Additive Manufacturing (AM) is a group of manufacturing technologies which are capable to produce 3D solid parts by adding successive layers of material. Parts are fabricated in an additive manner, layer by layer; and the geometric data can be taken from a CAD model directly. The main revolutionary aspect of AM is the ability of quickly producing complex geometries without the need of tooling, allowing for greater design freedom. As one of AM methods, Selective Laser Melting (SLM) is a process for producing metal parts with minimal subtractive post-processing required. It relies on the generation and distribution of laser generated heat to raise the temperature of a region of a powder bed to above the melting point. Due to high energy input to enable full melting of the powder bed materials, SLM is able to build fully dense metal parts without post heat treatment and other processing. Successful fabrications of parts by SLM require a comprehensive understanding of the main process controlling parameters such as energy input, powder bed properties and build conditions, as well as the microstructure formation procedure as it can strongly affect the final mechanical properties. It is valuable to control the parts' microstructure through controlling the process parameters to obtain acceptable mechanical properties for end-users. In the SLM process, microstructure characterisation strongly depends on the thermal history of the process. The temperature distribution in the building area can significantly influence the melting pool behaviour, solidification process and thermal mechanical properties of the parts. Therefore, it is important to have an accurate prediction of the temperature distribution history during the process. The aim of this research is to gain a better understanding of process control parameters in SLM process, and to develop a modelling methodology for the prediction of microstructure forming procedure. The research is comprised of an experiment and a finite element modelling part. Experimentation was carried out to understand the effect of each processing control parameters on the final part quality, and characterise the model inputs. Laser energy input, build conditions and powder bed properties were investigated. Samples were built and tested to gain the knowledge of the relationship between samples' density and mechanical properties and each process control factor. Heat transfer model inputs characterisation, such as defining and measuring the material properties, input loads and boundary conditions were also carried out via experiment. For the predictive modelling of microstructure, a methodology for predicting the temperature distribution history and temperature gradient history during the SLM process has been developed. Moving heat source and states variable material properties were studied and applied to the heat transfer model for reliable prediction. Multi-layers model were established to simulate the layer by layer process principles. Microstructure was predicted by simulated melting pool behaviour and the history of three dimensional temperature distribution and temperature gradient distribution. They were validated by relevant experiment examination and measurement.

With the development of electricity transmission systems, more and more insulators have been used in the system to isolate the high potential conductors from the earth. In order to secure the reliability of power system, it is necessary to understand the ageing mechanism of the insulators. A model for energy (heat) transfer between low current discharges and insulation surfaces has been built in this project which contributes to the understanding and prediction of insulator ageing. Within the experimental work, the temperature of low current discharges under different conditions has been measured with the “Best-fit” method. The temperature was found to vary between 1200 K and 2300 K with current level, sub cycle duration, gap length, electrode conductivity and polarity of DC discharges. The discharge temperature increases with the growth of current and sub cycle duration by means of the elevation of energy, while the discharge temperature is hotter between salt water droplets than between tap water droplets even though the former has a lower energy (I^2 Rt). The temperature is insensitive to a change of gap length and a positive discharge has a higher temperature than an equivalent negative one. The specific measurement shows the middle part is hotter than the electrode areas. Within the simulation work, the presence of water droplet(s) on the insulation surface concentrates and enhances the electric field over the surface which increases the risk of partial discharge. For practical insulators, this means the core, rather than the sheds, suffers more from discharges between water droplets as they are aligned to the electric field. This highlights the importance of keeping the core dry. The simulation of heat transfer between low current discharges insulation surface was achieved using COMSOL software. The simulated results show that the surface temperature increases rapidly in the first few seconds and arrives at a thermal equilibrium state after 20 seconds of discharge, which meets the experimental observation. The insulation surface temperature distribution under AC discharge is symmetric and the surface centre has the highest temperature which decreases towards the water droplets. In DC, the surface around the cathode is the hottest and the anode area is the coldest.

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Finite element models of friction welding can be used to estimate internal conditions of welds which are useful for weld analysis and developing experimental welding procedures. Many modeling techniques are used to accomplish these goals, each with relative strengths and weaknesses. A comparative analysis of friction welding models using different heat generation methods is presented. The three different heat generation methods examined were viscoplastic friction, constant steady-state generation, and experimentally measured power data. The models were compared against each other using three output measurements: temperature, axial force, and upset. The friction model predicted temperatures within 40 degrees C. Temperature accuracy improved at a higher upset rate and higher spindle speed, when weld samples heated up faster. The model was excellent at predicting upset, with accuracy within 1.5%. Maximum force was predicted within 9-18%. The constant heat generation model typically predicted temperatures within 30 degrees C. Upset was estimated within 7%. Maximum force was predicted within 12% at high feed rates, but accuracy dropped to 28% when feed rate was reduced. The motor power model was the most accurate model at estimating temperature, with a typical accuracy within 25 degrees C. Axial upset was predicted within 5%. Maximum force was predicted within 1-8%, with greater accuracy occurring at higher feed rates.

Målet med detta examensarbete var att utforma ett koncept för friktionsmätning i trycksatt ångmiljö mellan materialparen trä/metall och metall/metall. Krav på konstruktionen var att hastigheten skulle kunna regleras mellan 0-100 meter per sekund under sex bars övertryck i 100 % luftfuktighet vid temperatur upptill 180 grader Celsius till uppdragsgivaren Mittuniversitetet i Sundsvall. Arbetets utförande redovisas i denna rapport, målet är att utforma ett koncept, utforma en 3D modell av konceptet, utföra hållfasthetsberäkning som stöder att konceptet kan utstå specificerad belastning och undersöka om formförändringar av trycksatts anordning har en inverkan på de spänningar som uppstår. För att uppnå målet att utforma ett koncept användes en designprocess innehållande funktionsanalys, idégenerering enligt brainstorming och konceptutvärdering med beslutsmatris som resulterade i ett koncept för friktionsmätning där vissa komponenter definierades med krav och dimensionering av drivlina utfördes med programmet Gates Design flex Pro. Som metod för att konstruera en 3D-modell användes programmet Solidworks, för att undersöka konceptets hållfasthet utfördes dimensionering till en början med beräkningsprogrammet Matlab där materialet EN 1.4571 användes, därefter utfördes simuleringar med Solidworks för att undersöka egenfrekvenser hos utvalda komponenter av konstruktionen och hållfasthetsberäkningar. Hållfasthetsberäkningarna och undersökning av inverkan av formförändringar av inre hörn utfördes i Solidworks där tryck och temperatur tillsattes på tryckkärlets insida. Resultatet var att konceptet inte riskerar att hamna i egenfrekvens, konceptet kan i teorin producera hastigheten 101,64 meter per sekund. Maximal spänning enligt beräkningar i Matlab var 40,02 MPa, motsvarande värde vid simulering i Solidworks var 38,16 MPa. Vid undersökning av formförändring av inre hörn hos trycksatt anordning blev resultatet att en radie på 25 millimeter vid de inre hörnen hos tryckkärl gav en spänningsreducering på 29,5% och en minskning av utböjning med 12.5%. Projektet har lyckats med att uppfylla sina mål och kan i teorin producera den hastighet som efterfrågades, utstå de förhållanden som efterfrågas och utföra friktionstest med både materialen metall och trä.

The purpose of this study is to investigate small features in CAD geometries which have high influence on computational time and memory consumption during electromagnetic simulations using CAE software. Computational Electromagnetics (CEM) simulations of complex CAD geometries like passenger cars crash often simulations remain incomplete due to a lot of irrelevant details. The key to eliminating the limitations enumerated above is to remove irrelevant details in CAD geometries within the acceptable margin of accuracy. The maximum 5% percentage of error in accuracy during Computational Electromagnetics (CEM) simulations is compromised. CAD geometry is transferred into CAE geometry. The modification of geometry is done by removing irrelevant details to get optimal mesh and improve the computational time and memory consumption during simulations with ANSA and HYPERMESH software at their best potential. At the end, electromagnetic simulations are done on original and simplified CAD models in CST and in COMSOL. Only magnetic flux density distribution across the modified and unmodified CAD model by cut points 3D on different coordinate positions is analysed. The results are compared with quality of mesh in terms of accuracy and reduction in computational time and memory. The features in CAD geometries are identified, these features can be removed and computational time and memory consumption reduced with minimum loss of accuracy during simulation.

This dissertation focuses on studying membrane air dehumidification for a membrane moisture exchanger in a membrane heat pump system. The study has two parts: an optimization of membrane moisture exchanger for air dehumidification in the macroscale, and diffusion of water vapor in polymer nanocomposites membrane for humid air dehumidification in the nanoscale. In the first part of the research, the mass transport of water vapor molecules through hydrophilic silica nanochannel chains in hydrophobic polyurethane matrix was studied by simulations and experiments for different membrane moisture exchanger design configurations. The mass transport across the polymer nanocomposite membrane occurs with the diffusion of moist air water vapor molecules in the membrane moisture exchanger in a membrane heat pump air conditioning system for air dehumidification purposes. The hydrophobic polyurethane matrix containing the hydrophilic silica nanochannel chains membrane is responsible for transporting water vapor molecules from the feed side to the permeate side of the membrane without allowing air molecules to pass through.In the second part of the research, diffusion analysis of the polymer nanocomposite membrane were performed in the nanoscale for the polymer nanocomposite membrane. The diffusion phenomena through the polymer, the polymer nanocomposite without modifying the silica surfaces, and the polymer nanocomposite with two different silica modified surfaces were studied in order to obtain the highest water vapor removal through the membrane. Different membrane moisture exchanger configurations for optimal water vapor removal were compared to get the desired membrane moisture exchanger design using the finite element method (FEM) with the COMSOL Multiphysics software package. The prediction of mass transport through different membrane configurations can be done by obtaining the mass flux value for each configuration. An experimental setup of one membrane moisture exchanger design was introduced to verify the simulation results. Also, for different membrane structures, permeability was measured according to the ASTM E-96 method. The prediction of water vapor diffusion through the polymer nanocomposite was studied by molecular dynamics simulation with the MAPS 4.3 and LAMMPS software packages. As a new nanocomposite material used in air dehumidification application, water vapor diffusivity through Silica-Polyurethane nanocomposite membranes was measured by the random movement of water vapor molecules through the formed nanochannels in the nanocomposite. For the diffusivity value, the Einstein's relationship was employed for the movement of each single water vapor molecule during the simulation time for all suggested membranes. The results of the proposed research will contribute to enhancing the energy efficiency of air conditioning systems by choosing the membrane moisture exchanger configuration which maximizes water vapor removal while, at the same time, enhancing the silica surfaces with the desired surface modifier that will maximize diffusion through the membrane itself.

<p>There are significant problems during construction to establish an adequate foundation for fills and/or subgrade for pavements when the natural ground has low-bearing soils. Geosynthetics such as geogrids, geotextiles and/or geocells could provide an alternative, less costly in time and money, to establish an adequate foundation for the fill and/or subgrade. There is extensive evidence in the literature and on DOTs practices about the suitability of using geotextiles in pavements as separators. Previous studies have also shown that the use of geogrids in flexible pavements as a reinforcing mechanism could decrease the thickness of the base layer and/or increase the life of the pavement. In this study, analyses of selected pavement designs using Pavement ME, while considering geogrid-enhanced base or subgrade resilient modulus values, showed that geogrid-reinforcement, when placed at the interface between subgrade and base, did not produce significant benefits, as only a modest increase in pavement life was predicted. In addition, parametric finite element analyses were carried out to investigate the potential benefits of placing a geogrid at the base of a fill over a localized weak foundation zone. The analyses showed that the use of geogrids is beneficial only when: (a) the stiffness of the weak foundation soil is about an order of magnitude smaller than the rest of the foundation soil; and (b) the horizontal extent of the weak foundation soil is at least 30% of the base of the embankment foundation. The largest decrease in differential settlements at the surface of the fill, resulting from geogrid-reinforcement, was less than 20% and, therefore, it is unlikely that the sole use of geogrids would be sufficient to mitigate differential settlements. Based on previous studies, a geocell mattress, which is a three-dimensional geosynthetic filled with different types of materials, could act as a stiff platform at the base of an embankment and bridge over weak zones in the foundation. However, given the limited experience on the use of geocells, further research is required to demonstrate that geocells can be effectively used instead of other reinforcement methods.</p>

Being a widely used structure, composite shells have been studied for a long time. The features of small thickness, heterogeneity, and anisotropy of composite shells have created many challenges for analyzing them. A number of theories have been developed for modeling composite shells, while they are either not practical for engineering use, or rely on assumptions that do not always hold. Consequently, a better theory is needed, especially for the application on challenging problems such as shells involving thermoelasticity, viscoelasticity, or viscoplasticity.<br><br>In this dissertation, a shell theory based on mechanics of structure genome (MSG), a unified theory for multiscale constitutive modeling, is developed. This theory is capable of handling fully anisotropy and complex heterogeneity, and because the derivation follows principle of minimum information loss (PMIL) and using the variational asymptotic method (VAM), high accuracy can be achieved. Both a linear version and a nonlinear version using Euler method combined with Newton-Raphson method are presented. This MSG-based shell theory is used for analyzing the curing process of composites, deployable structures made with thin-ply high strain composite (TP-HSC), and material nonlinear shell behaviors.<br><br>When using the MSG-based shell theory to simulate the curing process of composites, the formulation is written in an analytical form, with the effect of temperature change and degree of cure (DOC) included. In addition to an equivalent classical shell theory, a higher order model with the correction from initial geometry and transverse shear deformation is presented in the form of the Reissner-Mindlin model. Examples show that MSG-based shell theory can accurately capture the deformation caused by temperature change and cure shrinkage, while errors exist when recovering three-dimensional (3D) strain field. Besides, the influence of varying transverse shear stiffness needs to be further studied.<br><br>In order to analyze TP-HSC deployable structures, linear viscoelasticity behavior of composite shells is modeled. Then, column bending test (CBT), an experiment for testing the bending stiffness of thin panels under large bending deformation, is simulated with both quasi-elastic (QE) and direct integration (DI) implementation of viscoelastic shell properties. Comparisons of the test and analysis results show that the model is capable of predicting most of the measured trends. Residual curvature measured in the tests, but not predicted by the present model, suggests that viscoplasticity should be considered. A demonstrative study also shows the potential of material model calibration using the virtual CBT developed in this work. A deployable boom structure is also analyzed. The complete process of flattening, coiling, stowage, deployment and recovery is simulated with the viscoelastic shell model. Results show that major residual deformation happens in the hoop direction.<br><br>A nonlinear version of the MSG-based general purpose constitutive modeling code SwiftComp is developed. The nonlinear solving algorithm based on the combined Euler-Newton method is implemented into SwiftComp. For the convenience of implementing a nonlinear material model, the capability of using user material is also added. A viscoelastic material model and a continuum damage model is tested and shows excellent match when compared with Abaqus results with solid elements and UMAT. Further validation of the nonlinear SwiftComp is done with a nonlinear viscoelastic-viscoplastic model. The high computational cost is emphasized with a preliminary study with surrogate model.

The Hashin failure criteria and damage evolution model for laminated fiber reinforced polymers are explored. A series of tensile coupon finite element analyses are run to characterize the variables in the physical model as well as modeling techniques for using an explicit dynamic solver for a quasi-static problem. An attempt to validate the model on an axial tube crush is presented. It was found that fiber buckling was not occurring at the impactor-tube interface. Results and speculation as to why the failure initiation is incorrect are discussed. Lessons learned from the tube crush are applied successfully to the quasi-static Formula SAE nosecone crush test. The model is validated by experimental data and the impact metrics between the test and model are within 5%. Future work and possible optimization techniques are discussed.