The goal of this work is to develop and characterize a manufacturing process that is able to create metal matrix composites with complex cellular geometries. The novel manufacturing method uses two distinct additive manufacturing processes: i) fabrication of patternless molds for cellular metal castings and ii) printing an advanced cellular ceramic for embedding in a metal matrix. However, while the use of AM greatly improves the freedom in the design of MMCs, it is important to identify the constraints imposed by the process and its process relationships. First, the author investigates potential differences in material properties (microstructure, porosity, mechanical strength) of A356 — T6 castings resulting from two different commercially available Binder Jetting media and traditional 'no-bake' silica sand. It was determined that they yielded statistically equivalent results in four of the seven tests performed: dendrite arm spacing, porosity, surface roughness, and tensile strength. They differed in sand tensile strength, hardness, and density. Additionally, two critical sources of process constraints on part geometry are examined: (i) depowdering unbound material from intricate casting channels and (ii) metal flow and solidification distances through complex mold geometries. A Taguchi Design of Experiments is used to determine the relationships of important independent variables of each constraint. For depowdering, a minimum cleaning diameter of 3 mm was determined along with an equation relating cleaning distance as a function of channel diameter. Furthermore, for metal flow, choke diameter was found to be significantly significant variable. Finally, the author presents methods to process complex ceramic structure from precursor powders via Binder Jetting AM technology to incorporate into a bonded sand mold and the subsequently casted metal matrix. Through sintering experiments, a sintering temperature of 1375 °C was established for the ceramic insert (78% cordierite). Upon printing and sintering the ceramic, three point bend tests showed the MMCs had less strength than the matrix material likely due to the relatively high porosity developed in the body. Additionally, it was found that the ceramic metal interface had minimal mechanical interlocking and chemical bonding limiting the strength of the final MMCs. / Ph. D.

The overall goal of this work is to improve the structural performance of cellular structures in bending applications by incorporating tensegrity behavior using long continuous fibers. The designs are inspired by the hierarchical cellular structure composition present in pomelo fruit and the structural behavior of tensegrity structures. A design method for analyzing and predicting the behavior of the structures is presented. A novel manufacturing method is developed to produce the cellular structures with tensegrity behavior through the combination additive manufacturing and metal casting techniques. Tensegrity structures provide high stiffness to mass ratio with all the comprising elements experiencing either tension or compression. This research investigates the possibility of integrating tensegrity behavior with cellular structure mechanics and provides a design procedure in this process. The placement of fibers in an octet cellular structure was determined such that tensegrity behavior was achieved. Furthermore, using finite element analysis the bending performance was evaluated and the influence of fibers was measured using the models. The overall decrease in bending stress was 66.6 %. Extending this analysis, a design strategy was established to help designers in selecting fiber diameter based on the dimensions and material properties such that the deflection of the overall structure can be controlled. This research looks to Additive Manufacturing (AM) as a means to introduce tensegrity behavior in cellular structures. By combining Binder Jetting and metal casting a controlled reliable process is shown to produce aluminum octet-cellular structures with embedded fibers. 3D-printed sand molds embedded with long continuous fibers were used for metal casting. The fabricated structures were then subjected to 4 point bending tests to evaluate the effects of tensegrity behavior on the cellular mechanics. Through this fabrication and testing process, this work addresses the gap of evaluating the performance of tensegrity behavior. The overall strength increase by 30%. The simulation and experimental results were then compared to show the predictability of this process with errors of 2% for octet structures without fibers and 6% for octet structures with fibers. / Master of Science / Cellular materials are a class of lightweight structures composed by a network of cells comprising inter-connected struts, which help in reducing the material present in the structure. These structures provide high stiffness for low mass, better shock-absorption, thermal and acoustic insulation. Best known examples in nature include honeycomb, bamboo and cedar. There is a constant desire to improve strength of the cellular structures while wanting low mass. This research aims to provide a new approach towards the enhancing structural performance of cellular structures for bending applications through designs featuring long continuous fibers to impose tensegrity behavior. The designs in this research are inspired by the structural composition of pomelo fruit and tensegrity arrangements, where continuous long fibers are observed to enhance structural performance. Tensegrity structures are another class of lightweight structures composed of compressive bars and pre-stressed strings/fibers such that the structural elements undergo either tension or compression. The absence of bending stress makes these structures more efficient. A design method for analyzing and predicting the behavior of the structures is presented. To address the imposing manufacturing challenges, a novel manufacturing method is developed, producing cellular structures with tensegrity behavior through the combination of Binder Jetting and metal casting techniques. Binder Jetting is an additive manufacturing process, which selectively binds sand, layer by layer to create molds of desired designs and metal can be cast into the printed molds to realize parts. The bending performance was evaluated and the influence of fibers was measured using the models. The overall decrease in bending stress was 66.6 %. The fabricated structures were then subjected to 4 point bending tests. The overall strength increased by 30%. The simulation and experimental results were then compared to show the predictability of this process with errors of 2% for octet structures without fibers and 6% for octet structures with fibers. This research takes another step towards creating efficient lightweight structures and adds to the efforts taken to build multifunctional hierarchical cellular materials, which can provide better performance while saving material. Potential applications of these structures include earthquake resistant wall panels, aircraft fuselage/interior supports, automotive chassis structure, beams for supporting roof loads, armor panels in battle tanks, ship building and packaging (electromechanical systems).

Surface defects in steel slabs during continuous casting pose significant challengesfor quality control and product integrity in the steel industry. Predicting and classifyingthese defects accurately is crucial for ensuring product quality and minimizing productionlosses. This thesis investigates the effectiveness of machine learning models in predictingsurface defects of varying severity levels (ordinal classes) during the primary coolingstage of continuous casting. The study evaluates four machine learning algorithms,namely, XGBoost (main and baseline models), Decision Tree, and One-vs.-Rest SupportVector Machine (O-SVM), all trained with imbalanced defect class data. Model evaluationis conducted using a set of performance metrics, including precision, recall, F1-score,accuracy, macro-averaged Mean Absolute Error (MAE), Receiver Operating Characteristic(ROC) curves, Weighted Kappa and Ordinal Classification Index (OCI). Results indicatethat the XGBoost main model demonstrates robust performance across most evaluationmetrics, with high accuracy, precision, recall, and F1-score. Furthermore, incorporatingtemperature data from the primary cooling process inside the mold significantly enhancesthe predictive capabilities of machine learning models for defect prediction in continuouscasting. Key process parameters associated with defect formation, such as tundish temperature,casting speed, stopper rod argon pressure, and submerged entry nozzle (SEN) argonflow, are identified as significant contributors to defect severity. Feature importance andSHAP (SHapley Additive exPlanations) analysis reveal insights into the relationship betweenprocess variables and defect formation. Challenges and trade-offs, including modelcomplexity, interpretability, and computational efficiency, are discussed. Future researchdirections include further optimization and refinement of machine learning models andcollaboration with industry stakeholders to develop tailored solutions for defect predictionand quality control in continuous casting processes.

Magnetic field-assisted freeze-casting was used to create porous B4C ceramic preforms. An optimum slurry consisted of a mixture of B4C powders with 6 wt.% Er2O3 powder in an H2O-PVA solution and was cooled at a rate of 1 °C/min from room temperature to -30 °C resulting in porous green state ceramic preform with vertical channels. The Er2O3 powder was added to improve the magnetic response of the slurry. The preform was then sublimated to remove H2O and then sintered. The sintered ceramic preform was then infiltrated in the most vertically aligned channel direction with molten Al (A356) metal through a vacuum-assisted pump to create the metal matrix composite (MMC). Finite element analysis simulations were used to analyze and predict the anisotropic effect of B4C channel alignment on mechanical properties. The mechanical properties of the composite were then experimentally found via compression testing, which was compared with rule-of-mixtures and finite element modeling simulations, to analyze the effect of anisotropy due to magnetic field-assisted freeze-casting. This study reinforces the viability of cost-effective magnetic field-assisted freeze-casting as a method to create highly directional ceramic preforms, which can be subsequently metal infiltrated to produce MMCs with highly anisotropic toughness.

Thermal management in die casting involves controlling heat transfer between the molten metal and the die surface. A cooling system integrated into the die facilitates the rate of heat extraction at the die-molten metal interface. However, non-uniformity of die surface temperature can occur due to the variation in the amount of heat that needs to be extracted from the casting leading to low casting quality. These variations are usually caused by differences in the casted part thicknesses. Therefore, effective die thermal management (DTM) is crucial, as it influences the quality of the final casted component in terms of its final shape, microstructure, and mechanical properties. The main objective of the present research work is to develop a new DTM algorithm that addresses the shortcomings of existing DTM techniques. Initially, the aim is to estimate the rate of heat transfer at the die-metal interface in order to identify locations experiencing the highest heat exposures (i.e., hot spots). Subsequently, a heat balance is used to determine the necessary adjustments to the cooling water flow rates fed into each cooling channel to mange the hot spot and to achieve a more uniform temperature distribution along the die interface. Ultimately, the goal is to develop a die thermal management model (DTMM) that can be used to vary the water flow rate in each cooling channel based on the rate of heat extraction required based on the casted part geometry. The DTMM has developed using inverse heat transfer techniques and validated using data obtained for a set of virtual and real experiments. The data of the virtual experiments were generated using numerical simulations carried out using the computer software Flow3D Cast. The numerical and real experiments were carried out for a gravity-fed die casting process of pure Aluminum in a wedge-shaped mold, which was intentionally selected to reproduce some non-uniformity in the thickness of the casted part. Such non-uniformity was used to assess the effectiveness of the developed DTMM. Simulation results obtained using Flow-3D have been compared with the experimental results in order to assess the predictive capabilities of Flow3D. The DTMM demonstrated a significant reduction in the maximum temperature difference along the die surface, achieving up to 92 % improvement. As a result, the die interface experienced a more uniform heat distribution when variable cooling flow rates were applied, in contrast to constant cooling flow rates. / Thesis / Doctor of Engineering (DEng) / A die thermal management model has been developed to predict the heat transfer rate at the die-metal interface and to determine the required changes to the rate of heat extraction by the cooling channels at different die sections to minimize temperature non-uniformity of the produced casting. The effectiveness of the developed thermal management model has been evaluated using both numerical and experimental data obtained for a wedge-shaped casting. The used casting shape was intended to mimic significant variations of the casting cross sections in order to create significant temperature non-uniformity along the die surface. The results obtained using the developed thermal management model showed the model’s effectiveness in reducing the temperature non-uniformity along the die-metal interface, hence within the produced casting.

Cross-gender casting (i.e. the casting of female performers for male parts and vice versa) of plays by William Shakespeare is not a scarce phenomenon and is getting more and more popular in the recent years. In spite of the frequent claim of the theatre-makers and critics that it is in fact a gender blind casting, where the gender of the performer does not matter, the thesis attempts to prove that, in fact, it is not the case. This is exemplified on three most frequently staged and also most commonly cross-gender cast plays: Hamlet, King Lear and Romeo and Juliet. Via these examples the thesis shows the variability of approaches to cross-gender casting and the differences in realization. In the first chapter, the key terminology is defined, in order to avoid confusion, discussing the differences between cross-dressing, travesty and cross-gender casting. That is followed by subchapters in which the basic frame of thought is suggested, building on Judith Butler's deconstruction of gender and the concept of gender performativity. The last subchapter of this section deals with the history of cross-gender casting, including the Elizabethan all-male staging tradition. The next three chapters are then devoted to each of the plays, analyzing the possible interpretive keys and motivations for a cross-gender cast...

För att kunna prediktera fel under processen precisionsgjutning, används simulering som ett verktyg att bestämma hur detaljer skall gjutas. Det finns flertalet parametrar som är möjliga att manipulera eller ändra. För att komma så nära ett verkligt scenario som möjligt behöver dessa parametrar optimeras mot verkligheten. Syftet med detta arbete är att analysera faktorer som påverkar värmeöverföring för att sedan presentera optimeringsförslag åt TPC Components AB mot de gjorda mätningarna. Detta görs för att kunna förutsäga till exempel hur snabbt ett föremål kyls i processen och hur det påverkar det slutgiltiga resultatet. Resultat från de optimerade simuleringarna jämförs mot ett praktiskt försök och även TPC Components tidigare standard utvärderas mot arbetets optimerade simuleringar. En viktig fråga är att undersöka varför simuleringsprogrammet inte blir identiskt med verkligheten och hur detta undersöks. Känslighetsanalyser utgör därmed en stor del av arbetet och det är av vikt att undersöka enskilda parametrar för att få en uppfattning om vad som påverkar resultatet och vad som går att bortse från. Resultatet av arbetet visar att ändrade parametrar för indata vid precisionsgjutning i TPC Components AB:s vakuumprocess har resulterat i en mer pålitlig simulering. Simuleringen bygger nu på vetenskapliga bevis och faktiska uppmätningar under processen för att kunna simulera så likt verkligheten som möjligt. Arbetet resulterar i att färre gjutförsök innan godkänt tillvägagångssätt för nya detaljer behövs, då simulering kommer att visa resultat närmare verkligheten. Arbetet har förbättrat TPC Components simuleringsarbete vilket kommer påverka både arbetstid, kostnader och miljö på ett positivt sätt. / Simulation of investment casting play a big role for prediction of problems in the process. TPC Components AB need their simulations to be optimised against the practical process in order to get results as close as possible to the results from real practice. This thesis is mapping the parameters sensitivity against TPC’s earlier standards to put forward what parameters the result is depending on. The optimization of the parameters is towards measurement of heat and time and practical trial in order to get a scientific ground. The heat transfer for complicated structure needs to be simulated in order to get a reasonable value to work with. Results shows that TPC’s earlier model of simulation have lack of measurement and important parameters are based on assumptions. The work done gave TPC a model closer to the real practice which can both mean faster decisions of how to cast new products and less costly practical trials.

Für den Zylinderkopf ist das Schwerkraftgießen ein etabliertes Gießverfahren. Jedoch gehen die Gießereien in der Ausführung des Schwerkraftgusses unterschiedlich vor. Durch die mannigfaltigen Anschnittsysteme und die sich dadurch ergebenden Vor- bzw. Nachteile bei der Herstellung entstehen Unterschiede bei Qualität und Kosten. Ziel dieser Arbeit ist es, Standards und Vereinheitlichungen während der Produktentstehung eines Zylinderkopfes zu etablieren, um eine gleichbleibende Qualität der Zylinderköpfe in den Gießereien zu gewährleisten. Dazu sind vielfältige Ansatzpunkte zu verfolgen. Eine Möglichkeit ist die geometrische Beurteilung des Zylinderkopfs, wie z.B. Wandstärken, Speisungswege und die Außengeometrien. Die nach Lastenheftvorgaben zu erfüllenden Eigenschaften spielen gleichermaßen eine Rolle und haben Einfluss auf die Wahl des Gießverfahrens. Mit Hilfe von speziellen Entscheidungsmethoden ist eine Vorauswahl für ein Gießverfahren möglich. Des Weiteren werden mittels experimentellen Untersuchungen die Entscheidungen gestützt. Die Gießsimulation ist als zusätzliches Auslegungswerkzeug einzusetzen. Hierbei sind Gussfehler im Bauteil zu lokalisieren und zu vermeiden. Unzureichende Speisungswege oder zu geringe Wandstärken durch komplizierte Kerngeometrien sind zu ermitteln. Des Weiteren sind Vorhersagen zu Dendritenarmabständen und Materialausnutzung (Speiserdimensionierung) möglich, die direkt mit der Wahl des Gießverfahrens zusammenhängen. Die Verzahnung von Geometrie- und Metallurgiefaktoren führt idealerweise zur Definition von Standardisierungsaspekten zur Auswahl der Gießtechnologie bei der Zylinderkopfentwicklung. Durch eine parallele Produkt- und Prozessentwicklung ist eine Verkürzung des Produktentstehungsprozesses erreichbar.

Made available in DSpace on 2014-06-11T19:35:03Z (GMT). No. of bitstreams: 0 Previous issue date: 2009-03-24Bitstream added on 2014-06-13T20:06:15Z : No. of bitstreams: 1 zequetto_mm_dr_araca.pdf: 383469 bytes, checksum: 3fd20e10aa2c413edb650399efcff201 (MD5) / No processo de fundição pela cera perdida, os materiais envolvidos podem apresentar interações entre si e o de tempo despendido para se obter as estruturas metálicas é oneroso. Assim, o objetivo deste trabalho foi avaliar a influência da propriedade física de resistência à compressão de revestimentos fosfatados indicados para altas temperaturas de fundição, utilizando os métodos de aquecimento convencional (MAC) e rápido (MAR), e analisar a rugosidade de superfície e a alteração dimensional do produto final da fundição (a peça metálica) obtido com as ligas metálicas Ni-Cr (Verabond II) e Ni-Cr-Ti (Fit Cast Titanium). Os revestimentos estudados Castorit Super C, Castorit All Speed, Heat Shock e Micro Fine 1700 foram vazados em uma matriz de silicone que permitiu obter amostras com formato cilíndrico (n=200), medindo 10mm de diâmetro e 20mm de comprimento. A resistência (MPa) deles foi determinada à temperatura ambiente (resistência fria) após 15, 30 e 60 minutos de manipulação, e também imediatamente após serem submetidos aos métodos de aquecimento MAC e MAR (resistência de queima), por meio de uma máquina de ensaio universal, em velocidade de 0,05mm/min e carga de 150kgf. Após inclusão, aplicação dos métodos de aquecimento e fundição às amostras (n=120) para rugosidade de superfície (Ra-μm), foram avaliadas por um rugosímetro Mitutoyo Surftest SJ-401 com cut-off de 0,8mm e três repetições em cada amostra. A alteração dimensional foi determinada pela diferença entre os valores dimensionais da cera e da peça fundida (n=60) utilizando-se o software AutoCad2008. Os valores médios obtidos foram submetidos à análise de variância (ANOVA) e ao teste de Tukey (p<0,05), apresentando os valores de resistência à compressão diferentes entre os revestimentos (Heat Shock os valores maiores) e entre os tempos de mensuração em relação... / In the lost wax casting procedure, the involved materials can present interactions among them and the time used to obtain the metallic structures is onerous. Thus, the purpose of this study was to evaluate the influence of the compressive strength physical property of phosphate-bonded investment materials indicated for high casting temperatures, utilizing conventional heating (CHM) and quick heating methods (QHM), and analyze the surface roughness and the dimensional accuracy of the final casting product (the metallic piece) obtained from Ni-Cr (Verabond II) and Ni-Cr-Ti (Fit Cast Titanium) metallic alloys. Castorit Super C, Castorit All Speed, Heat Shock and Micro Fine 1700 investment materials were poured into a silicone matrix in order to obtain cylindrical samples (n=200), measuring 10mm in diameter and 20mm in length. Their strength (MPa) was determined at room temperature (green strength) after 15, 30 and 60 minutes of manipulation, and also immediately after being submitted to the CHM and QHM heating methods (fired strength), by means of an universal testing machine at 0,05mm/min speed and 150kgf load. After investing, applying the heating methods and casting the samples (n=120) for surface roughness (Ra), the samples were evaluated with a Mitutoyo Surftest SJ-400 profilometer with 0,8mm cut-off, three times in each sample. The dimensional accuracy was determined by the difference among the dimensional values of the wax and of the metallic piece (n=60) through the software AutoCad2008. The mean values obtained were submitted to ANOVA and Tukey tests (p <0.05), and the results showed that the values of compressive strength were different among the investment materials (Heat Shock presenting the highest values) and among the analysis times with a direct relation of time and strength increase, but there was no difference between CHM and QHM. Moreover, it was observed no differences... (Complete abstract click electronic access below)

This thesis is focused on the calculation of production costs with the introduction of licensed production of submersible sludge pumps in company Tomasek Milan - TOMEX. The aim of this work is the introduction of licensed production and determine the manufacturing cost. In the theoretical section describes the methods for determining a production layout, calculation methods and methods of return on investment. The practical part deals with the determination of a suitable arrangement of production, production calculations and evaluation of overall investment.