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High performance cutting tools are essential in many industry areas. Cemented carbides (WC-Co) are common materials used for these applications due to the excellent mechanical properties. The mechanical properties of the material are manly dependent on the WC grain size distribution.To be able to tailor the material properties it is important to be able to characterize and control the WC grain size.In this study a quantitative method for WC grain size distribution measurements has been developed using the automated electron backscatter diffraction (EBSD) technique. The EBSD system was optimized for a fast and accurate measurement. Using the method approximately 2000-3000 WC grains can be measured in approximately 25 minutes. This will give reliable statistics and information about the material.The method was used to compare materials produced with three different milling methods; traditional 30l ball mill, method A and B. Two WC raw materials with different initial particle sizes, one coarser and one finer, was milled aiming for similar grain sizes in the sintered structure. The results showed some tendency for a larger fraction of large grains in the materials produced using the ball mill compared to the materials produced with method A and B. The difference between the milling methods was larger using a raw material with a coarser initial particle size.The developed quantitative method was successfully used to compare grain size distributions of different materials in a fast and quantitative way. The differences between the materials were small and materials with similar grain size distribution and mechanical properties could be produced using both the traditional ball mill method and method A and B.

Amorphous ribbons of alloy composition Fe75B10Si15 are cast by melt spinning and annealed to partially nanocrystalline states. The magnetic properties are investigated by VSM and MTGA. Structure is examined using XRD and SEM. Results obtained show nanostructured material with excellent soft magnetism in samples annealed at temperatures below the crystallization temperature as well as enhancement of magnetic hardness for annealing at high temperatures. This validates Herzer’s Random Anisotropy model of magnetism in nanostructured materials and provides basis for further inquiry into tweaking alloy compositions and/or manipulating annealing parameters. Also, increase of Curie temperature is noted with respect to increasing annealing temperatures arising from stress relaxation, validating a study on the relationship between the two.

In the manufacturing industry, the mechanics of metal-cutting is well-understood and used to improve cutting processes. The mechanics of wood-cutting are still in its early stages and further research is required. Although there is a lack of knowledge regarding cutting mechanics for wood, today's cutting speeds in modern sawmills are as high as 100 m/s and the production rate and quality are high, to the cost of unnecessary wood-based waste. To be able to reduce waste it is necessary to understand the process of wood machining in detail. A Kistler 9129AA dynamometer was commissioned in a custom rotation machine and compared to an already existing sensor. It was shown that there were significant deviations between the measurement results of the evaluated sensor system and the Kistler 9129AA dynamometer. In this specific setup, the Kistler dynamometer was not able to deliver the same results as the existing sensor system. Therefore, the eligibility of the Kistler 9129AA dynamometer to measure cutting forces in wood could not be concluded.

The purpose of this project was to study Svenska Aerogel AB’s product Quartzene®, and develop its capacity as a thermal insulator. Quartzene® is a silica based mesoporous material developed by Svenska Aerogel AB, with properties similar to aerogels produced by the sol-gel process. In this report, the correlation between pore structure and thermal conductivity in the material has been studied using techniques, such as scanning electron microscopy, focused ion beam, finite element simulations and transient plane source. Its properties are interesting because of the expanding market of insulated vacuum panels; in which Svenska Aerogel AB wish to expand to. It was found that the pore sizes of M21-BU increased after compression, and the pore sizes of M4-0-2 decreased. The pore sizes of M21-BU became so large that the Knudsen effect is no longer of interest, and that could explain the different behaviors in thermal conductivity.

Additive manufacturing (AM) of parts using a layer by layer approach has seen a rapid increase in application for production of net shape or near-net shape complex parts, especially in the field of aerospace, automotive, etc. Due to the superiority of manufacturing complex shapes with ease in comparison to the conventional methods, interest in these kinds of processes has increased. Among various methods in AM, laser powder bed fusion (LPBF) is one of the most widely used techniques to produce metallic components. As in all manufacturing processes, residual stress (RS) generation during manufacturing is a relevant issue for the AM process. RS in AM are generated due to a high thermal gradient between subsequent layers. The impact of residual stresses can be significant for the mechanical integrity of the built parts and understanding the generation of RS and the effect of AM process parameters is therefore important for a broader implementation of AM techniques. The work presented in this licentiate thesis aims to investigate the influence of build orientation on the RS distribution in AM parts. For this purpose, L-shaped Inconel 718 parts were printed by LPBF in three different orientations, 0°, 45°, and 90°, respectively. Inconel 718 was selected because it is a superalloy widely used for making gas turbine components. In addition, IN718 has in general good weldability which renders it a good material for additive manufacturing. Residual stress distributions in the parts removed from the build plate were measured using neutron diffraction technique. A simple finite element model was developed to predict the residual stresses and the effect of RS relaxation due to the separation of the parts and build plate. The trend of residual stress distribution predicted was in good agreement with experimental results. In general, compressive RS at the part center and tensile RS near the surface were found. However, while the part printed in 0° orientation had the least amount of RS in all three principal directions of part, the part built in 90° orientation possessed the highest amount of RS in both compression and tension. The study has shown that residual stress distributions in the parts are strongly dependent on the building process. Further, it has shown that the relaxation of RS associated with the removal of the parts from the build plate after printing has a great impact on the final distribution of residual stress in the parts. These results can be used as guidelines for choosing the orientations of the part during printing.

Plasma centrifugal atomization is a method widely used in the production of spherical powders of metals and alloys with relatively low melting points. A novel plasma centrifugal atomization process suitable for high melting point materials (i.e. 3500 ᵒC and above) was developed by Metasphere Technology AB, currently Höganäs Sweden AB. In this process, feedstock material in the form of crushed powder with particle sizes in the range 400-1000 µm is fed into a rotating crucible and subsequently melted by the glow discharge of a plasmatron. Due to high rotational speeds, a melt film forms at the edge of the crucible and breaks into fine droplets that are ejected into the reactor chamber and solidified in a whirl of cold inert gases. Capability of the plasmatron to reach very high temperatures, combined with extremely rapid cooling of the ejected droplets, allow for the fabrication of fine powders of refractory alloys exhibiting metastable phases that cannot be obtained otherwise.  Oil drilling, ore processing and metal shaping applications, among other, require tool materials capable of withstanding harsh working conditions under heavy loads. Owing to their physical, chemical and mechanical properties, tungsten-carbon alloys are among the most suited materials for such applications. Melting followed by rapid solidification of tungsten-carbon mixtures with 3.9 wt.% C results in a biphasic structure composed of WC lamellae inserted in a W2C matrix, known as cast tungsten carbide (CTC). Due to the metastable nature of both phases present, CTC exhibits exceptional mechanical properties. CTC is mainly used as reinforcing dispersed phase in metal matrix composite hardfacing overlays, which are deposited by plasma transferred arc (PTA) welding or laser cladding onto steel tools. High-entropy alloys (HEAs) are defined as multi-component solid solutions with equimolar or near-equimolar concentration of all principal elements. Owing to their outstanding mechanical, corrosion, erosion, oxidation and radiation resistance properties compared to conventional alloys, HEAs are among the most suited materials for aerospace and nuclear applications. Several processing routes have allowed for laboratory-scale production of HEAs. Nevertheless, size and shape of bulk components that can be thus produced are largely limited. In a quest for up-scaling the processing of high-end bulk HEA components, plasma centrifugal atomization of pre-alloyed refractory HEA spherical powders suitable for additive manufacturing was envisaged. In this work, capabilities of the novel plasma centrifugal atomization for processing of refractory alloys into fine spherical powders have been evaluated based on two different material systems, namely CTC and a refractory HEA containing Ti, V, Zr, Nb, Mo, Hf, Ta, W. Challenges of local mechanical characterization of micron-sized powders have been addressed and a robust method for testing of individual particles has been developed. Mechanical properties such as hardness and fracture toughness of plasma atomized CTC powders have been extensively investigated and related to the corresponding thermal stories. Experimental results suggest significant straining of the crystal lattice in the case of as-atomized CTC, possibly due to extremely high cooling rates experienced by the solidifying particles. This has been ruled out the main reason for the outstanding mechanical properties of plasma atomized CTC compared to both spheroidized CTC and conventional cast & crushed CTC. Effective stress relieve was possible upon heat treatment. Plasma atomization of the refractory HEA yielded similar results, where an extremely fine microstructure with no noticeable chemical segregation was obtained. Indentation hardness of this novel microstructure was found to be approximately 25% higher than that of similar alloys reported in literature. HEA powder thus produced was then consolidated into bulk HEAs with very simple geometries, proving that this powder can be further processed into components of more or less complexity for pre-defined applications.

In collaboration with Kongsberg Automotive, the thesis focuses on material selection and redesigning the shift fork for additive manufacturing using topology optimization. The shift fork is a component in the gear shifting mechanism in the automotive industry. The current shift fork at Kongsberg is manufactured from aluminum using die-casting. This design and material do not withstand huge dynamic loads in commercial vehicles. The material to withstand the loading conditions and is widely available across powder manufacturers is selected using the weighted properties method. The topology optimization of the design resulted in a 50 % reduction in mass. The shift fork's two legs undergo uneven load distribution due to eccentricity. The optimized models are simulated using Finite Element Analysis to validate the design. The optimized design is obtained such that the difference in displacement between both legs is within 50 %. Numerous metal powder manufacturers and 3D printing service providers were contacted to understand the current additive manufacturing market.

Demand for high-quality graphite is expected to experience an extraordinary growth rate, in large part due to its wide range of industrial applications such as adsorbents, lubricants, electrodes, etc. This thesis developed a novel sustainable approach to produce green-graphite materials by applying biochar, acarbon-rich valuable by-product obtained from biomass, as a carbon precursor. Meanwhile, iron-based catalysts are applied to enable the graphitization at a relatively lower temperature. This study focuses on the different parameters which could affect the evolution of carbon structure. The samples were mixed with catalyst in two ways, dry mixing and wet impregnation. Aside from the addition method, several parameters including temperature, heating duration, and iron loading amount were varied from 800 to 1300 ℃, 1 to 6 hours, and 0 to 33.6% respectively, to figure out an optimum graphitization process. The samples were characterized by X-ray diffraction, Raman scattering, SEM and particle size distribution analysis. Based on the characterization results, it was confirmed that with the increase of the graphitization temperature, duration and amount of iron loading, synthetic graphite performs a better graphitization and a higher conversion rate. Meanwhile, a detailed dissolution-precipitation mechanism was introduced and discussed in the context of iron-carbon equilibrium phase diagram to explain this catalytic process. / Efterfrågan på högkvalitativ grafit förväntas uppleva en extraordinär tillväxttakt, till stor del på grund av dess breda utbud av industriella applikationer som adsorbenter, smörjmedel, elektroder etc.  Denna avhandling utvecklar ett nytt hållbart tillvägagångssätt för att producera grön-grafit genom att använda biokol, en kolrik värdefull biprodukt erhållen från biomassa, som en kolprekursor. Även järnbaserade katalysatorer används för att möjliggöra grafitisering vid relativt lägre temperaturer. Denna  studie fokuserar på  de olika  parametrar  som  kan  påverka  bildandet  av kolstrukturen. Proverna blandades med katalysatormaterialet på två sätt, torrblandning och våtimpregnering. Förutom tillsatsmetoden justeras flera andra parametrar, inklusive temperatur, uppvärmningstid och mängd järnbelastning för  att  få  en optimal  grafitiseringsprocess.  Proverna karakteriserades därefter genom röntgendiffraktion, Ramanspridning, SEM och  partikelstorleksfördelningsanalys. Baserat på karakteriseringsresultaten bekräftades det att med en ökande grafitiseringstemperatur, varaktighet och mängd av järnbelastning, får syntetisk grafit en bättre grafitisering och en högre omvandlingsgrad. Även en detaljerad upplösnings-utfällningsmekanism introducerades och diskuterades i sammanhanget av järn-kol jämviktsfasdiagrammet  för  att förklara den katalytiska processen.

At every joint there is a redundant set of muscle activated during movement or loading of the system. Optimization techniques are needed to evaluate individual forces in every muscle. The objective in this thesis was to use static optimization techniques to calculate individual muscle forces in the human extremities. A cost function based on a performance criterion of the involved muscular forces was set to be minimized together with constraints on the muscle forces, restraining negative and excessive values. Load-sharing, load capacity and optimal forces of a system can be evaluated, based on a description of the muscle architectural properties, such as moment arm, physiological cross-sectional area, and peak isometric force. The upper and lower extremities were modelled in two separate studies. The upper extremity was modelled as a two link-segment with fixed configurations. Load-sharing properties in a simplified model were analyzed. In a more complex model of the elbow and shoulder joint system of muscular forces, the overall total loading capacity was evaluated. A lower limb model was then used and optimal forces during gait were evaluated. Gait analysis was performed with simultaneous electromyography (EMG). Gait kinematics and kinetics were used in the static optimization to evaluate of optimal individual muscle forces. EMG recordings measure muscle activation. The raw EMG data was processed and a linear envelope of the signal was used to view the activation profile. A method described as the EMG-to-force method which scales and transforms subject specific EMG data is used to compare the evaluated optimal forces. Reasonably good correlation between calculated muscle forces from static optimization and EMG profiles was shown. Also, the possibility to view load-sharing properties of a musculoskeletal system demonstrate a promising complement to traditional motion analysis techniques. However, validation of the accurate muscular forces are needed but not possible. Future work is focused on adding more accurate settings in the muscle architectural properties such as moment arms and physiological cross-sectional areas. Further perspectives with this mathematic modelling technique include analyzing pathological movement, such as cerebral palsy and rheumatoid arthritis where muscular weakness, pain and joint deformities are common. In these, better understanding of muscular action and function are needed for better treatment. / QC 20101116