been analysed scientifically and general studies on them have been published, analysis of military equipment has been scarce and mostly secluded as part of excavation reports of individual sites. Scientific analysis though, can provide independent ways of studying military equipment. It can answer questions about production and distribution of the raw materials and finished objects and is capable of informing on reasons for technological choices (the intention of obtaining determinate colours, for example), and identification of military units. A total of 216 copper-alloy military objects from the British sites of South Cadbury Castle, Ham Hill, Usk, Carlisle, Chester and Kingsholm, and the German site of Kalkriese were selected for obtaining metallurgical characterisation: chemical analysis at major, minor and trace element level and microstructural analysis to obtain fabrication history and identifying any plating. The analytical techniques employed were atomic absorption spectrometry (AAS), scanning electron microscopy with energy dispersive x-ray spectrometry (SEM-EDS), optical microscopy and multivariate statistics methods such as principal component analysis (PCA), discriminant analysis (DA) and multivariate analysis of variance (MANOVA). The aim of the project was to characterise the chemical and physical make-up of Roman military copper-alloy metalwork from the 1st century AD, with especial interest in the immediate post-conquest period. The results of the analysis show a difference between the Roman military equipment from British sites and the equipment from Kalkriese, based on trace element patterns. This difference can be explained by a large input of material into Britain that had been made in the years before AD43 in preparation for the conquest. Contrary to recent scholarship, and based on compositional and microstructural evidence, some lorica segmentata brass fittings seem to have been centrally produced. Primary brass and specific gunmetal compositions seem to be associated with the military and probably chosen primarily for their appearance and resemblance to gold, rather than for their mechanical properties. The possibility of mechanised production of brass is explored based on the brass ingot from Sheepen.

The introduction of ceramic matrix composites (CMCs) for structural applications in the hot section of a gas turbine provides many potential benefits over conventional alloy materials, including facilitating elevated operating temperatures. The development of an oxide-oxide CMC composed of commercially available Nextel 720 (3M) fibres within a porous alumina matrix was presented. A simple, low cost processing method involving slurry impregnation and subsequent consolidation and densification was developed, facilitating the production of dried pre-impregnated fabric (‘pre-preg’) that can be stored in ambient conditions. Detailed investigation into the effect of three types of PVA binder, the effect of 0-20wt% additions of an alumina precursor (ACH), the influence of a bimodal particle distribution and the effect of sintering at temperatures between 1100 and 1300°C on processing and mechanical properties was completed in order to optimise the material. The optimised composite material, composed of Nextel 720 fibres within a submicron alumina particle matrix with 10wt% ACH sintered at 1200°C, exhibited mean flexural strength >205MPa, short beam shear strength >12MPa and tensile strength >146MPa. These results were comparable to similar oxide CMCs previously reported, validating this material.

Research has been undertaken to develop new yttria slurry systems for use in mould face coats for investment casting TiAl alloy, solving the pre-gelation problems of commercial yttria slurry systems to increase slurry life. Meanwhile, the new face coats should also have excellent sintering properties, chemical inertness, surface finish and be easy to prepare. The processes of developing the new slurry started with the filler powder investigation by adding different sintering additives into the yttria powder to achieve good sintering properties. Then the best filler powder candidates were selected to make the slurry. Finally, the new face coat slurries were used to make the shell face coat and the chemical inertness of those shells were investigated through the sessile drop and investment casting. In the research, the filler powder and face coat sintering properties were quantified through density, dilatometer testing, X-ray diffraction (XRD) and microstructural change at different testing temperatures. The interaction of different face coat systems and the metal were identified using hardness tests, sessile drop contact angle and the microstructural change at the metal/shell interface. In this research, three water-based binder face coat systems containing YF\(_3\), Y\(_2\)O\(_3\)+0.5wt% Al\(_2\)O\(_3\)+ 0.5 wt% ZrO\(_2\) (YAZ), and B\(_2\)O\(_3\) additives were found to have similar or even better sintering properties compared to a commercial face coat. Meanwhile, they had long life.

Two different Pt-aluminised bond coats, with varying thicknesses and Pt-contents were examined, regarding the in uence of bond coat phases on the oxide growth. This was done in a series of short term (3, 7 and 10 minutes) oxidation experiments at 1100°C. These clearly showed different types of oxide growing on Ni3Al and NiAl phases in the low Pt specimens. It could also be shown that the transition from NiAl to Ni3Al already occurs at these early stages of oxidation. On the high Pt specimens the same types of oxide are growing on Ni3Al and PtAl2. In addition, the high Pt specimens were examined after longer times at temperature (up to 100 hours), to gain information on the bond coat phase transformations happening at high platinum contents. It could be shown that the chromium content plays an important role with regards to phase stability fields in the ternary Ni-Al-Pt diagram. Oxidation kinetics on these samples show that the oxide is not growing at a parabolic rate, but is characterized by a time exponent of 0.145, which may be attributed to a theta to alpha a transformation in the oxide.

Investigations into micro-slot milling of high carbon, high chromium hardened AISI D2 cold work tool steel using 0.5mm diameter coated (TiAlN) tungsten carbide end mills were carried out. Performance was assessed in terms of tool life/tool wear, surface roughness, cutting forces, burr formation, slot geometry accuracy and workpiece surface integrity. The influence of operating parameters (cutting speed, feed rate and depth of cut) on tool life, surface roughness, burr width and cutting forces was evaluated using full factorial experiment design. Analysis of results included main effects plot and calculation of percentage contribution ratios (PCR) for each of the primary variable factors and their interactions were assessed via analysis of variance (ANOVA). The test array was further extended to allow for implementation of Response Surface Methodology (RSM) analysis in order to optimise tool life and surface roughness. Dual-response (cutting speed and feed rate) contours of metal removal rate and tool life/surface roughness were generated from the respective model equations. These were further developed to identify combinations of cutting speed and feed per tooth for the best tool life/surface roughness at specific metal removal rates. Finally, the impact of coatings and tool geometry on tool life and workpiece surface roughness was investigated.

Modern cobalt-chromium (CoCr) alloy compositions, for hip implants, were developed to resist the issues of wear and corrosion; however they still succumb to degradation. While the literature is vast, there is still a lack of understanding of the variability in implant-metal derivatives generated, and the effect such products can have on biological components other than just cells. In this thesis the effect of Co ions on type I collagen (main component of the extracellular matrix) was investigated. The conformation of the triple-helix was maintained, however the time taken for fibril formation to complete increased with Co concentration. In addition, with increasing Co, the collagen matrix became more heterogeneous and cellular attachment and proliferation was reduced. It is likely that Co ions are interacting with a C-O (hydroxyl) group. An overlooked population of degradation products was also investigated. They were found to be highly dependent upon the local environment. Media composition resulted in changes to the morphology, while pH directed the initiation of precipitation. A pH < 5 resulted in no observed pellet. In addition, the presence of Co ions in the media resulted in a change of Cr speciation. Finally, an approach is presented for sub-micron (600nm) x-ray absorption near edge spectroscopy (XANES) mapping of ex vivo tissue. Sub-micron XANES maps contained at least 4 spectra, determined through principal component analysis and clustering. A 5x5 pixel region was averaged for comparison to the 3μm beam approach. Both spectra contained similar features representative of chromium phosphate suggesting that XANES with a micron-sized beam (standard approach) cannot represent the full chemical variability present within the tissue.

The objective of this thesis was to develop a new methodology for the improvement of the interface properties of gold electrodes for neural implants. The goal was to increase the surface area without a change in geometrical footprint of the electrode with nano-fabrication tools. A process has been created that uses Nanosphere Lithography for masking layer deposition and anisotropic etching to fabricate nanostructures on the surface of the electrodes. Optimisation of the process parameters led to a control of structure shape, which allowed to produce a variety of shapes. The effect of the nano-structures on the interface was investigated by impedance spectroscopy and complementary electrochemical measurements. It showed that the interface impedance could be decreased significantly by up to a magnitude of scale with the surface modifications. In addition a porous columnar form of sputtered gold was found that also showed decreased interface impedance compared to standard gold films. A set of neural implants was designed and fabricated to test the effect of surface modification in vitro in neurological tissue. The surface modification process was successfully implemented in the device fabrication. The in-vitro assessment showed signs of improved interface performance compared to unmodified devices.

Maritime transport has profound importance for the world economy. Vessels of all sizes constantly transport large numbers of passengers and goods across the sea, often under adverse operational conditions. Vessels need to exhibit high levels of reliability, availability, maintainability and safety (RAMS). However, at the same time their performance needs to be optimised ensuring the lowest possible fuel consumption with the maximum operational capacity and range without compromising RAMS. Sweating of naval assets and profitability should be maximised for the operator ensuring investment in future projects and supporting the growth of maritime transport and world economy as a whole. Vessels have been traditionally manufactured using naval steel grades such AH, DH and EH. Smaller leisure and specialised purpose vessels such as patrol boats, etc. have been built using fibre-reinforced composite (FRC) materials. This trend is gradually penetrating the market of larger commercial vessels including freight and cruise ships. However, these are still the early days and further investigation of the optimum FRC manufacturing techniques and mechanical properties together with an in-depth understanding of the damage mechanics are required before such materials can become more commonplace. This project has investigated different glass FRCs using different manufacturing techniques. Glass fibres are preferred due to their lower cost in comparison with carbon fibres. The use of carbon FRCs in maritime applications is limited to the fabrication of racing and high performance speedboat vessels. Samples manufactured under laboratory conditions have been compared with those manufactured by a shipyard. It has been seen that the in-house samples had generally superior performance. Steel-to-composite joints have also been assessed including different designs. The effect of different features in the design such as drilled holes and bolts on the mechanical performance of the manufactured samples has also been evaluated. The damage mechanisms involved during damage propagation and features causing damage initiation have been considered. Damage initiation and subsequent evolution have been monitored using acoustic emission (AE). Various signal processing approaches have been employed (manual and automatic) for optimum evaluation of the AE data obtained in a semiquantitative manner. It has been shown that AE could be applied effectively for structural health monitoring of naval structures in the field. Several factors and parameters that need to be considered during acquisition and analysis have been successfully determined. The key results of the study together with mechanical testing and characterisation of samples employed are presented in summarised form within the present thesis.

Total disc arthroplasty (TDA) can be used to replace a degenerated intervertebral disc in the spine. There are different designs of TDAs, but one of the most common is a ball-and-socket combination. Contact between the bearing surfaces of such designs can result in high frictional torque, which can then result in wear and implant loosening. This study was designed to determine the effects of change in design factors, such as dimensions and material combinations, on friction and wear of ball-and-socket TDAs. Friction tests were carried out on generic models with ball radii 10, 12, 14 and 16 mm. Three material combinations were investigated; metal-on-metal, metal-on-polymer and for the first time polymer-on-metal. Wear tests were performed on metal-on-polymer Charité® TDAs and generic metal-on-metal models to compare the wear rate under the same conditions. Friction test results showed that polymer-on-metal TDAs create less friction than metal-on-polymer and metal-on-metal TDAs. Wear test results showed that under the same conditions, metal-on-metal TDAs create 23 times less wear debris than metal-on-polymer. The results were in agreement with studies on total hip arthroplasty (THA). The results of this work suggest possible alternatives for future TDA designs.