The constantly tightening emission regulations demand the engines to be moreefficient, to get more power out of smaller engines. Higher engine loads andcomponent temperatures are causing more stresses to engine components. Therefore,a company that produces engines wanted to study if it would be possible to increasethe capabilities of the components by optimising the used material. In this final project work, a cylinder head will be studied. The cylinder heads for theengines are made of ductile cast iron. The limits of that material are near safety limits,and therefore a better material is needed. In this work are some previous studiesanalysed and tried to find how to optimise the used material. The optimised materialshould have better thermal conductivity properties combined with sufficient strengthproperties. Previous studies were analysed to gather knowledge of the elements that affect thematerial parameters. Those studies showed that copper, silicon, pearlite fraction, andthe use of chills are the elements to be optimised. Silicon and pearlite fraction waschosen as optimisation parameters because of their effect on the thermal conductivityand strength properties. Copper was chosen as an optimisation variable due to its effecton the pearlite formation. Chills were used to affect the cooling rate and thereby thepearlite formation. The work was made using MAGMASOFT™ simulation software to simulate cylinderhead casting. The simulated cylinder head was divided into 4 parts for the simulations.For those sections were then set targets for pearlite fraction according to previousstudies. The silicon content was kept constant in the simulation, based on the studiespresented in this work. Copper content was simulated with variations from 0 to 0.7weight-%, and chill heights were simulated from 20 to 60 mm and without chills. After simulating the different variables, the results were analysed. Then the selectedcasting simulation result was mapped to finite element simulation mesh to include thelocal material parameters to finite element simulation. With the finite elementsimulation, the estimated lifetime of the component was simulated. By analysing the casting simulation results, an optimal combination was found. Theoptimal material parameters for a cylinder head casting would be copper 0.5weight-%, silicon 1.9 weight-% and chills thicker than 40 mm on the flame plate. Theoptimised material gives more possibilities to develop engines even further when thecomponent demands are growing.

This thesis is about laser powder bed fusion (L-PBF) of the nickel-based superalloy: Alloy 247LC. Alloy 247LC is used mainly in gas turbine blades and processing the blades with L-PBF confers performance advantage over the blades manufactured with conventional methods. This is mainly because L-PBF is more suitable, than conventional methods, for manufacturing the complex cooling holes in the blades. The research was motivated by the need for academia and industry to gain knowledge about the processability of the alloy using L-PBF. The knowledge is essential in order to eventually solve the problem of cracking which is a major problem when manufacturing the alloy. In addition, dense parts with low void content should be manufactured and the parts should meet the required performance. Thus, the thesis answered some of the important questions related to process parameter-microstructure-defect relationships. The thesis presented an introduction in chapter 1. A literature review was made in chapter 2 to 4. In chapter 2, the topic of additive manufacturing was introduced followed by an overview of laser powder bed fusion. Chapter 3 focused on superalloys. Here, a review was made from the broader perspective of superalloys but was eventually narrowed down to the characteristics of nickelbased superalloys and finally Alloy 247LC. Chapter 4 reviewed the main research on L-PBF of Alloy 247LC. The methodology applied in the thesis was discussed in chapter 5. The thesis applied statistical design of experiments to show the influence of process parameters on the defects and microstructure, so a detail description of the method was warranted. This was given at the beginning of chapter 5 and followed by the description of the L-PBF manufacturing and the characterization methods. The main results and discussions, in chapter 6, included a preliminary investigation on how the process parameters influenced the amount of discontinuity in single track samples. This was followed by the results and discussions on the investigation of voids, cracks and microhardness in cube samples (detail presentation was given in the attached paper B). Finally, the thesis presented results of the microstructure obtainable in L-PBF manufactured Alloy 247LC. The initial results of the microstructure investigation were presented in paper A.

The state-of-the-art tools for machining metals are primarily based on a metal-ceramic composite(WC-Co) coated with different combinations of carbide, nitride and oxide coatings. Combinations of these coating materials are optimized to withstand specific wear conditions. Oxide coatings are especially desired because of their possible high hot hardness, chemical inertness with respect to the workpiece, and their low friction. This thesis deals with process and coating characterization of new oxide coatings deposited by physical vapor deposition (PVD) techniques, focusing on the Cr-Zr-O and Al-Cr-Si-O systems. The thermal stability of α-Cr0.28Zr0.10O0.61 deposited by reactive radio frequency (RF)-magnetron sputtering at 500 °C was investigated after annealing up to 870 °C. The annealed samples showed transformation of α-(Cr,Zr)2O3 and amorphous ZrOx-rich areas into tetragonal ZrO2 and bcc Cr. The instability of the α-(Cr,Zr)2O3 is surprising and possibly related to the annealing being done under vacuum, facilitating the loss of oxygen. The stabilization of the room temperature metastable tetragonal ZrO2 phase, due to surface energy effects, may prove to be useful for metal cutting applications. The observed phase segregation of α-(Cr,Zr)2O3 and formation of tetragonal ZrO2 with corresponding increase in hardness for this pseudo-binary oxide system also opens up design routes for pseudo-binary oxides with tunable microstructural and mechanical properties. The inherent difficulties of depositing insulating oxide films with PVD, demanding a closed circuit, makes the investigation of process stability an important part of this research. In this context, we investigated the influence of adding small amount of Si in Al-Cr cathode on plasma characteristics ,process parameters, and coating properties. Si was chosen here due to a previous study showing improved erosion behavior of Al-Cr-Si over pure Al-Cr cathode without Si incorporation in the coating. This work shows small improvements in cathode erosion and process stability (lower pressure and cathode voltage) when introducing 5 at % Si in the Al70Cr30-cathode. This also led to fewer droplets at low cathode current and intermediate O2 flow. A larger positive effect on cathode erosion was observed with respect to cleaning the cathode from oxide contamination by increasing cathode current with 50%. However, higher cathode current also resulted in increased amount of droplets in the coating which is undesirable. Through plasma analysis the presence of volatile SiO species could be confirmed but the loss of Si through volatile SiO species was negligible, since the coating composition matched the cathode composition. The positive effect of added Si on the process stability at the cathode surface should be weighed against Si incorporation in the coating. This incorporation may or may not be beneficial for the final application since literature states that Si promotes the metastable γ-phase over the thermodynamically stable α-phase of pure Al2O3, contrary to the effect of Cr, which stabilizes the α-phase.

Jag fångades av dekorsnickeriets sinnrika konstruktioner och dess strävan att finna pragmatiska lösningar anpassade till teaterrummets särskilda krav på mångsidighet, flexibilitet och hanterbarhet. I mitt arbete redovisar och resonerar jag kring ett urval av grundläggande teknikeroch metoder. Samt vad som är kännetecknande för arbetet i ateljéverkstaden. Hur detta tillsammans skulle kunna tillämpas inom möbelkonstruktion och utformande av offentliga miljöer. Dessa egenskaper, tekniker och tillvägagångssätt skapar tillsammans med mina egna erfarenheter inom möbelsnickeri ett ramverk kring en undersökande formgivnings och tillverkningsprocess av en möbel. Jag ser detta arbete som en riktning i min utvecklingsprocess som konstruktör och möbelsnickare. Vidare ser jag ett ökat behov av flexibla och slitstarkamöbler för att möta framtida krav på ökad resurshushållning av våra gemensamma tillgångar. / I was caught up in the ingenious constructions of décor carpentry and its efforts to find pragmatic solutions adapted to the theatre room’s particular demands for versatility, flexibility and manageability. In my work, I present and discuss a selection of basic techniques and methods. And what is characteristic of the work in the studio workshop. How this could be applied together in furniture construction and the design of public environments.These characteristics, techniques and approaches, together with my own experience in furniture carpentry, create a framework for an investigative design and manufacturing process of a piece of furniture. I see this work as a direction in my development process as a designer and furniture carpenter. Furthermore, I see an increased need for flexible and durable furniture tomeet future demands for increased resource management of our common assets.

This thesis focuses on the tribological performance of tool surfaces in two steel working operations, namely wire drawing and hot rolling. In all forming operations dimensions and surface finish of the products are of utmost importance. Forming basically includes three parts – forming conditions excluded – that may be changed; work material, tool and (possibly) lubricant. In the interface between work material and tool, the conditions are very aggressive with – generally or locally – high temperatures and pressures. The surfaces will be worn in various ways and this will change the conditions in the process. Consequently, the surface finish as well as the dimensions of the formed product may change and in the end, the product will not fulfil the requirements of the customer. Therefore, research and development in regard to wear, and consequently tribology, of the forming tools is of great interest. The investigations of wire drawing dies focus on coating adhesion/cohesion, surface characteristics and material transfer onto the coated steel both in laboratory scale as well as in the wire drawing process. Results show that it in wire drawing is possible to enhance the tribological performance of drawing dies by using a lubricant together with a steel substrate coated by a polished, dual-layer coating containing both hard and friction-lowering layers. The investigations of hot rolling work rolls focus on microstructure and hardness as well as cracking- and surface characteristics in both laboratory scale and in the hot strip mill. Results show that an ideal hot work roll material should be made up of a matrix with high hardness and a large amount of complex, hard carbides evenly distributed in the microstructure. The surface failure mechanisms of work rolls are very complex involving plastic deformation, abrasive wear, adhesive wear, mechanical and thermal induced cracking, material transfer and oxidation. This knowledge may be used to develop new tools with higher wear resistance giving better performance, lower costs and lower environmental impact.

Yttria stabilized zirconia (YSZ) is the state of the art ceramic top coat material used for TBC applications. The desire to achieve a higher engine efficiency of agas turbine engine by increasing the turbine inlet temperature has pushed YSZ toits upper limit. Above 1200°C, issues such as poor phase stability, high sinteringrates, and susceptibility to CMAS (calcium magnesium alumino silicates) degradation have been reported for YSZ based TBCs. Among the new materials,gadolinium zirconate (GZ) is an interesting alternative since it has shown attractive properties including resistance to CMAS attack. However, GZ has a poor thermo-chemical compatibility with the thermally grown oxide leading to poor thermal cyclic performance of GZ TBCs and that is why a multi-layered coating design seems feasible.This work presents a new approach of depositing GZ/YSZ multi-layered TBCs by the suspension plasma spray (SPS) process. Single layer YSZ TBCs were also deposited by SPS and used as a reference.The primary aim of the work was to compare the thermal conductivity and thermal cyclic life of the two coating designs. Thermal diffusivity of the YSZ single layer and GZ based multi-layered TBCs was measured using laser flash analysis (LFA). Thermal cyclic life of as sprayed coatings was evaluated at 1100°C, 1200°C and 1300°C respectively. It was shown that GZ based multi-layered TBCs had a lower thermal conductivity and higher thermal cyclic life compared to the single layer YSZ at all test temperatures. The second aim was to investigate the isothermal oxidation behaviour and erosion resistance of the two coating designs. The as sprayed TBCs were subjected toisothermal oxidation test at 1150°C. The GZ based multi-layered TBCs showed a lower weight gain than the single layer YSZ TBC. However, in the erosion test,the GZ based TBCs showed lower erosion resistance compared to the YSZ singlelayer TBC. In this work, it was shown that SPS is a promising production technique and that GZ is a promising material for TBCs.

Super duplex stainless steel (SDSS) has found a wide use in demanding applications such as offshore, chemical and petrochemical industries thanks to its excellent combination of mechanical properties and corrosion resistance. Welding of SDSS, however, is associated with the risk of precipitation of secondary phases and formation of excessive amounts of ferrite in the weld metal and heat affected zone. The present study was therefore aimed at gaining knowledge about the effect of multiple welding thermal cycles on the microstructure and possible sensitization to corrosion of welds in SDSS.Controlled and repeatable thermal cycles were produced by robotic welding. Oneto four autogenous TIG-remelting passes were applied on 2507 type SDSS plates using low or high heat inputs with pure argon as shielding gas. Thermal cycles were recorded using several thermocouples attached to the plates. Thermodynamic calculations and temperature field modelling were performed in order to understand the microstructural development and to predict the pitting corrosion resistance. Etching revealed the formation of different zones with characteristic microstructures: the fused weld zone (WZ) and the heat affected zone composed of the fusion boundary zone (FBZ), next to the fusion boundary, and further out Zone 1 (Z1) and Zone 2 (Z2). The WZ had a high content of ferrite and often nitrides which increased with increasing number of passes and decreasing heati nput. Nitrogen content of the WZ decreased from 0.28 wt.% to 0.17 wt.% after four passes of low heat input and to 0.10 wt.% after four passes of high heatinput. The FBZ was reheated to high peak temperatures (near melting point) and contained equiaxed ferrite grains with austenite and nitrides. Zone 1 was free from precipitates and the ferrite content was similar to that of the unaffected base material. Sigma phase precipitated only in zone 2, which was heated to peak temperatures in the range of approximately 828°C to 1028°C. The content of sigma phase increased with the number of passes and increasing heat input.  All locations, except Z1, were susceptible to local corrosion after multiplere heating. Thermodynamic calculations predicted that a post weld heat treatment could restore the corrosion resistance of the FBZ and Z2. However, the pitting resistance of the WZ cannot be improved significantly due to the nitrogen loss. Steady state and linear fitting approaches were therefore employed to predict nitrogen loss in autogenous TIG welding with argon as shielding gas. Two practical formulas were derived giving nitrogen loss as functions of initial nitrogen content and arc energy both predicting a larger loss for higher heat input and higher base material nitrogen content. A practical recommendation based on the present study is that it is beneficial to perform welding with a minimum number of passes even if this results in a higherheat input as multiple reheating strongly promotes formation of deleterious phases.

Heat generated in a machining process is a common and critical obstacle faced in today's machining industries. The heat generated in the cutting zone has a direct negative influence on the tool life which, in turn contributes to increase the manufacturing costs. Especially, in machining of Heat Resistant Super Alloys, HRSA this is a very limiting factor. HRSA are capable of retaining their mechanical strength and hardness at elevated temperatures. This property is advantageous in the application in e.g. aero-engines but also a disadvantage, since it also lowers the machinability significantly. This work is an attempt to improve the heat transfer from the cutting zone, which would lead to an increase in the tool life. To achieve this goal, the cutting tool has been modified to create an improved interface between the coolant and tool in the high-temperature areas. Two generations of inserts have been designed and investigated. Firstly, an insert with surface texture features has been created with the purpose of increasing the available surface area for heat dissipation: First generation, Gen I. Secondly, a GenII was designed as a further improvement of Gen I. Here, several channel features on the rake face were added, reaching out from the contact zone to the near proximity of the cutting edge. This with the purpose of improving access of the coolant closer to the cutting edge. The experiments were conducted in facing operations of Alloy 718 with uncoated round carbide inserts. All experiments were carried out with high-pressure coolant assistance, with a pressure of 16 MPa on the rake face and 8 MPa on the flankface, respectively.The two generations of inserts, Gen I and Gen II, were experimentally evaluated by tool wear analysis in comparison with a regular insert. The results shows that the tool life increased significantly for the Gen I insert, compared to a catastrophic failure of the regular insert at the same conditions. Regarding the Gen II insert,an increase in tool life by approximately 30 to 40 percent compared to Gen I insert was observed.

Hot-pressed aluminium and silicon coated boron steel is used in the car industry where high tensile strength is of great importance, such as in the safety cage of a car where deformation has to be kept to a minimum in case of a collision. After hot-pressing the AlSi-boron steel shows excellent properties with high tensile strength, minimal spring back and also shows good protection against corrosion. A thickness of the AlSi coating of 150 [g/m2] for AlSi coated boron steel is typically used by the car industry today. However the coating thickness would be desirable to be minimized to 80 [g/m2]. Welding of this boron steel with 80 [g/m2]have shown difficulties; and it’s not clear why this occurs. In this report the metallurgical properties of the different coating layers will be investigated, simulations with Thermocalc module Dictra will be used, SEM/EDS will be used to characterize phases in coating layers and correlate to weldability. Resistance spot welding tests will also be performed where the welding parameters of pre-pulse, pulse time, time in between pulses and current will be varied to achieve desirable weld plug diameter without expulsion. Hardness testing in form of micro Vickers will executed. The Materials used will be USIBOR® 1500, AS80 with four different annealing times and one sample of AS150.

When transporting a sea cable, what is commonly called a caterpillar is used, but the most common said is a cable tensioner. These machines can be found in a flurry of different variants, where there are a multitude of competitors, which applies demands to having an extremely distinctive machine. Therefore  from  a  market  analysis  it  have  been  identified  that  a  lack  of  quality  regarding  the machines are a factor. A poor quality shortage that usually occurs in hard weather conditions, but this is something that should not happen as it may lead to machine breakdown. Semcon AB in Karlskrona constructs and then collaborates with Ronneby Svets & Smide, who manufacture cable carousels, armrests and other equipment for the cable industry but not the cable tensioner that are ordered separately by external companies. This is the background to why the project is created because Semcon sees a need to eliminate this bottleneck and also expand their product portfolio for customer recovery. The aim it therefore, together with Semcon, develop a new concept for a completely  new cable tensioner with given preferences, rough drawing and selection of qualitative features for the machine in order to be competitive with its future overall solution for the cable industry.    To find a solution to the described problem, a product development process has been followed to establish  structure.  The  process  include  a  planning,  concept  development,  design  and  detailed development phase. From the first phase, a wide understanding of how the complex machine works and where its deficiencies may be. Even hidden customer needs in form of interviews with cable manufacturers in Karlskrona and with industries that handle sea cable were conducted to get a broader spectrum. The needs are transformed into specifications to generate concepts based on the rankings of the measurably formulated specifications. Followed up by an evaluation where the best concepts were taken to the design phase and detailed development. All design calculations have been made, either by hand or with computer-based programs.   The work has resulted in an innovative concept of a whole cable tensioner with all key components, rough drawing, together with a new thinking solution regarding the contact face between the cable and the machine, developed through experiments and theory studies. As this project is very broad, the overall project has been divided into two master thesis works and all electronics are handles by  an  electrical/automation  company.  Therefore,  for  a  broader  understanding  and  information about functionality, reference is made to the second project “Konceptutveckling kring funktionerna hos en kabeldragare” authored by Anton Hansson.   It is extremely important to mention that the outcome of this project is intended to be a concept for a new innovative cable tensioner. This means that with future work on the concept, which includes  continued  depth  of  calculation  and  further  contact  with  suppliers,  can  provide  an opportunity  to  manufacture  the  generated  concept.  Another  development  area  Semcon  must proceed with is to review the safety routines of the machine. The authors of this report believe that a highly competitive solution has been presented, and that work contributes to a strong foundation for  the  development  of  transporting  sea  cable  technology  in  the  future  with  the  help  of  this innovative concept.