Constitutive relationships are developed to describe the water transport characteristics of the gas diffusion layer (GDL) of proton exchange membrane fuel cells (PEMFCs). Additionally, experimental fixtures and procedures for the determination of the constitutive relationships are presented. The water transport relationships are incorporated into analytical models that assess the impact of the water transport relations and that make PEMFC performance predictions. The predicted performance is then compared to experimental results. The new constitutive relationships are significantly different than the currently popular relationships used in PEMFC modeling because they are derived from experiments on actual PEMFC gas diffusion layer materials. In prior work, properties of the GDL materials such as absolute permeability, liquid water relative permeability, porosity, and capillary behavior are often assumed or used as adjustment parameters in PEMFC models to simplify the model or to achieve good fits with polarization data. In this work, the constitutive relations are not assumed but are determined via newly developed experimental techniques. The experimental fixtures and procedures were used to characterize common GDL materials including carbon papers and carbon cloths, and to investigate common treatments applied to these materials such as the bulk application of a hydrophobic polymer within the porous structure. A one-dimensional model is developed to contrast results based on the new constitutive relations with results based on commonly used relationships from the PEMFC literature. The comparison reveals that water transport relationships can have a substantial impact on predicted GDL saturation, and consequently a significant impact on cell performance. The discrepancy in saturation between cases can be nearly an order of magnitude. A two-dimensional model is also presented that includes the impact of the compressed GDL region under the shoulder of a bipolar plate. Results show that the compression due to the bipolar plate shoulder causes a significant increase in liquid saturation, and a significant reduction in oxygen concentration and current density for the paper GDL. In contrast, compression under the shoulder has a minimal impact on the cloth GDL. Experimental inputs to the 2-D model include: absolute permeability, liquid water relative permeability, the slope of the capillary pressure function with saturation, total porosity, GDL thickness, high frequency resistance, and appropriate Tafel parameters. Computational polarization curve results are compared to experimental polarization behavior and good agreement is achieved. / Ph. D.

The gas diffusion layer (GDL) is one of the key components in a polymer electrolyte membrane (PEM) fuel cell. It performs several functions including the transport of reactant gases and product water to and from the catalyst layer, conduction of both electrons and heat produced in the catalyst layer, as well as mechanical support for the membrane. The overarching goal of this work is to thoroughly examine the GDL structure and properties for use in PEM fuel cells, and more specifically, to determine how to characterize the GDL experimentally ex-situ, to understand its performance in-situ, and to relate theory to performance through controlled experimentation. Thus, the impact of readily measured effective water vapor diffusivity on the performance of the GDL is investigated and shown to correlate to the wet limiting current density, as a surrogate of the oxygen diffusivity to which it is more directly related. The influence of microporous layer (MPL) design and construction on the fuel cell performance is studied and recommendations are made for optimal MPL designs for different operating conditions. A method for modifying the PTFE (Teflon) distribution within the GDL is proposed and the impact of distribution of PTFE in the GDL on fuel cell performance is studied. A method for characterizing the surface roughness of the GDL is developed and the impact of surface roughness on various ex-situ GDL properties is investigated. Finally, a detailed analysis of the physical structure and permeability of the GDL is provided and a theoretical model is proposed to predict both dry and wet gas flow within a GDL based on mercury intrusion porosimetry and porometry data. It is hoped that this work will contribute to an improved understanding of the functioning and structure of the GDL and hence advance PEM fuel cell technology.

Aufgrund des weltweit steigenden Energiebedarfs, dessen Deckung derzeit größtenteils auf fossilen Brennstoffen basiert, ist es nötig geworden, die Entwicklung alternativer Möglichkeiten zur Erzeugung von Elektroenergie als Primärenergie voranzutreiben. Eine dieser alternativen Möglichkeiten ist die Brennstoffezellentechnologie, welche sowohl in stationären als auch mobilen Anwendungen zum Einsatz kommen kann. Ihrer weitreichenden Verbreitung stehen bislang die aufgrund des großen Fertigungsaufwandes hohen Herstellungskosten der benötigten Komponenten im Wege. Hierzu zählen die Gasdiffusionslagen des weit verbreiteten Typs der wasserstoffbetriebenen Polymerelektrolytbrennstoffzelle. Es treten zwischen den einzelnen Fertigungsschritten im Herstellungsprozess dieser Gasdiffusionslagen Wechselwirkungen auf, die zu unerwünschten Materialveränderungen führen. Die Ursachen dieser Wechselwirkungen sind nicht vollends verstanden. Eine Vertiefung des Verständnisses der Herstellungsprozesse soll die Grundlage für eine Optimierung der Prozessführung bilden. Es sollen eine Kostenreduktion sowie eine Leistungssteigerung der Gasdiffusionslagen ermöglicht werden.:1 Einleitung 1 2 Stand der Technik 5 2.1 Brennstoffzellen 5 2.2 Gasdiffusionslagen 11 3 Problemstellung und Zielsetzung 17 4 Analyse und Klassifizierung von GDL-Fehlern 20 4.1 Fehlerklassifizierung 22 4.2 Fehleridentifizierung 26 4.3 Auswahl zu analysierender Fehlerbilder 27 4.4 Charakteristika der ausgewählten Fehlerbilder 42 4.4.1 Bahndeformationen 42 4.4.2 Umlaufende Verdickungen von Wickeln in Umfangsrichtung 44 4.4.3 Längs- und Queraufrauhungen sowie Rauhspuren 45 5 Theoretische Grundlagen 49 5.1 Physikalische und mechanische Grundlagen 49 5.1.1 Zug-, Biege- und Druckspannungen in Warenbahnen 49 5.1.2 Elastizitäts- und Kompressionsmoduli 52 5.1.3 Elastizität und Plastizität 53 5.1.4 Umformmechanismen im GDL-Basisvliesstoff und Versagensarten von Fasern 54 5.2 Statistik 55 5.2.1 Korrelationsanalyse 55 5.2.2 Regressionsanalyse 56 5.2.3 Zweistichproben-t-Tests und Konfidenzintervalle 56 5.2.4 Stichprobenumfang 57 5.3 Qualitätsregelkreise 58 6 Eingesetzte Untersuchungsmethoden 60 6.1 Mechanische Eigenschaften 64 6.1.1 Höchstzugkraft und Höchstzugkraftdehnung 64 6.1.2 Elastizitätsmodul und Kompressibilität 66 6.1.3 Elastische und plastische Deformation bei Zugbelastungen 67 6.1.4 Flächenmasse 70 6.1.5 Biegesteifigkeit 72 6.1.6 Dickenmessung 74 6.2 Thermische Eigenschaften 75 6.2.1 Wärmeleitfähigkeit 75 6.3 Bildgebende Verfahren 78 6.3.1 Schliffbildmikroskopie 78 6.3.2 Rasterelektronenmikroskopie 78 6.3.3 µ-Computertomographie 79 7 Herstellungsverfahren der untersuchten Gasdiffusionslagen im Überblick 81 8 Basisvliesstoffherstellung 84 8.1 Prozess der Vliesbildung und Verfestigung 84 8.2 Charakterisierung des GDL-Basisvliesstoffes 90 8.3 Fehlerbilder des GDL-Basisvliesstoffes 103 9 Dickenkalibrierung 113 9.1 Prozess der Dickenkalibrierung des GDL-Basisvliesstoffes 113 9.2 Charakterisierung des dickenkalibrierten GDL-Basisvliesstoffes 120 9.3 Fehlerbilder des dickenkalibrierten GDL-Basisvliesstoffes 130 9.3.1 Prozessbeobachtung 130 9.3.2 Hypothesenbildung und Verifikation 135 9.3.3 Maßnahmen zur Fehlervermeidung 146 10 Carbonisierung 156 10.1 Prozess der Carbonisierung 156 10.2 Charakterisierung carbonisierten GDL-Substrates 157 10.3 Fehlerbilder im Carbonisierprozess 163 11 Data Mining für die GDL-Herstellung 167 11.1 Datenerhebung 167 11.2 Auszuwertende Parameter 172 11.3 Ergebnisse der Parameteranalysen 173 12 Qualitätsregelkreise zum GDL-Produktionsprozess 178 12.1 Wulstbildung und Längsaufrauhung 178 12.2 Queraufrauhung 181 13 Zusammenfassung und Ausblick 184 14 Literaturverzeichnis 186 15 Abbildungsverzeichnis 192 16 Abkürzungsverzeichnis 201 17 Formelverzeichnis 203 18 Anlagenverzeichnis 204 / Due to worldwide increasing energy consumption, which is mainly covered by fossile fuels nowadays, it has become a necessity to further develop alternative possibilities to create electricity as primary energy. One alternative technology to accomplish this is fuel cell technology which can be used in stationary as well as in mobile applications. One aspect hindering its widespread use is the high manufacturing cost of the needed components due to the complicated production processes. Among these are gad diffusion layers of the commonly used hydrogen-driven polymer electrolyte fuel cells. There are interactions occurring between the several production steps leading to unwanted changes in material properties. The causes of these interactions are not completely understood. A deeper understanding of these shall be the basis for optimizations in process design and therefore cost reductions and improvements in performance of gas diffusion layers can be achieved.:1 Einleitung 1 2 Stand der Technik 5 2.1 Brennstoffzellen 5 2.2 Gasdiffusionslagen 11 3 Problemstellung und Zielsetzung 17 4 Analyse und Klassifizierung von GDL-Fehlern 20 4.1 Fehlerklassifizierung 22 4.2 Fehleridentifizierung 26 4.3 Auswahl zu analysierender Fehlerbilder 27 4.4 Charakteristika der ausgewählten Fehlerbilder 42 4.4.1 Bahndeformationen 42 4.4.2 Umlaufende Verdickungen von Wickeln in Umfangsrichtung 44 4.4.3 Längs- und Queraufrauhungen sowie Rauhspuren 45 5 Theoretische Grundlagen 49 5.1 Physikalische und mechanische Grundlagen 49 5.1.1 Zug-, Biege- und Druckspannungen in Warenbahnen 49 5.1.2 Elastizitäts- und Kompressionsmoduli 52 5.1.3 Elastizität und Plastizität 53 5.1.4 Umformmechanismen im GDL-Basisvliesstoff und Versagensarten von Fasern 54 5.2 Statistik 55 5.2.1 Korrelationsanalyse 55 5.2.2 Regressionsanalyse 56 5.2.3 Zweistichproben-t-Tests und Konfidenzintervalle 56 5.2.4 Stichprobenumfang 57 5.3 Qualitätsregelkreise 58 6 Eingesetzte Untersuchungsmethoden 60 6.1 Mechanische Eigenschaften 64 6.1.1 Höchstzugkraft und Höchstzugkraftdehnung 64 6.1.2 Elastizitätsmodul und Kompressibilität 66 6.1.3 Elastische und plastische Deformation bei Zugbelastungen 67 6.1.4 Flächenmasse 70 6.1.5 Biegesteifigkeit 72 6.1.6 Dickenmessung 74 6.2 Thermische Eigenschaften 75 6.2.1 Wärmeleitfähigkeit 75 6.3 Bildgebende Verfahren 78 6.3.1 Schliffbildmikroskopie 78 6.3.2 Rasterelektronenmikroskopie 78 6.3.3 µ-Computertomographie 79 7 Herstellungsverfahren der untersuchten Gasdiffusionslagen im Überblick 81 8 Basisvliesstoffherstellung 84 8.1 Prozess der Vliesbildung und Verfestigung 84 8.2 Charakterisierung des GDL-Basisvliesstoffes 90 8.3 Fehlerbilder des GDL-Basisvliesstoffes 103 9 Dickenkalibrierung 113 9.1 Prozess der Dickenkalibrierung des GDL-Basisvliesstoffes 113 9.2 Charakterisierung des dickenkalibrierten GDL-Basisvliesstoffes 120 9.3 Fehlerbilder des dickenkalibrierten GDL-Basisvliesstoffes 130 9.3.1 Prozessbeobachtung 130 9.3.2 Hypothesenbildung und Verifikation 135 9.3.3 Maßnahmen zur Fehlervermeidung 146 10 Carbonisierung 156 10.1 Prozess der Carbonisierung 156 10.2 Charakterisierung carbonisierten GDL-Substrates 157 10.3 Fehlerbilder im Carbonisierprozess 163 11 Data Mining für die GDL-Herstellung 167 11.1 Datenerhebung 167 11.2 Auszuwertende Parameter 172 11.3 Ergebnisse der Parameteranalysen 173 12 Qualitätsregelkreise zum GDL-Produktionsprozess 178 12.1 Wulstbildung und Längsaufrauhung 178 12.2 Queraufrauhung 181 13 Zusammenfassung und Ausblick 184 14 Literaturverzeichnis 186 15 Abbildungsverzeichnis 192 16 Abkürzungsverzeichnis 201 17 Formelverzeichnis 203 18 Anlagenverzeichnis 204

Ce travail de thèse a été consacré à l'élaboration d'un nouveau type de membranes de nanofiltration efficaces avec des propriétés améliorées (flux élevé et rétention élevée, et de bonnes propriétés mécaniques) en déposant un revêtement assemblé couche-par-couche (LbL) sur des supports poreux. Après avoir systématiquement étudié le mécanisme de croissance des films assemblés couche par couche des polyélectrolytes choisis et la relation entre les structures de ces films et les performances des membranes résultant, nous avons identifié avec succès les meilleures structures multicouches pour la construction de membranes de nanofiltration de référence avec des performances optimales. En outre, en prenant avantage de la technique LbL, nous avons introduit une couche de diffusion latérale assemblée soit de nanofibrilles de cellulose ou de nanotubes de carbone, qui permet d’augmenter le flux de 30% tout en conservant la même rétention par rapport à la membrane de référence. En plus, les films assemblés à base de chitosan et nanofibrils de cellulose ont montré une forte résistance à la traction allant jusqu’à 450 MPa et un module d’Young jusqu’à 50 GPa. / This thesis work was devoted to the development of a novel and efficient nanofiltration membrane with improved properties (high flux and high retention, good mechanical strength) by coating Layer-by-Layer (LbL) assembled films onto porous membrane support. After having systematically studied the growth mechanism of LbL-assembled films of chosen polyelectrolytes and the relationship between the structures of these films and the membrane performance of the resulting NF membranes, we successfully identified the best multilayer structures for constructing nanofiltration membranes (NF) of reference with optimal membrane performance. Furthermore, taking advantages of the LbL-assembly, we successfully introduced LbL-assembled lateral diffusion layer that is made of either cellulose nanofibrils or carbon nanotubes, which in turn led to membranes with 30% higher flux. In addition, the LbL-assembled films of chitosan and cellulose nanofibrils showed surprisingly strong tensile strength of up to 450 MPa and a high Young modulus of up to 50 GPa.

Construed bachelor work features into problems hydrogen fuel articles and survey on low-temperature fuell elements with polymeric electrolyte (PEMFC). Basic sight work is study feature catalyzers on base MnOx on real fuel cell type PEMFC. Exit are then measured characteristic this way creation fuel cell.

A potencialidade do eletrodo de cobre em meio alcalino foi demonstrada para o determinação de etanol a +0,6 V vs Ag/AgCl. A participação de espécies solúveis de Cu(III) no processo eletrocatalítico envolvendo a oxidação do etanol foi demonstrada por experimentos utilizando eletrodo disco-anel. A influência do potencial de pré-tratamento no sinal anódico foi investigada e correlacionada com a morfologia dos filmes formados na superfície do eletrodo por EDS (Energy Dispersive X-Ray Spectroscopy), indicando que as espécies de Cu(III) são originadas a partir da oxidação da camada de CuO. As medidas de etanol foram realizadas por amperometria em 0,6 V (vs Ag/AgCl). A repetibilidade das medidas utilizando padrão aquoso de etanol 0,05 % (v/v) foi de 3 % (v/v) e os limites de detecção e quantificação foram de 0,005 % (v/v) e 0,01 % (v/v), respectivamente. Nas condições experimentais otimizadas, o sensor amperométrico foi utilizado para o monitoramento da concentração de etanol no ar exalado (BrAC), que foi convenientemente coletado em um balão de borracha (V = 3 L) e introduzido em uma solução de NaOH 1 mol L-1 (V = 10 mL). O sensor apresentou uma faixa linear para concentrações de etanol em ar exalado na faixa de 0,26 – 130 mg L-1, operando de acordo com os parâmetros analíticos especificados na Legislação Brasileira para a quantificação de etanol no ar exalado em condutores de veículos automotores. A constante de eliminação de etanol do corpo humano também foi investigada e os resultados concordaram com os valores da literatura. Empregando-se eletrodos de Cu e Au foram também desenvolvidas outras metodologias para a quantificação de dipirona, glicose e ácido ascórbico e sistemas em fluxo. Estudos sobre o desenvolvimento e propriedades de um sistema gerador-coletor foram realizados e o dispositivo foi utilizado em titulações de substâncias redutoras com iodo gerado eletroquimicamente. / A copper disc working electrode in alkaline solutions was demonstrated to act as a suitable amperometric sensor for ethanol determination at +0.6 V vs Ag/AgCl. The participation of free-soluble Cu(III) species in the electrocatalytic process involving the anodic oxidation of ethanol has been demonstrated by rotating ring-disc electrode voltammetry. The influence of the pretreatment potential on the anodic signal was investigated and a correlation with the morphology of the electrode surface characterized by Energy Dispersive X-Ray Spectroscopy (EDS) indicated that the Cu(III) species is originated from the oxidation of a CuO layer. Ethanol measurements were performed in the amperometric mode at 0.6 V (vs Ag/AgCl). The repeatability of the measurements for a 0.05 % aqueous ethanol solution was estimated as 3 %, and the detection and quantification limits were determined as 0.005 % and 0.01 %, respectively. At the optimum experimental conditions, the amperometric sensor was used to monitor the concentration of ethanol in breath (BrAC), which was conveniently collected in a rubber air balloon (volume = 3 L) and introduced in a 1 mol L-1 NaOH working solution (volume = 10 mL). The sensor can measure a person\'s breath ethanol over the concentration range 0.26 - 130 mg L-1 by operating it according to an established protocol, of which the analytical parameters are specified by the Brazilian Legislation for BrAC measurements in drivers. The rate of ethanol degradation in the body was followed, and the results agree with predictions in the literature. Methodologies for the determination of dipyrone, glucose and ascorbic acid were also developed by using Cu and Au electrodes. Features of a dual-band electrochemical cell were investigated towards the development of a generator-collector system, which was employed in titrations with electrogenerated iodine.

Lack of energy storage is a key issue in the development of renewable energy sources. Most renewables, especially solar and wind, when used alone, cannot sustain a reliably constant power output over an extended period of time. These sources generally generate variable amounts of power intermittently, therefore, an efficient electrical energy storage (EES) method is required to better temporally balance power generation to power consumption. One of the more promising methods of electrical energy storage is the unitized regenerative fuel cell (UFRC.) UFRCs are fuel cells that can operate in a charge-discharge cycle, similar to a battery, to store and then to subsequently release power. Power is stored by means of electrolysis while the products of this electrolysis reaction can be recombined as in a normal fuel cell to release the stored power. A major advantage of UFRCs over batteries is that storage capacity can be decoupled from cell power, thus reducing the potential cost and weight of the cell unit. Here we investigate UFRCs based on hydrogen-halogen systems, specifically hydrogen-bromine, which has potential for improved electrode reaction kinetics and hence cheaper catalysts and higher efficiency and energy density. A mathematical model has been developed to analyze this system and determine cell behavior and cycle efficiency under various conditions. The conventional H2-Br2 URFCs, however also so far have utilized Pt catalysts and Nafion membranes. Consequently, a goal of this work was to explore alternate schemes and materials for the H2-Br2 URFC. Thus, three generations of test cells have been created. The first two cells were designed to use a molten bromide salt, ionic liquid or anion exchange membrane as the ion exchange electrolyte with the liquids supported on a porous membrane. This type of system provides the potential to reduce the amount of precious metal catalyst required, or possibly eliminate it altogether. Each cell showed improvement over the previous generation, although the results are preliminary. The final set of results are promising for anion exchange membranes on a cost basis compared Nafion. Another promising energy storage solution involves liquid methanol as an intermediate or as a hydrogen carrier. An alternative to storing high-pressure hydrogen is to produce it on-board/on-site on demand via a methanol electrocatalytic reformer (eCRef), a PEM electrolyzer in which methanol-water coelectrolysis takes place. Methanol handling, storage, and transportation is much easier than that for hydrogen. The hydrogen produced via methanol eCref may then be used in any number of applications, including for energy storage and generation in a standard H2-O2 PEM fuel cell. The mathematical modeling and analysis for an eCref is very similar to that of the HBr URFC. In this work, a comprehensive model for the coelectrolysis of methanol and water into hydrogen is created and compared with experimental data. The performance of the methanol electrolyzer coupled with a H2-O2 fuel cell is then compared for efficiency to that of a direct methanol fuel cell data and was found to be superior. The results suggest that an efficient and small paired eCRef-fuel cell system is potentially be a cheaper and more viable alternative to the standard direct methanol fuel cell. Both the H2-Br2 URFC and the methanol eCref in combination with a H2-O2 fuel cell have significant potential to provide higher energy efficiency and energy density for EES purposes.

A potencialidade do eletrodo de cobre em meio alcalino foi demonstrada para o determinação de etanol a +0,6 V vs Ag/AgCl. A participação de espécies solúveis de Cu(III) no processo eletrocatalítico envolvendo a oxidação do etanol foi demonstrada por experimentos utilizando eletrodo disco-anel. A influência do potencial de pré-tratamento no sinal anódico foi investigada e correlacionada com a morfologia dos filmes formados na superfície do eletrodo por EDS (Energy Dispersive X-Ray Spectroscopy), indicando que as espécies de Cu(III) são originadas a partir da oxidação da camada de CuO. As medidas de etanol foram realizadas por amperometria em 0,6 V (vs Ag/AgCl). A repetibilidade das medidas utilizando padrão aquoso de etanol 0,05 % (v/v) foi de 3 % (v/v) e os limites de detecção e quantificação foram de 0,005 % (v/v) e 0,01 % (v/v), respectivamente. Nas condições experimentais otimizadas, o sensor amperométrico foi utilizado para o monitoramento da concentração de etanol no ar exalado (BrAC), que foi convenientemente coletado em um balão de borracha (V = 3 L) e introduzido em uma solução de NaOH 1 mol L-1 (V = 10 mL). O sensor apresentou uma faixa linear para concentrações de etanol em ar exalado na faixa de 0,26 – 130 mg L-1, operando de acordo com os parâmetros analíticos especificados na Legislação Brasileira para a quantificação de etanol no ar exalado em condutores de veículos automotores. A constante de eliminação de etanol do corpo humano também foi investigada e os resultados concordaram com os valores da literatura. Empregando-se eletrodos de Cu e Au foram também desenvolvidas outras metodologias para a quantificação de dipirona, glicose e ácido ascórbico e sistemas em fluxo. Estudos sobre o desenvolvimento e propriedades de um sistema gerador-coletor foram realizados e o dispositivo foi utilizado em titulações de substâncias redutoras com iodo gerado eletroquimicamente. / A copper disc working electrode in alkaline solutions was demonstrated to act as a suitable amperometric sensor for ethanol determination at +0.6 V vs Ag/AgCl. The participation of free-soluble Cu(III) species in the electrocatalytic process involving the anodic oxidation of ethanol has been demonstrated by rotating ring-disc electrode voltammetry. The influence of the pretreatment potential on the anodic signal was investigated and a correlation with the morphology of the electrode surface characterized by Energy Dispersive X-Ray Spectroscopy (EDS) indicated that the Cu(III) species is originated from the oxidation of a CuO layer. Ethanol measurements were performed in the amperometric mode at 0.6 V (vs Ag/AgCl). The repeatability of the measurements for a 0.05 % aqueous ethanol solution was estimated as 3 %, and the detection and quantification limits were determined as 0.005 % and 0.01 %, respectively. At the optimum experimental conditions, the amperometric sensor was used to monitor the concentration of ethanol in breath (BrAC), which was conveniently collected in a rubber air balloon (volume = 3 L) and introduced in a 1 mol L-1 NaOH working solution (volume = 10 mL). The sensor can measure a person\'s breath ethanol over the concentration range 0.26 - 130 mg L-1 by operating it according to an established protocol, of which the analytical parameters are specified by the Brazilian Legislation for BrAC measurements in drivers. The rate of ethanol degradation in the body was followed, and the results agree with predictions in the literature. Methodologies for the determination of dipyrone, glucose and ascorbic acid were also developed by using Cu and Au electrodes. Features of a dual-band electrochemical cell were investigated towards the development of a generator-collector system, which was employed in titrations with electrogenerated iodine.

Sélectionner des traitements de surface pour l’industrie nécessite de prendre en compte : les propriétés à conférer au substrat, la nature et la géométrie de celui-ci et les caractéristiques du milieu extérieur. Certaines combinaisons de ces paramètres rendent difficile la sélection d’un traitement unique, d’où le recours à des multitraitements de surface. Dès lors, se posent les questions suivantes : - Utiliser des multitraitements de surface peut se faire en scindant les différentes requêtes en sous-ensembles, de manière à ce que chaque traitement réponde à l’un d’eux. Dans quel ordre ces requêtes doivent-elles être introduites par rapport au substrat ? - Comment sélectionner les traitements de surface répondant à chaque requête individuelle ? - Comment classer des multitraitements en termes d’adéquation au problème posé ? Dans ce travail, les première et troisième questions sont abordées, en explorant les requêtes concernant habituellement les dispositifs de moulage de l’aluminium : - Résistance aux contraintes d’origine thermique. - Résistance à la corrosion par les métaux fondus. - Résistance au frottement. L’analyse de la bibliographie relative aux traitements de surface utilisés dans ces systèmes a été analysée et des « architectures »-types ont été identifiées (chapitre 3). On prévoit, par exemple, un traitement conférant la résistance à la fatigue superficielle, ainsi qu’un revêtement étanche et résistant à l’aluminium fondu. Une barrière thermique est parfois préconisée. Pour chacune des architectures, des traitements de surface individuels peuvent être sélectionnés. Un « facteur de performance » permettant de classer les solutions par rapport au problème de la fatigue thermique a été construit (chapitre 4) et discuté dans deux situations : - Lorsqu’un revêtement est présent, et que les contraintes d’origine thermique (différence de dilatation thermique couche-substrat) menacent de le rompre lors de l’immersion dans un milieu corrosif à haute température. Des essais de corrosion dans de l’aluminium fondu ont été réalisés sur un acier revêtu par du nitrure de chrome dopé à l’aluminium, synthétisé par déposition physique en phase vapeur (chapitre 5 – collaboration : Inasmet). - Lorsque des variations thermiques rapides menacent de rompre le substrat et la (les) couches. Des essais de fatigue thermique ont été réalisés sur de l’acier à outils pour travail à chaud non traité, boruré ou recouvert d’un multitraitements (zircone yttriée / NiCrAlY / boruration / acier). Le revêtement en zircone yttriée a été obtenu par projection par plasma. L’essai de fatigue thermique a été modélisé et le facteur de performance, discuté (chapitre 6). Au chapitre 7, les architectures-types ont été introduites dans une méthodologie de sélection des multi-traitements de surface, qui a été appliquée dans deux cas : - Celui des moules de fonderie, devant résister à la fatigue thermique et à la corrosion par l’aluminium fondu. Le facteur de performance a été extrapolé à d’autres situations qu’aux chapitres 5 et 6. Les solutions habituellement proposées pour résoudre ce problème sont retrouvées. - Celui de deux pièces en acier frottant l’une contre l’autre en présence d’aluminium fondu. To select surface treatments, one must account for the required functional properties, the substrate features and the solicitations the substrate must endure. Certain combinations of these parameters make it difficult to select a single surface treatment, a reason why several successive treatments are preferred. To select them, one needs to determine: - How to divide the several requests into groups and how to stack up these groups from the substrate to the outer surface, so that each treatment deals with one specific group of requests/properties. - How to select individual layers for each group of properties. - How to rank the multi-treatments in terms of relevance for a given application. In this work, one tries to answer the first and the third questions, by studying the case of aluminium foundry, in which the industrial devices frequently face the following solicitations: - Thermal stress (thermal fatigue, thermal expansion mismatch). - Presence of corrosive molten metal. - Sliding wear. In the literature, several “standard” architectures are proposed (chapter 3), like a diffusion layer reducing superficial fatigue plus a corrosion barrier layer. A thermal barrier coating is also sometimes proposed. For each of these architectures, one can select individual treatments. To rank them, one devised a “performance index” for thermal stress (chap.4), which is discussed for two cases: - For large differences between layer and substrate thermal expansion coefficients, when both are put into contact with a high temperature corrosive medium, the layer may be damaged. One discusses this case by examining the corrosion caused by molten aluminium for a steel substrate coated by anticorrosive chromium nitride doped with aluminium. The layer is produced by physical vapour deposition (chap. 5 – cooperation: Inasmet). - Repeated fast surface temperature transients can also damage the substrate and/or the layer by thermal fatigue. One conducted thermal fatigue tests with samples of hot work tool steel, respectively untreated, simply borided and protected by a multilayer. In the last case, top coat is yttria stabilised zirconia, followed by a nickel superalloy and then a borided layer (undercoat). One synthesized the zirconia coating by plasma spray and one modelled the thermal fatigue (chap. 6). In chap. 7, architectures from chap. 2 are introduced in a multi-treatment selection routine, which is applied in two cases: - Foundry moulds for molten aluminium, withstanding both thermal fatigue and corrosion. The devised performance index is extrapolated beyond the tests of chap. 5 and 6 to treatments for this industrial application, thereby quantifying their respective merits. - A foundry device exposed to molten metal and sliding wear.

Sélectionner des traitements de surface pour l’industrie nécessite de prendre en compte :les propriétés à conférer au substrat, la nature et la géométrie de celui-ci et les caractéristiques du milieu extérieur. Certaines combinaisons de ces paramètres rendent difficile la sélection d’un traitement unique, d’où le recours à des multitraitements de surface. Dès lors, se posent les questions suivantes :<p>- Utiliser des multitraitements de surface peut se faire en scindant les différentes requêtes en sous-ensembles, de manière à ce que chaque traitement réponde à l’un d’eux. Dans quel ordre ces requêtes doivent-elles être introduites par rapport au substrat ?<p>- Comment sélectionner les traitements de surface répondant à chaque requête individuelle ?<p>- Comment classer des multitraitements en termes d’adéquation au problème posé ?<p>Dans ce travail, les première et troisième questions sont abordées, en explorant les requêtes concernant habituellement les dispositifs de moulage de l’aluminium :<p>- Résistance aux contraintes d’origine thermique.<p>- Résistance à la corrosion par les métaux fondus.<p>- Résistance au frottement.<p>L’analyse de la bibliographie relative aux traitements de surface utilisés dans ces systèmes a été analysée et des « architectures »-types ont été identifiées (chapitre 3). On prévoit, par exemple, un traitement conférant la résistance à la fatigue superficielle, ainsi qu’un revêtement étanche et résistant à l’aluminium fondu. Une barrière thermique est parfois préconisée.<p>Pour chacune des architectures, des traitements de surface individuels peuvent être sélectionnés. Un « facteur de performance » permettant de classer les solutions par rapport au problème de la fatigue thermique a été construit (chapitre 4) et discuté dans deux situations :<p>- Lorsqu’un revêtement est présent, et que les contraintes d’origine thermique (différence de dilatation thermique couche-substrat) menacent de le rompre lors de l’immersion dans un milieu corrosif à haute température. Des essais de corrosion dans de l’aluminium fondu ont été réalisés sur un acier revêtu par du nitrure de chrome dopé à l’aluminium, synthétisé par déposition physique en phase vapeur (chapitre 5 – collaboration :Inasmet).<p>- Lorsque des variations thermiques rapides menacent de rompre le substrat et la (les) couches. Des essais de fatigue thermique ont été réalisés sur de l’acier à outils pour travail à chaud non traité, boruré ou recouvert d’un multitraitements (zircone yttriée / NiCrAlY / boruration / acier). Le revêtement en zircone yttriée a été obtenu par projection par plasma. L’essai de fatigue thermique a été modélisé et le facteur de performance, discuté (chapitre 6).<p>Au chapitre 7, les architectures-types ont été introduites dans une méthodologie de sélection des multi-traitements de surface, qui a été appliquée dans deux cas :<p>- Celui des moules de fonderie, devant résister à la fatigue thermique et à la corrosion par l’aluminium fondu. Le facteur de performance a été extrapolé à d’autres situations qu’aux chapitres 5 et 6. Les solutions habituellement proposées pour résoudre ce problème sont retrouvées.<p>- Celui de deux pièces en acier frottant l’une contre l’autre en présence d’aluminium fondu.<p><p>To select surface treatments, one must account for the required functional properties, the substrate features and the solicitations the substrate must endure. Certain combinations of these parameters make it difficult to select a single surface treatment, a reason why several successive treatments are preferred. To select them, one needs to determine:<p>- How to divide the several requests into groups and how to stack up these groups from the substrate to the outer surface, so that each treatment deals with one specific group of requests/properties.<p>- How to select individual layers for each group of properties.<p>- How to rank the multi-treatments in terms of relevance for a given application.<p>In this work, one tries to answer the first and the third questions, by studying the case of aluminium foundry, in which the industrial devices frequently face the following solicitations:<p>- Thermal stress (thermal fatigue, thermal expansion mismatch).<p>- Presence of corrosive molten metal.<p>- Sliding wear.<p>In the literature, several “standard” architectures are proposed (chapter 3), like a diffusion layer reducing superficial fatigue plus a corrosion barrier layer. A thermal barrier coating is also sometimes proposed.<p>For each of these architectures, one can select individual treatments. To rank them, one devised a “performance index” for thermal stress (chap.4), which is discussed for two cases:<p>- For large differences between layer and substrate thermal expansion coefficients, when both are put into contact with a high temperature corrosive medium, the layer may be damaged. One discusses this case by examining the corrosion caused by molten aluminium for a steel substrate coated by anticorrosive chromium nitride doped with aluminium. The layer is produced by physical vapour deposition (chap. 5 – cooperation: Inasmet).<p>- Repeated fast surface temperature transients can also damage the substrate and/or the layer by thermal fatigue. One conducted thermal fatigue tests with samples of hot work tool steel, respectively untreated, simply borided and protected by a multilayer. In the last case, top coat is yttria stabilised zirconia, followed by a nickel superalloy and then a borided layer (undercoat). One synthesized the zirconia coating by plasma spray and one modelled the thermal fatigue (chap. 6).<p>In chap. 7, architectures from chap. 2 are introduced in a multi-treatment selection routine, which is applied in two cases:<p>- Foundry moulds for molten aluminium, withstanding both thermal fatigue and corrosion. The devised performance index is extrapolated beyond the tests of chap. 5 and 6 to treatments for this industrial application, thereby quantifying their respective merits.<p>- A foundry device exposed to molten metal and sliding wear.<p><p> / Doctorat en Sciences de l'ingénieur / info:eu-repo/semantics/nonPublished