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Failure mechanisms in APS and SPS thermal barrier coatings during cyclic oxidation and hot corrosionJonnalagadda, Krisha Praveen January 2017 (has links)
Thermal Barrier Coatings (TBCs) are advanced material systems that are being used in the hot sections of gas turbines such as combustor, turbine blades, and vanes. The top ceramic coating in TBCs provides insulation against the hot gases and the intermediate metallic bond coat provides oxidation and corrosion resistance to the underlying turbine components. Durability of thermal barrier coatings is very important for the overall performance of the gas turbine. TBCs can fail in several different ways and there is a combination of more than one failure mechanism in most situations. One of the most widely used TBC is atmospheric plasma sprayed (APS) yttria stabilized zirconia (YSZ). Both the deposition technique and the TBC material have certain limitations. The main aim of this research is to study new TBC materials and/or new deposition techniques and compare with the conventional YSZ and understand their failure mechanisms during cyclic oxidation and hot corrosion. Thermal cyclic oxidation of a newly developed high purity nano YSZ thermal barrier coating has been studied. Cross sectional analysis of exposed as well as completely failed samples showed a mixed-type failure caused by crack propagation parallel to the bond coat/top coat interface. The majority of the damage occurred towards the end of the coating life. A finite element model has been developed to study the probability of crack growth along different paths that leads to the final failure. Hot corrosion mechanism in suspension plasma sprayed two-layer gadolinium zirconate/YSZ, three-layer dense gadolinium zirconate/gadolinium zirconate/YSZ, and a single-layer YSZ has been studied in the presence of sodium sulfate and vanadium pentoxide. The test results showed that gadolinium zirconate coatings were more susceptible to corrosion compared to YSZ coatings despite gadolinium zirconate coatings having lower reactivity with the corrosive salts. Thermal cycling behavior of a high chromium bond coat has been studied. Cross-sectional analysis showed formation of sandwich type microstructure with chromium rich oxide and alumina as the top and the bottom layers. Inter-diffusion of minor elements between different MCrAlY coatings – substrate systems has been studied using, diffusion simulation software, DICTRA. The simulation results showed that the diffusion of minor elements in the coatings is dependent on the rate of β phase depletion in the beginning. After the depletion of β phase there was no clear dependence of the coating composition on the diffusion of minor elements.
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Phased Array Ultrasonic Testing of Austenitic Stainless Steel Welds of the 11 T HL-LHC Dipole MagnetsLorentzon, Marcus January 2018 (has links)
A routine non-destructive test method based on Phased Array Ultrasonic Testing (PAUT) has been developed and applied for the inspection of the first 11 T dipole prototype magnet half shell welds, and the test results are compared with the radiography and visual inspection results of the same welds. A manual scanner and alignment system have been developed and built to facilitate the inspection of the 5.5 m long welds, and to assure reproducibility of the PAUT results. Through the comparison of distance readings and signal amplitude for different focus lengths, a focal law with focus at 25 mm sound path has been selected for the routine inspection of the 15 mm thick austenitic stainless steel 11 T dipole welds. The defocusing properties (beam spread) due to the cylindrical geometry of the half shells and the sound path distance to the area of interest were taken into account. Dedicated sensitivity calibration weld samples with artificial defects (side-drilled-holes) have been designed and produced from 11 T dipole prototype austenitic stainless steel half shell welds. These provide representative calibration for the strongly attenuating and scattering austenitic stainless steel weld material. One scan with two phased array probes aligned parallel to the weld in 2 mm distance from the weld cap edge, and one scan with the probes aligned parallel to the weld in 12 mm distance from the weld cap edge are sufficient to show if the inspected welds fulfil the requirements of weld quality level B according to ISO 5817. The standard test duration for the two scans of the two 5.5 m long horizontal welds of the 11 T dipole magnets is about one day, provided that no defects are found that need to be characterized in more detail.
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Sinnenas Rum - Ytor för bastumiljö / The room of senses – Surfaces for the sauna enviromentbergman, martin January 2010 (has links)
I denna rapport kan läsaren följa händelseförloppet med framtagningen av en fysisk mood-board med tillhörande grafisk manual. Läsaren kommer att få en allmän förståelse för hur det semantiska hos en produkt påverkar dess användare samt hur detta påverkar produktens resultat på marknaden. I projektet pressenteras en tämligen oanvänd metod som, kortfattat; syftar till att ta vara på en målgrupps specifika känslor om exempelvis en produkt för att göra denna mer optimerad. I detta projekt handlade det mer om att ta fram specifika strukturer vilka tillslut kom att leda till ett antal speciellt utvalda ytor och material åt företaget Tylö® AB. Materialet tillsammans med speciella ytor skall komma att skapa en mer elegant känsla i deras kommande sortiment. Metoden som används för att nå fram till resultatet heter Kansei Engineering. / This report handles the development of a graphic manual and a physical mood-board with specific number of surfaces for the sauna manufacturing company Tylö® AB in Halmstad. The reader will have a general understanding of how the semantic of a product affects its users, and how this affects the product's performance on the market. The project is based on a fairly unused method, which basically is used for; seize a target group specific feeling about a specific product to make it more optimized. In this project, it was more about the development of specific structures on surfaces, which eventually came to lead to a number of specially selected materials and surfaces for the company Tylö ® AB. The materials, together with special surfaces, probably come to create a more elegant feeling in their upcoming concepts. The method that was used to achieve the target is called Kansei Engineering.
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Laser cutting and piercing: Experimental and theoretical investigationPocorni, Jetro January 2017 (has links)
This thesis concerns experimental investigations of laser cutting and piercing, with theoretical and practical discussions of the results. The thesis is made up of an introduction to laser cutting and six scientific Papers. These Papers are linked in such a way that each of them studies a different aspect of laser cutting: process efficiency in Paper I, morphology and melt flow on the laser cut front in Papers II, III and IV and laser piercing in Papers V and VI. Paper I investigates the effect of material type, material thickness, laser wavelength, and laser power on the efficiency of the cutting process for industrial state-of-the-art CO2 and fibre laser cutting machines. Here the cutting efficiency is defined in its most fundamental terms: as the area of cut edge created per Joule of laser energy. In Paper II a new experimental technique is presented which has been developed to enable high speed imaging of laser cut fronts produced using standard, commercial parameters. The results presented here suggest that the cut front produced when cutting 10 mm thick medium section stainless steel with a fibre laser and a nitrogen assist gas is covered in humps which themselves are covered in a thin layer of liquid. Paper III presents numerical simulations of the melt flow on a fibre laser ablation-driven processing front during remote fusion cutting, RFC. The simulations were validated with high speed imaging observations of the processing front. The simulation results provide explanations of the main liquid transport mechanisms on the processing front, based on information on the temperature, velocity and pressure fields involved. The results are of fundamental relevance for any process governed by a laser ablation induced front. In Paper IV cutting fronts created by CO2 and fibre lasers in stainless steel at thicknesses between 2 mm and 10 mm have been ‘frozen’ and their geometry has been measured. The resulting three-dimensional shapes have been curve fitted as ninth order polynomials. Various features of the cutting front geometry are discussed, including the lack of correlation of the cut front inclination with either the relevant Brewster angle or the inclination of the striations on the cut edge. In this paper, mathematical descriptions of the cutting fronts are obtained, which can be used as input parameters by any researcher in the field of laser cutting simulations. Paper V investigates the subject of laser piercing. Before any cut is started the laser needs to pierce the material. In this paper the laser piercing process is investigated using a wide range of laser pulse parameters, for stainless steel using a fibre laser. The results reveal the influence of pulse parameters on pierce time and pierced hole diameter. A high speed imaging camera was used to time the penetration event and to study the laser-material interactions involved in drilling the pierced holes. In Paper VI a ‘dynamic’ or ‘moving beam’, laser piercing technique is introduced for processing 15 mm thick stainless steel. One important aspect of laser piercing is the reliability of the process because industrial laser cutting machines are programmed for the minimum reliable pierce time. In this work a comparison was made between a stationary laser and a laser which moves along a circular trajectory with varying processing speeds. High speed imaging was employed during the piercing process to understand melt behavior inside the pierce hole. Throughout this work experimental techniques, including advanced high speed imaging, have been used in conjunction with simulations and theoretical analysis, to provide new knowledge for understanding and improving laser beam cutting and its associated piercing process.
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Förbättrad korrosionmetod för Höganäs AB lödningslegeringarR Lacno, Jeronimo January 2017 (has links)
Denna rapport sammanfattar och jämför två olika korrosionmetoder, Höganäs interna korrosionstest och korrosions test enligt VDA 230-214. Målet har varit att med dessa två tester som bakgrund, ta fram en ny metod som löser Höganäs problem med upprepbarhet. Genom att med noggrant utförande gått igenom processen för hårdlödning, beredning av syror, korrosionsprovning under 4 veckor och processen för undersökning av mikrostrukturen på lödningsfogen, så har man lyckats få ut ett kvantitativt resultat. Förbättringen av den interna korrosionsmetoden valdes att basera sig enbart på svavelsyran och samtidigt istället att bereda syralösningar genom att styra pH värdet mellan ett aggresivt och ett mindre aggresivt värde. Man valde också att jämföra två produkter som ska hålla samma korrosionsegenskaper, Brazelet F300 och Brazelet Ni613. Produkten F300 är utvecklade av Höganäs AB och skillnaden gentemot den licensierade produkten Ni613 är att F300 innehåller järn och mindre nickel. Tidigare utredningar har gjorts för att jämföra dessa produkterna men har visat olika resultat. Denna utredning har lett till en metod för att kvantifiera korrosionsmotståndet hos de olika loden istället för att bara visuellt bedöma om korrosionsmotståndet är bra eller dåligt. Denna metoden har även lett till framtida arbeten för utvärdering av andra syror. / This report summarizes and compares two different corrosion methods, Höganäs internal corrosion test and a corrosion test according to VDA 230-214. The goal has been to develop a new method that solves Höganäs problems with repeatability with these two tests as a background. By carefully studying the process of brazing, acid preparation, corrosion testing for 4 weeks and the microstructure testing process on the brazed joint, you have managed to get a quantitative result. The improvement of the internal corrosion method was chosen to be based on the sulfuric acid and preparing acid solutions by controlling the pH value between an aggressive and a less aggressive value. It was also chosen to compare two products that has the same corrosion properties, Brazelet F300 and Brazelet Ni613. The difference between F300 and Ni613 is that the F300 contains iron and less nickel. Previous investigations have been made to compare these products but have shown different results. This investigation has led to a method of quantifying the corrosion resistance of the different brazing instead of only visually judging whether the corrosion resistance is good or bad. This method will be used for future work to investigate other acids.
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Design and manufacturing of SLM printed tooling for plastic injection moldingTing, Huang, Daniel, Nordqvist January 2021 (has links)
The thesis work is to show that the use of SLM (Additive Manufacturing) compared with the traditional process to make injection molds will have advantages in design, especially in waterways. This thesis work gives seven different versions of design applied to the SLM method to analyze and compare them in Solidworks® and Moldflow® to figure out what design is suitable for the SLM method. Through analysis of different versions, the finding of this thesis work is that the conformal waterway of design and lighter but stead structure in the SLM method causes the SLM molds' cooling performance to be almost 15% better than the conventional way and shorten the production time by 18% per product. Based on the advantages of the SLM method in cooling system design and structure optimization, the company can use the SLM method in the production process to improve economic and environmental benefits.
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Suspension plasma sprayed thermal barrier coatings for internal combustion engines / Suspensionsprutade termiska barriärbeläggningar för förbränningsmotorerUczak de Goes, Wellington January 2020 (has links)
The upward trend in internal combustion engine efficiency is likely driven by the depletion of fossil fuels. Since no replacement in sight can deliver energy comparable to the conventional oil, there is a need to use it more rationally and effectively. Thermal barrier coatings have been seen for a long time as a solutionto increase the thermal efficiency of gas turbine engines but suffer from the lackof strong applicability in internal combustion engines. This is due to the different restrictions when comparing the environment on the gas turbines and in internal combustion engines. To overcome this problem and, at the same time, expand the application field of thermal barrier coatings, more efforts need to be devoted.In this work, different top coat materials using various deposition techniques were evaluated and categorized in three different thermal barrier coating (TBC) architectures. The first was the lamellar yttria-stabilized zirconia (YSZ) top coat deposited by atmospheric plasma spray (APS), used as a reference sample. The second architecture was a columnar suspension plasma spray (SPS) TBC with YSZ and gadolinium zirconate (GZO) top coat. The SPS process can produce avariety of microstructures, and they were, for the first time, tested in an internal combustion engine. The third architecture was an SPS top coat, with an additional layer on the top, called a sealing layer of either metallic or ceramic material, both never investigated in a diesel engine application earlier. For the thermophysical properties investigation, a combination of laser flashanalysis (LFA) and modeling with object-oriented finite element (OOF) was employed to understand the properties in all the applications. The performance of the coatings was evaluated in two different ways, by thermal cyclic tests, basedon the TBCs behavior under cyclic thermal loads and by single-cylinder engine experiment. The characterization of the coatings was done by scanning electron microscope (SEM) before and after the thermal cyclic tests.The performance properties were correlated with coatings microstructure and thermophysical properties. It was shown that a columnar TBC produced by SPS had a superior engine efficiency in the single cylinder engine experiment.
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Effect of austenitising temperature and cooling rate on microstructures of hot-work tool steelsColl Ferrari, María Teresa January 2015 (has links)
The average size of hot-work tools has gradually increased over the past years.This affects the effective temperature cycle tools experience during hardening,as large dimensions prevent uniform and rapid cooling, and thereby the resulting microstructures and properties. In order to avoid the formation of coarse structures or cracking during heat treatment it has become common practise to lower the austenitising temperature below that recommended by the steel manufacturer.In this work, therefore, the effects of austenitising at temperatures lower thancommonly recommended are investigated. Three 5% Cr hot-work tool steelsalloyed with Mo and V were heat treated, resulting microstructures andtempering carbides were studied and transformation characteristics determined for different austenitising temperatures and different cooling rates. The temperatures and cooling rates have been chosen to be representative for heat treatments of different sizes of tools. Bainite rather than martensite formed during slow cooling regardless of austenitising temperature. A lowered austenitising temperature produced largeramounts of both bainite and retained austenite while a higher caused graingrowth. Carbon partitioning during the bainitic transformation resulted in anincrease of the carbon content in the retained austenite of at least 0.3 wt.%. The austenitising temperature influences also the type and amount of tempering carbides that precipitate, which affects the properties of the steel. Higher austenitising temperatures favour the precipitation of MC carbides during tempering. The Mo rich M2C type carbides were proven to be more prone to coarsening during service at 560°C-600°C, while V rich MC carbides preserve their fine distribution. A best practice heat treatment needs to balance the increase of grain size with increasing austenitising temperatures, with the possibility to form more tempering carbides. Higher austenitising temperatures also give less retained austenite, which can affect dimensional stability and toughness negatively after tempering
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Challenges in Resistance Welding of Ultra High Strength SteelsTolf, Erik January 2015 (has links)
Increasing the use of Ultra High Strength Steels (UHSS) in vehicle bodystructures is important for reducing weight and cutting CO2 emissions. This thesis investigates challenges in resistance welding that can be a barrier to implementing UHSS as a replacement for low strength steels in vehicle structures. Empirical research has been performed to offer new approaches for improved joint strength and to increase knowledge on cracking mechanisms in resistance projection welding and resistance spot welding of UHSS. By optimising the current build-up phase and peak current during the first milliseconds of weld time, it was shown that the strength could be improved by up to two-fold for projection welded joints. An approach to improve the ductility and strength of resistance spotwelds in UHSS using reduced cooling time was unsuccessful. The reduced cooling rate after weld metal solidification did not fully create the desired softened microstructure. The study on the surface cracking mechanism in resistance spot welded dual-phase UHSS showed that cracking is linked to the galvanization method. It is proposed that formation of aluminium oxide layers on the electrode tips increases the surface temperature and thereby increases the probability for liquid metal embrittlement and surface cracking. / <p>QC 20150526</p>
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Återfjädring vid bockning av höghållfast stål / Springback in bending of high strength steelWikström, Gabriel January 2012 (has links)
No description available.
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