MCrAlY coatings are commonly applied as the bond coat in TBCs used in modern gas turbines. Cold spray (or CS), characterized by low process temperature and high particle impact velocity, has been demonstrated as a promising alternative to thermal spray processes, such as air plasma spray (APS) and high velocity oxygen fuel (HVOF), for manufacturing MCrAlY coatings. The general objective of the thesis research is to characterize CS deposition on a single-crystal nickel-base superalloy and to develop low-cost/high-performance NiCoCrAlTaY coatings using the CS technique. Several individual studies were carried out with each having a specific focus towards achieving the general research objective. CS deposition of NiCoCrAlTaY coatings using nitrogen was first examined to verify the feasibility of replacing the expensive helium gas typically used as the CS process gas. Several materials were used as the substrates, and the effects of substrate materials and surface preparation on coating microstructure and properties were investigated. Recycling of non-deposited powder particles was then explored to reduce the costs associated with the feedstock powder. A cost model that includes the economics of powder recycling was developed for the CS process, showing that the use of nitrogen and powder recycling could potentially be cost-effective for CS deposition of MCrAlY coatings. A CS process that can produce in-situ nanocrystalline NiCoCrAlTaY coatings was proposed to develop coatings with enhanced oxidation performance. This CS approach utilizes conventional commercial powders instead of pre-milled nanocrystalline powders. Detailed characterization using the scanning electron microscope (SEM), scanning transmission electron microscope (STEM), and X-ray diffraction (XRD) was carried out to investigate the microstructure of the resulting CS NiCoCrAlTaY coatings, single-crystal substrate, and their interface. Isothermal oxidation performance of the CS NiCoCrAlTaY coatings was evaluated at 1100°C for 1h to 500h. Results revealed that the nanostructure promoted the α-Al2O3 scale formation and sustained α-Al2O3 scale growth, suggesting good isothermal oxidation performance. Finally, the effects of different processing sequences on CS NiCoCrAlTaY coating characteristics and short-term isothermal oxidation performance were investigated. Specifically, CS deposition of NiCoCrAlTaY coatings was carried out on single-crystal superalloy substrates that underwent various degrees of full heat treatments prior to being coated. The remaining superalloy heat treatments required were then performed on the coated samples after the CS deposition. The microstructures of the superalloy substrates and CS NiCoCrAlTaY coatings were characterized after each heat treatment. Isothermal oxidation performance of the coated samples following different sequences was evaluated at 1100°C for 2 hours. The results suggested a promising processing sequence that could potentially further improve the oxidation performance of CS NiCoCrAlTaY coatings.

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The modern painting process in automotive industry is complex and a lot of factors affect the result. The trial and error method is used today to control the quality and introduce new colours. This method takes a lot of time and does not show any clear numbers of how the process is affected by changing the parameters. During this thesis, we have investigated a delimited number of parameters. The work is based on experiments performed on samples that represents a flat surface of the cab, to reduce experimental costs. Our master thesis is done at Scania in Oskarshamn, where all the cabs for the European production is produced. The objectives with this thesis has been to explain how the process parameters of the robotic applicator affect the paint distribution, paint thickness and the colour of the top coat. We also optimised the process by finding which settings gives an even paint distribution, a correct thickness and an accepted colour of the top coat. We have been using Design of Experiments to achieve the goals of this study. Design of Experiments is a statistic method that is used to perform experiments effectively. It also shows the effect of changing the factors from a low to a high level. We have chosen to divide the workflow into three parts: screening, optimisation and confirmation. The experiments are performed during the daily production to replicate the real circumstances. The shape air, paint flow and high rotation is the most important parameters to control. Paint flow also seems to have a linear impact on the thickness of the top coat layer. The Shape air and the high rotation on the other hand mainly affect the distribution of the top coat layer. Different levels are needed for the shape air and high rotation depending on what paint flow is used. The optimal settings of the factors for our colour were found to be paint flow at 82 %, the shape air at 90 %, the high rotation at 90 % and high voltage at 100 %. The optimal settings give a result of 1,535 μm in spread and 40,08 μm in mean thickness. Our settings compared to today’s results contributes to a reduced paint consumption, better quality and therefore less rework.

京都大学 / 0048 / 新制・課程博士 / 博士(エネルギー科学) / 甲第17795号 / エネ博第278号 / 新制||エネ||58(附属図書館) / 30602 / 京都大学大学院エネルギー科学研究科エネルギー社会・環境科学専攻 / (主査)教授 石原 慶一, 教授 東野 達, 准教授 奥村 英之 / 学位規則第4条第1項該当 / Doctor of Energy Science / Kyoto University / DFAM

京都大学 / 0048 / 新制・課程博士 / 博士(農学) / 甲第19192号 / 農博第2131号 / 新制||農||1034(附属図書館) / 学位論文||H27||N4938(農学部図書室) / 32184 / 京都大学大学院農学研究科応用生物科学専攻 / (主査)教授 奥野 哲郎, 教授 佐久間 正幸, 准教授 吉田 天士 / 学位規則第4条第1項該当 / Doctor of Agricultural Science / Kyoto University / DFAM

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ABSTRACT<p> Canada is currently the world leader in red lentil exports, a crop of significant economic importance to Western Canadian producers. It is important for the maintenance and growth of foreign markets that our growers are able to provide a consistent product. In the past few years, our exported red lentils have had variable quality, largely due variable weather conditions. A study was conducted to determine the effect of various preharvest treatments on the milling quality of our current red lentil cultivars. These cultivars, listed in order of increasing seed size, were CDC Robin, CDC Imperial CL, CDC Rosetown, CDC Blaze, CDC Impact CL, CDC Rouleau, CDC Redberry and CDC Red Rider. Replicated plots of each variety were grown in the summers of 2005 and 2006 at Floral, SK and Rouleau, SK. These were chosen with the intent of maximizing environmental differential between locations, especially in terms of soil texture and moisture availability. All locations were laid out using a randomized complete block design with four replicates. Replicated plots of each cultivar were subjected to preharvest treatments of desiccation with Diquat or swathing at early, recommended and late stages of maturity. The milling quality of the harvested lentils was determined for all treatment and cultivar combinations.<p> Before preharvest treatments were applied, each plot was assigned a maturity rating based on a 1 (immature) 9 (very mature) scale. Plants exhibiting pods with a buckskin colour and texture on the bottom third of the plant were considered to be at early maturity and assigned a rating of 3. Similarly, when pods of buckskin colour and texture were found in the middle third of the plant, a maturity rating of 6 was assigned while a value of 9 would be assessed when the entire plant had all brown, rattling pods except for a small portion of buckskin pods in the top third of the canopy.<p> Based on this 1-9 scale, a total of six different harvest treatments were carried out: swathing or chemical desiccation at early, intermediate or late stages of maturity. Swathed plots were cut using a gas-powered sickle-mower, then covered with bird mesh which was staked to the ground until harvest to prevent wind damage. Desiccated plots were sprayed with Reglone (diquat) using a CO2-pressurized backpack sprayer. They were left standing until harvest. Following mechanical harvest, seed from each plot was placed in mesh bags and forced-air-dried to approximately 13% moisture, then placed in a controlled storage chamber held at 5oC.<p> Seed samples of two complete sets of replicated treatments were cleaned, then sized by passing them over round, then slotted sieves using the forty-shakes method. The two most frequent seed diameter and thickness fractions from each plot were set aside for milling. Samples were hydrated to 12.5% moisture which is the ideal moisture content for high milling quality according to research conducted by Dr. Ning Wang at the Grain Research Laboratory in Winnipeg, MB. The samples were then milled using either a Satake or a Turkish table top pulse dehuller. Following milling, samples were passed through a Carter dockage tester (Simon-Day Ltd., Winnipeg, MB) to separate whole and split seeds from broken or damaged seeds and hull material. Each sample was assessed for: 1) milling efficiency (percent split and unsplit cotyledons recovered from the total sample); 2) football recovery (percent dehulled lentils with unsplit cotyledons); and 3) dehulling efficiency (percent of cotyledons with over 98% of the seed coat removed. Dehulling efficiency values were assessed using a DuPont AcurumTM seed scanner (DuPont Canada, Toronto, ON).<p> Under favorable harvest conditions, preharvest treatments had no effect on milling efficiency, percent football recovery or dehulling efficiency. However, plots subjected to cool, wet harvest conditions produced lentil samples of highly variable milling quality. Early desiccation significantly reduced milling efficiency to below 70%, whereas early swathing resulted in milling efficiency above 85%. CDC Robin and CDC Imperial CL had the highest milling efficiencies. Similarly, cool wet harvest conditions caused percent football recovery to drop from approximately 80% to around 50%. Early swathing was the most effective for producing footballs, with smaller-seeded varieties producing the most. Cool, wet harvest caused dehulling efficiency to drop from the 97.3 99.9% range to 91.5 98.7%. Early desiccation had the most negative effect on dehulling efficiency, whereas early swathing produced the highest values. Under these conditions, smaller-seeded varieties had the lowest dehulling efficiencies.<p> The results of this study will be valuable for developing agronomic practices specific to red lentil and for improving the quality of Canadas exported product.

ABSTRACT<p> Canada is currently the world leader in red lentil exports, a crop of significant economic importance to Western Canadian producers. It is important for the maintenance and growth of foreign markets that our growers are able to provide a consistent product. In the past few years, our exported red lentils have had variable quality, largely due variable weather conditions. A study was conducted to determine the effect of various preharvest treatments on the milling quality of our current red lentil cultivars. These cultivars, listed in order of increasing seed size, were CDC Robin, CDC Imperial CL, CDC Rosetown, CDC Blaze, CDC Impact CL, CDC Rouleau, CDC Redberry and CDC Red Rider. Replicated plots of each variety were grown in the summers of 2005 and 2006 at Floral, SK and Rouleau, SK. These were chosen with the intent of maximizing environmental differential between locations, especially in terms of soil texture and moisture availability. All locations were laid out using a randomized complete block design with four replicates. Replicated plots of each cultivar were subjected to preharvest treatments of desiccation with Diquat or swathing at early, recommended and late stages of maturity. The milling quality of the harvested lentils was determined for all treatment and cultivar combinations.<p> Before preharvest treatments were applied, each plot was assigned a maturity rating based on a 1 (immature) 9 (very mature) scale. Plants exhibiting pods with a buckskin colour and texture on the bottom third of the plant were considered to be at early maturity and assigned a rating of 3. Similarly, when pods of buckskin colour and texture were found in the middle third of the plant, a maturity rating of 6 was assigned while a value of 9 would be assessed when the entire plant had all brown, rattling pods except for a small portion of buckskin pods in the top third of the canopy.<p> Based on this 1-9 scale, a total of six different harvest treatments were carried out: swathing or chemical desiccation at early, intermediate or late stages of maturity. Swathed plots were cut using a gas-powered sickle-mower, then covered with bird mesh which was staked to the ground until harvest to prevent wind damage. Desiccated plots were sprayed with Reglone (diquat) using a CO2-pressurized backpack sprayer. They were left standing until harvest. Following mechanical harvest, seed from each plot was placed in mesh bags and forced-air-dried to approximately 13% moisture, then placed in a controlled storage chamber held at 5oC.<p> Seed samples of two complete sets of replicated treatments were cleaned, then sized by passing them over round, then slotted sieves using the forty-shakes method. The two most frequent seed diameter and thickness fractions from each plot were set aside for milling. Samples were hydrated to 12.5% moisture which is the ideal moisture content for high milling quality according to research conducted by Dr. Ning Wang at the Grain Research Laboratory in Winnipeg, MB. The samples were then milled using either a Satake or a Turkish table top pulse dehuller. Following milling, samples were passed through a Carter dockage tester (Simon-Day Ltd., Winnipeg, MB) to separate whole and split seeds from broken or damaged seeds and hull material. Each sample was assessed for: 1) milling efficiency (percent split and unsplit cotyledons recovered from the total sample); 2) football recovery (percent dehulled lentils with unsplit cotyledons); and 3) dehulling efficiency (percent of cotyledons with over 98% of the seed coat removed. Dehulling efficiency values were assessed using a DuPont AcurumTM seed scanner (DuPont Canada, Toronto, ON).<p> Under favorable harvest conditions, preharvest treatments had no effect on milling efficiency, percent football recovery or dehulling efficiency. However, plots subjected to cool, wet harvest conditions produced lentil samples of highly variable milling quality. Early desiccation significantly reduced milling efficiency to below 70%, whereas early swathing resulted in milling efficiency above 85%. CDC Robin and CDC Imperial CL had the highest milling efficiencies. Similarly, cool wet harvest conditions caused percent football recovery to drop from approximately 80% to around 50%. Early swathing was the most effective for producing footballs, with smaller-seeded varieties producing the most. Cool, wet harvest caused dehulling efficiency to drop from the 97.3 99.9% range to 91.5 98.7%. Early desiccation had the most negative effect on dehulling efficiency, whereas early swathing produced the highest values. Under these conditions, smaller-seeded varieties had the lowest dehulling efficiencies.<p> The results of this study will be valuable for developing agronomic practices specific to red lentil and for improving the quality of Canadas exported product.