This thesis focuses on the application of nanocrystalline transition metal oxide TiO2, WO3 and NiO thin films in new “green” building technologies. Specifically, their physicochemical properties in photocatalytic, self-cleaning and gas sensing applications are studied. There is an intimate connection between comfort issues, health, with connections to energy efficiency, leading to a need for intelligent building materials and green architecture. The importance of good indoor environment is augmented by the fact that modern man in developed countries spends some 90 % of his time inside buildings and vehicles. Poor air quality may lead to discomfort of the person inhabiting a building and in ultimately cause adverse health effects. Thin films of nanocrystalline TiO2 were prepared using reactive DC magnetron sputtering. Crystalline mesoporous films of WO3 and NiO were prepared using advanced gas deposition technique (AGD). The crystal structure, morphology, optical and chemical properties of the films were characterized by using grazing incidence X-ray diffraction (GIXRD), scanning electron microscopy (SEM), UV/Vis spectroscopy and X-ray photoelectron spectroscopy (XPS), respectively. The photocatalytic properties and adsorption of both organic and inorganic molecules on pure and functionalized films were probed by in situ Fourier transform infrared spectroscopy (FTIR). The gas sensing properties of sensors based on TiO2, WO3 and NiO were investigated by conductivity measurements and noise spectroscopy. It was found for the first time that NiO based thin film sensors can be used to detect H2S and NO2 at low temperatures – down to room temperature. Hybrid WO3 sensors functionalized with multiwalled carbon nanotubes (MWCNTs) were used to detect NO2, CO and NH3 gases. These hybrid gas sensors show improved recovery properties compared to unmodified WO3 sensors. TiO2 based gas sensors were able to detect low concentrations of H2S by noise spectroscopy provided that the sensors were irradiated by UV light. Furthermore we show that sulphur is photo-fixated in crystalline TiO2 films upon simultaneous SO2 gas exposure and UV irradiation. Studies of the kinetics and identity of the photo-fixated sulphur complexes show that these are formed by photo-induced reactions between oxygen and SO2 at oxygen surface vacancy sites in TiO2. The sulphur modified TiO2 films show interesting self-cleaning properties compared to the pure films. / Felaktigt tryckt som Digital Comprehensive Summaries of Uppsala Dissertations from the Faculty of Science and Technology 739

<p> </p><p>In orthopaedic practice, fractures are usually stabilised with metal screws or rods. This is done in order to keep the fracture parts in place during the rather slow healing process. The healing time can potentially be reduced by local- or systemic treatment with different bone promoting drugs. In later years, lithium, otherwise used to treat bipolar disease, has shown promise to be such a drug.</p><p> </p><p>The aim of this master thesis was to find a way to coat metal bone screws with lithium and to characterise the coating. The coating was to be designed in such a way that it could release lithium to the surrounding bone tissue.</p><p> </p><p>Lithium chloride was incorporated into a titanate sol-gel and attached to silicon wafers and stainless steel screws by dip coating. Wafers were used for initial <em>in vitro</em> studies of how lithium changed coating characteristics. This was studied using ellipsometry, AFM and SEM. Lithium is most probably physisorbed and not incorporated into the network building up the sol-gel. Coating structure is changed as more lithium is incorporated. For large amounts of lithium, the nanoparticles normally formed when curing the sol-gel are inhibited. One effect of this is reduced bioactivity, seen as a reduced ability for calcium phosphate crystals to nucleate on the coating when immersed in simulated body fluid.</p><p>Lithium release was investigated using AAS. Lithium is released from the coating, showing a burst effect. By changing the number of coating layers used, the release profile can be partly altered. The coating was also applied to screws, showing good attachment, and the lithium release profile was similar to the one seen from wafers.</p><p>Finally, a screw model was used in rats to assess the effect of local lithium treatment from screws and systemic lithium treatment on fracture healing. In the model, a screw was inserted in tibia, mimicking a fracture. When the bone around the screw was healed, a pullout test was performed, giving information about the strength of the bone surrounding the screw. No significant difference could be found for either local- or systemic lithium treatment compared to control. However, when evaluating the strength of intact bone in a similar way, a positive effect of systemic lithium treatment could be seen. Therefore, it is still likely that lithium has a positive effect on bone and further studies are needed to fully evaluate its role in fracture healing.</p><p> </p> / <p><p>Vid behandling av benbrott stabiliseras vanligtvis frakturen internt med metallskruvar och</p><p>metallstavar. Detta görs för att hålla brottbitarna på plats under den relativt långsamma läkprocessen. Det är möjligt att minska tiden för frakturläkning genom att lokalt eller systemiskt behandla med olika läkemedel som främjar bentillväxt. På senare år har det presenterats bevis för att litium, som annars används som psykofarmaka, fungerar som ett sådant läkemedel.</p><p> </p><p>Syftet med detta examensarbete var att hitta en metod för att fästa litium på benimplantat. Litium skulle fästas på ett sådant sätt att frisläppning till omgivande vävnad blev möjlig.</p><p> </p><p>Litiumklorid inkorporerades i en titanat-solgel och lager av detta lades på kiselytor och rostfria skruvar genom s.k. ”dip-coating”. Kiselytorna användes för initiala <em>in vitro</em>-studier av hur litium ändrade beläggningens egenskaper. Litium sitter antagligen fast på ytan av det tredimensionella nätverk som utgör solgelen, istället för att sitta inbundet i nätverket. Lagerstrukturen ändras ju mer litium som inkorporeras och vid stora mängder skapas inte de nanopartiklar som vanligtvis finns i en solgel-baserad beläggning. En följd av detta är reducerad bioaktivitet för beläggningen, dvs. en minskad förmåga för kalciumfosfatkristaller att bildas på ytan. Litium frisläpps från beläggningen, dock sker denna frisläppning snabbt. Genom att belägga ytan med flera lager av solgel kan frisläppningskinetiken delvis ändras. Solgelen kunde också med god vidhäftning appliceras på skruvar och frisläppningskinetiken från en skruv är liknande den från en kiselyta.</p>Slutligen användes en skruvmodell i råtta för att undersöka vilken effekt lokal respektive systemisk litiumbehandling har på frakturläkning. I modellen efterliknas ett benbrott genom att en skruv sätts in i skenbenet.  När benvävnaden runt skruven har läkt görs ett utdragstest på skruven vilket ger information om benets styrka. Ingen signifikant skillnad i skruvens utdragskraft kunde ses mellan de båda försöksgrupperna och kontrollgruppen. Däremot hade gruppen som fick systemisk litiumbehandling fått starkare ben totalt, vilket indikerar att litium har effekt på <em>intakt</em> ben. På grund av dessa resultat finns det fortfarande skäl att tro att litium har en positiv påverkan på ben, varför dess effekt på frakturläkning bör undersökas ytterligare. </p>

In orthopaedic practice, fractures are usually stabilised with metal screws or rods. This is done in order to keep the fracture parts in place during the rather slow healing process. The healing time can potentially be reduced by local- or systemic treatment with different bone promoting drugs. In later years, lithium, otherwise used to treat bipolar disease, has shown promise to be such a drug.   The aim of this master thesis was to find a way to coat metal bone screws with lithium and to characterise the coating. The coating was to be designed in such a way that it could release lithium to the surrounding bone tissue.   Lithium chloride was incorporated into a titanate sol-gel and attached to silicon wafers and stainless steel screws by dip coating. Wafers were used for initial in vitro studies of how lithium changed coating characteristics. This was studied using ellipsometry, AFM and SEM. Lithium is most probably physisorbed and not incorporated into the network building up the sol-gel. Coating structure is changed as more lithium is incorporated. For large amounts of lithium, the nanoparticles normally formed when curing the sol-gel are inhibited. One effect of this is reduced bioactivity, seen as a reduced ability for calcium phosphate crystals to nucleate on the coating when immersed in simulated body fluid. Lithium release was investigated using AAS. Lithium is released from the coating, showing a burst effect. By changing the number of coating layers used, the release profile can be partly altered. The coating was also applied to screws, showing good attachment, and the lithium release profile was similar to the one seen from wafers. Finally, a screw model was used in rats to assess the effect of local lithium treatment from screws and systemic lithium treatment on fracture healing. In the model, a screw was inserted in tibia, mimicking a fracture. When the bone around the screw was healed, a pullout test was performed, giving information about the strength of the bone surrounding the screw. No significant difference could be found for either local- or systemic lithium treatment compared to control. However, when evaluating the strength of intact bone in a similar way, a positive effect of systemic lithium treatment could be seen. Therefore, it is still likely that lithium has a positive effect on bone and further studies are needed to fully evaluate its role in fracture healing. / Vid behandling av benbrott stabiliseras vanligtvis frakturen internt med metallskruvar och metallstavar. Detta görs för att hålla brottbitarna på plats under den relativt långsamma läkprocessen. Det är möjligt att minska tiden för frakturläkning genom att lokalt eller systemiskt behandla med olika läkemedel som främjar bentillväxt. På senare år har det presenterats bevis för att litium, som annars används som psykofarmaka, fungerar som ett sådant läkemedel.   Syftet med detta examensarbete var att hitta en metod för att fästa litium på benimplantat. Litium skulle fästas på ett sådant sätt att frisläppning till omgivande vävnad blev möjlig.   Litiumklorid inkorporerades i en titanat-solgel och lager av detta lades på kiselytor och rostfria skruvar genom s.k. ”dip-coating”. Kiselytorna användes för initiala in vitro-studier av hur litium ändrade beläggningens egenskaper. Litium sitter antagligen fast på ytan av det tredimensionella nätverk som utgör solgelen, istället för att sitta inbundet i nätverket. Lagerstrukturen ändras ju mer litium som inkorporeras och vid stora mängder skapas inte de nanopartiklar som vanligtvis finns i en solgel-baserad beläggning. En följd av detta är reducerad bioaktivitet för beläggningen, dvs. en minskad förmåga för kalciumfosfatkristaller att bildas på ytan. Litium frisläpps från beläggningen, dock sker denna frisläppning snabbt. Genom att belägga ytan med flera lager av solgel kan frisläppningskinetiken delvis ändras. Solgelen kunde också med god vidhäftning appliceras på skruvar och frisläppningskinetiken från en skruv är liknande den från en kiselyta. Slutligen användes en skruvmodell i råtta för att undersöka vilken effekt lokal respektive systemisk litiumbehandling har på frakturläkning. I modellen efterliknas ett benbrott genom att en skruv sätts in i skenbenet.  När benvävnaden runt skruven har läkt görs ett utdragstest på skruven vilket ger information om benets styrka. Ingen signifikant skillnad i skruvens utdragskraft kunde ses mellan de båda försöksgrupperna och kontrollgruppen. Däremot hade gruppen som fick systemisk litiumbehandling fått starkare ben totalt, vilket indikerar att litium har effekt på intakt ben. På grund av dessa resultat finns det fortfarande skäl att tro att litium har en positiv påverkan på ben, varför dess effekt på frakturläkning bör undersökas ytterligare.

<p>In industrial use of paint systems a swift processing is crucial. Another very important issue is to improve the quality of the final coating. This report investigates the film formation process of powder coatings, specially the spreading of individual powder particles. The obtained results can be used to understand and control the film formation process. In this way the desired levelling can be achieved and thus the desired gloss or other surface characteristics that may be required. This means that the method could be used when evaluating different polymer and additive combinations that could be used to change film formation behaviour or curing time for powder coating systems to suit various substrates. It makes it possible to avoid and minimize different surface defects as orange peel or cratering in the powder coated film.</p><p>We used a reflection optical microscope to better understand the film formation process and especially the spreading of a powder melt on surfaces with various surface energies. The obtained data were: the particle diameter, the area, area ratio and the contact angle of the powder particle as a function of time and temperature. This information can be used to derive the surface tension of any powder melt.</p><p>In this report we evaluate the dependencies of temperature, heat rate and surface energy for powder coatings on different substrates. The method provides information that can be used to optimize the film formation of a specific powder coating/substrate combination. This method can be used to evaluate the powder spreading and levelling on different substrates from a surface tension point of view.</p><p>We found, as expected, that the powder flows out on a hydrophilic surface and is inhibited by a hydrophobic. The increase of the area ratio on a hydrophilic surface was about five times as the initial area coverage and on a hydrophobic surface only two times the initial area coverage. The contact angle between the melted powder particle on the different surface types could be calculated. The melt surface tension could be calculated since three substrates surfaces with various surface energies were used. The melt surface tension was found to be about 18.5 mN/m.</p> / <p>Sammanfattning</p><p>Vid industriell användning av ett färgsystem är det viktigt med en snabb och smidig målningsprocess. En viktig del är att förbättra kvaliteten på den färdiga ytan. Denna rapport undersöker filmbildningsprocessen för pulverfärg, närmare bestämt spridningen av individuella pulverpartiklar. Resultaten från utvärderingen av denna metod kan användas för att bättre förstå och få kontroll över filmbildningsprocessen. Med denna undersökningsmetod kan den önskade utslätningen uppnås och därmed den önskade glansen eller annan yteffekt som kan vara önskvärd.</p><p>Metoden kan användas för att utvärdera olika polymer- och additivkombinationer som kan användas för att ändra filmbildningens uppförande eller bestämma härdningstiden för en pulverfärg att passa ett visst substrat. Metoden gör det möjligt att förhindra och minska olika ytdefekter såsom apelsinskals- eller kratereffekter i pulverfärgens yta.</p><p>Ett optiskt reflectionsmikroskop användes för att bättre kunna förstå filmbildningsprocessen och särskilt spridningen av smält pulver på substrat med olika ytenergier. De mätdata vi fick var partikeldiameter, area, areaförändring och kontaktvinkeln för pulverpartiklar som funktion av tid och temperatur. Ur denna information kunde pulversmältans ytenergier härledas.</p><p>I denna rapport utvärderas pulvrets beroende av temperatur, uppvärmning och ytenergi på olika substrat. Denna metod ger information som kan användas för att optimera filmbildningen av en specifik kombination av pulverfärg och substrat. Denna metod kan också användas för att utvärdera pulverspridning och utjämning av färgfilmen på olika substrat med avseende på ytenergierna.</p><p>Som förväntat flyter pulvret ut på hydrofila ytor och utflytningen ändras på en hydrofob yta. På en hydrofil yta sprider sig partikeln till fem gånger den ursprungliga arean över substratet och motsvarande två gånger för en hydrofob yta. Kontaktvinkeln mellan en smält pulverpartikel på olika sorters substrat från utförda mätningar beräknas utifrån utförda mätningar. Kontaktvinklar mellan pulver och olika substrat kan användas för att beräkna smältans ytspänning. Smältans ytspänning kan beräknas då experiment gjorts på tre sorters ytor med olika kända ytenergier. Smältans ytspänning var 18,5 mN/m.</p><p>Slutsatsen är att det går att observera och utvärdera resultaten av utsmältningsförloppet för pulverfärg med denna metod.</p>

An ionic liquid (IL) is a salt, which usually is in the liquid state at normal temperature and pressure. The properties of ILs can be adjusted for various processes and applications by choosing different combinations of ions. Similar to other salts, ILs contain only ions with positive (cations) and negative (anions) charges in equal proportions. However, to prevent solidification, ions in ionic liquids usually contain bulky organic chemical groups, which, apart from electrostatic interactions, promote other types of interactions between ions, such as: (i) van-der-Waals interactions; (ii) hydrogen bonding; (iii) - stacking, etc., depending on the particular chemical structure of the ions. All these interactions, in combination, may lead to formation of specific microstructures in ILs, which may vary with temperature caused by changing thermal rotational and translational energies of the ions. Ions in these microstructures may have preferential orientations relative to each other, maintain anisotropic properties similar to those in liquid crystals or, in some specific cases, may even separate into microscopically organised liquid phases. Therefore, the dynamics of ILs may also be dependent on their microstructure. In many practical applications ionic liquids are placed on surfaces or in confinements. Solid surfaces introduce extra forces, which may be specific to the charge of the ions or/and to functional groups in the ILs. The geometry and interactions of ions in confinements or/and pores of materials may also disrupt specific bulk microstructures of ILs. Both confinement effects and interactions of ions with surfaces are manifested in the translational dynamics of the ions. One of the most direct and informative methods to study translational dynamics of ILs is pulse-field-gradient nuclear magnetic resonance (PFG-NMR).In this thesis the results of PFG-NMR studies on a few classes of ILs are reported: (i) the historically “standard” (since Walden’s discovery in 1914) ionic liquid, the ethylammonium nitrate (EAN) and (ii) halogen-free orthoborate-based phosphonium, imidazolium and pyrrolidinium ILs with varied structure and lengths of alkyl chains in cations, and varied structures of orthoborate anions. These ILs were studied in bulk at different temperatures, and also in confinements, such as between parallel glass and Teflon plates and in mesoporous Vycor glass. It was found that diffusion coefficients of cations and anions in EAN, phosphonium and pyrrolidinium orthoborate ILs in bulk are different, but according to the standard Stocks-Einstein model, they correspond to diffusion of ions in homogeneous liquids. A change in the chemical structure of one of the ions results in a change in both the diffusion coefficient of the oppositely charged ion and the activation energy of diffusion for both ions in an IL. Similar effects were observed from the chemical shifts and diffusion coefficients measured by NMR for imidazolium orthoborate ILs dissolved in polyethylene glycol solutions, in which imidazolium cations strongly interact with PEG molecules, further affecting the diffusion of orthoborate anions via electrostatic interactions. A liquid-liquid phase separation was suggested for a few phosphonium and pyrrolidinium bis(mandelato)borate ILs, in which a divergence of diffusion coefficients and activation energies of diffusion for cations and anions was detected at temperatures below ca 50 °C. In addition, a free-volume theory was invoked to explain the dependences of density of ILs on the alkyl chain length in cations.It was also found that for a phosphonium bis(salicylato)borate IL confined in 4 nm mesoporous Vycor glass the diffusion coefficients of ions increase by a factor of 35! This phenomenon was explained by the dynamic heterogeneity of this IL in micropores and empty voids of the Vycor glass. For EAN IL in confinements between glass and Teflon plates, the diffusion of ethylammonium cations and nitrate anions is significantly anisotropic, i.e. slower in the direction of the normal to the plates and faster along the plates compared to diffusion of the ions in bulk. A plausible explanation of this PFG NMR data is that EAN forms layers near polar and non-polar solid surfaces. A similar phenomenon, to a lesser extent, was also observed for phosphonium cations of bis(mandelato)borate, bis(salicylato)borate and bis(oxalato)borate confined between glass plates. The results of these studies may have implications in modeling tribological performance, i.e., friction and wear reduction for contact pairs of different materials lubricated by various classes of ionic liquids. / För godkännande; 2016; 20160420 (andfil)

The work presented in this thesis deals with experimental and theoretical studies related to alumina thin films. Alumina, Al2O3, is a polymorphic material utilized in a variety of applications, e.g., in the form of thin films. However, controlling thin film growth of this material, in particular at low substrate temperatures, is not straightforward. The aim of this work is to increase the understanding of the basic mechanisms governing alumina growth and to investigate novel ways of synthesizing alumina coatings. The thesis can be divided into two main parts, where the first part deals with fundamental studies of mechanisms affecting alumina growth and the second part with more application-oriented studies of high power impulse magnetron sputter (HiPIMS) deposition of the material. In the first part, it was shown that the thermodynamically stable α phase, which normally is synthesized at substrate temperatures of around 1000 °C, can be grown using reactive sputtering at a substrate temperature of merely 500 °C by controlling the nucleation surface. This was done by predepositing a Cr2O3 nucleation layer. Moreover, it was found that an additional requirement for the formation of the α phase is that the depositions are carried out at low enough total pressure and high enough oxygen partial pressure. Based on these observations, it was concluded that energetic bombardment, plausibly originating from energetic oxygen, is necessary for the formation of α-alumina (in addition to the effect of the chromia nucleation layer). Moreover, the effects of residual water on the growth of crystalline films were investigated by varying the partial pressure of water in the ultra high vacuum (UHV) chamber. Films deposited onto chromia nucleation layers exhibited a columnar structure and consisted of crystalline α-alumina if deposited under UHV conditions. However, as water to a partial pressure of 1*10-5 Torr was introduced, the columnar α-alumina growth was disrupted. Instead, a microstructure consisting of small, equiaxed grains was formed, and the γ-alumina content was found to increase with increasing film thickness. To gain a better understanding of the atomistic processes occurring on the surface, density functional theory based computational studies of adsorption and diffusion of Al, O, AlO, and O2 on different α-alumina (0001) surfaces were also performed. The results give possible reasons for the difficulties in growing the α phase at low temperatures through the identification of several metastable adsorption sites and also show how adsorbed hydrogen might inhibit further growth of α-alumina crystallites. In addition, it was shown that the Al surface diffusion activation energies are unexpectedly low, suggesting that limited surface diffusivity is not the main obstacle for low-temperature α-alumina growth. Instead, it is suggested to be more important to find ways of reducing the amount of impurities, especially hydrogen, in the process and to facilitate α-alumina nucleation when designing new processes for low-temperature deposition of α-alumina. In the second part of the thesis, reactive HiPIMS deposition of alumina was studied. In HiPIMS, a high-density plasma is created by applying very high power to the sputtering magnetron at a low duty cycle. It was found, both from experiments and modeling, that the use of HiPIMS drastically influences the characteristics of the reactive sputtering process, causing reduced target poisoning and thereby reduced or eliminated hysteresis effects and relatively high deposition rates of stoichiometric alumina films. This is not only of importance for alumina growth, but for reactive sputter deposition in general, where hysteresis effects and loss of deposition rate pose a substantial problem. Moreover, it was found that the energetic and ionized deposition flux in the HiPIMS discharge can be used to lower the deposition temperature of α-alumina. Coatings predominantly consisting of the α phase were grown at temperatures as low as 650 °C directly onto cemented carbide substrates without the use of nucleation layers. Such coatings were also deposited onto cutting inserts and were tested in a steel turning application. The coatings were found to increase the crater wear resistance compared to a benchmark TiAlN coating, and the process consequently shows great potential for further development towards industrial applications.

The aim of this Master’s Degree thesis project is to design and develop point diffraction interferometer plates. In this project the PDI plates are re-designed, changing the design which was used in previous projects in Halmstad University. The transparency of PDI plates can be controlled by coating them with NiCr film. Firstly, four plates with coating of different thickness of NiCr were developed. The relationship between transmittance and the thickness of NiCr was established by testing these plates for transmittance and reflectance with the help of a laser and an optical power meter. The absorption coefficient of clear substrates and reflection of light is also taken into account to achieve the correct results. The parameters like the diameter of semi-transparent area around the pinholes and the size of pinholes is chosen after fully understanding its application. The lay-out and description of design is also included in the report.

Volvo Powertrain, VPT, i Köping tillverkar idag växellådor för tunga fordon. Till medeltunga fordon köper Volvo växellådor från bland annat underleverantören ZF. Volvo vill undersöka scenariot att ta fram AMT - växellådor för medeltunga fordon. I-shift modellen AT2412, som är dimensionerad för en max belastning på 2400 Nm och anpassad för tunga lastbilar, skulle kunna fungera även i medeltunga fordon men är då överdimensionerad och onödigt tung. Med tanke på kommande utvecklingsprojekt behöver Volvo öka sin kunskap hur val av tillverkningsmetoder påverkar vikt och tillverkningskostnader. Det behövs för att öka förståelsen för hur olika prioriteringar ska göras med avseende på vikt och tillverkningskostnader. Examensarbetets syfte var att ge denna förståelse för hur olika tillverkningsprocesser påverkar en transmissions utformning med avseende på mått och vikt utifrån ett givet momentområde. Målet med examensarbetet var att påvisa samband mellan valet av tillverkningsmetoder för enskilda artiklar och hur mycket det kan påverka den kompletta transmissionens vikt samt tillverkningskostnad. Arbetet var avgränsat till att analysera modifierade kugghjul i baslådan. Första delen av arbetet bestod av att dimensionera nya kugghjul anpassade för max belastning på 1600 Nm, detta utifrån samma produktionsupplägg som för befintliga kugghjul som återfinns i bland annat AT2412. Den andra delen bestod av att ta fram faktorer för hur olika tillverkningsmetoder påverkar dimensioneringen och för varje enskilt kugghjul beräkna vikt och tillverkningskostnad då åtta kombinationer av tillverkningsmetoder används. Avslutningsvis gjordes en summering för att visa vilka varianter som ger en optimal växellåda utifrån minimal vikt respektive minimal tillverkningskostnad. Resultatet visar att valet av tillverkningsmetoder leder till att vikten på kugghjulen kan reduceras mer eller mindre. Generellt visar beräkningarna att kugghjul som slipas, kulpenas och manganfosfateras får lägst vikt och blir dyrast att producera. Lägsta tillverkningskostnad uppnås genom att vissa tillverkningsprocesser som kulpening och manganfosfatering utesluts men detta måste då kompenseras med ökad kuggbredd vilket leder till högre vikt. Om VPT väljer att ta fram en ny variant av I-shift där kugghjulen är dimensionerade för 1600Nm så kan växellådan göras 6-11 kg lättare och tillverkningskostnaderna för kugghjulen kan minska med ca 10 procent. / Volvo Powertrain, VPT, in Köping currently manufactures transmissions for heavy-duty vehicles. For medium-duty vehicles Volvo purchase transmissions from their parts supplier ZF. Volvo wants to investigate the scenario to develop AMT - gearboxes for medium-duty vehicles. The I-shift model AT2412, which is designed for a maximum load of 2400 Nm and adapted for heavy-duty vehicles, would be able to function even in the medium-duty vehicles, but would be oversized and excessively heavy. In view of future development Volvo need to increase their knowledge in how the choices of manufacturing methods affect the mass and the manufacturing costs. They need to increase the understanding to make the optimal priorities with respect to mass and manufacturing costs. This study aimed to provide this understanding of how different processes affect a transmission design with respect to mass and measures from a given torque range. The aim of the study was to demonstrate the influence of the choice of production methods for individual items and how much it can affect the complete transmission's mass and manufacturing cost. The work was limited to analyzing the modified gears in the base unit. The first part of the work consisted of designing new gears designed for a maximum load of 1600 Nm, based on the same list of operations as the existing gears, which are found in AT2412. The second part consisted of revealing the factors for the different processes affecting the design regarding to fatigue and structural strength. For eight combinations of manufacturing processes the mass and manufacturing cost was calculated for each gear. Finally, a summary was made to show which combination of manufacturing methods that would give the optimum transmission based on minimum mass and minimum manufacturing cost. The results show that the choice of production methods leads to more or less reduction of mass of the gears. Generally, the calculations show that the gear that is ground, shootpeened and manganese phosphated get the lowest mass and become the most expensive to produce. On the other hand, lower manufacturing cost can be achieved by excluding certain manufacturing operations as shootpeening and manganese phosphate, but this must be compensated by increased facewidth of the gear, leading to increased mass. If VPT decide to develop a new variant of the I-shift in which the gears are designed for 1600Nm then the gearbox can be 6-11 kg lighter and the manufacturing costs of the gears can be reduced by about 10 percent.