In comparison with Si-based converters, the emerging Medium Voltage (MV) SiC-based converters can achieve higher blocking voltage capability, lower on-resistance, faster switching speed with less switching related losses and run under higher temperature. Thus, theoretically, it can achieve much higher power density, which becomes very promising for future power transmission and distribution. However, in order to achieve the desired high power density, insulation system of the MV SiC-based converter must be compact. Therefore, challenges for the insulation system gradually appeared, as the insulation size becomes smaller and the Electric field (E-field) intensity significantly increases. Under such high E-field intensity, it is necessary and important to eliminate Partial Discharge (PD) for such power converters, since the converter system is vulnerable to PDs. Developing an insulation design, assessment and online monitoring method to help reach a compact and PD free insulation system for MV SiC-based converters is a goal of this work. General insulation design and assessment guidelines based on experimental PD investigation and physics-based model –Experimental PD investigation is completed for internal void discharge, surface discharge, and point discharge representative coupons under square excitations. Based on the data and the existing knowledge about PD mechanisms, widely accepted PD models are selected. Using these physics-based models, simulation results can demonstrate the major features observed in the experiments. With the experimental data and valid PD models, several general insulation design and assessment guidelines are proposed, which could be further applied during converter prototypes development. Partial Discharge elimination methodology and design examples – By using the laminated bus as the design example, internal void evaluation and analysis method is demonstrated. Then, targeting the internal PD-free design with reasonable insulation thickness, several insulation improvement methods are applied and experimentally verified by using representative coupons. After understanding the possible ways for evaluating and eliminating internal voids, a PCB-based planar bus is designed and fabricated, which shows great insulation improvement after experimental verification. In order to eliminate PDs in the air and shrink the insulation distance, three ways for managing E-field distribution in air are demonstrated by three examples. First, by using the interconnections among the power modules, Rogowski-based current-sensing board, and the laminated bus as an example, E-field distribution can be estimated by Finite Element Analysis (FEA) and its management can be achieved by geometrical modifications. Second, for the one-turn inductor, a methodology is demonstrated that builds a coaxial insulation structure with proper termination technology in order to squeeze air out of the insulation system. Finally, E-field shielding technology is applied along the heatsink edges in order to make the E-field distribution uniform and to shrink the insulation distance between the heatsink and the cooling system. After improving the insulation, this work shrinks the converter unit size by around 50% while maintaining its PD-free status under normal operation conditions. Besides the significant increase in power density and weight reduction, the entire converter system has less ringing and better current-sharing performance due to reductions of the parasitic inductance. Partial Discharge online monitoring via acoustic and photon detection methods –Targeting the online monitoring and even localization of surface discharge for power converter applications, two novel types of sensors have been proposed and fabricated. In order to verify the concepts, one example with experimental results has been given for each type of sensor. The experimental data demonstrates that such sensors can be placed inside the converter and online monitoring can be realized for surface or corona discharges by capturing either the acoustic signal or the photons that are generated by discharge events. / Doctor of Philosophy / A unproper designed insulation system can take more than 50% volume of Medium Voltage (MV) SiC-based converters and have significant internal or external Partial Discharge (PD), which can not only accelerate the insulation aging but also risk to multiple aspects of the converter system. Therefore, developing an insulation design, assessment and online monitoring method to help reach a compact and PD free insulation system for MV SiC-based converters is a goal of this work. Experimental PD investigation is completed for internal void discharge, surface discharge, and point discharge representative coupons under square excitations. Several general insulation design and assessment guidelines are proposed based on the experimental PD investigation and physics-based explanations, which are further applied during converter prototypes development. Then, PD elimination methodology is developed and demonstrated by design examples. By using the laminated bus as an example, internal void evaluation and analysis method is demonstrated. Then, targeting the internal PD-free design with reasonable insulation thickness, several insulation improvement methods are applied and experimentally verified by using representative coupons. In order to eliminate PDs in air and shrink the insulation distance, three ways for managing E-field distribution in air are demonstrated by three examples. First, by using the interconnections among the power modules, Rogowski-based current-sensing board, and the laminated bus as an example, E-field distribution can be estimated by Finite Element Analysis (FEA) and its management can be achieved by geometrical modifications. Second, for the one-turn inductor, a coaxial insulation structure with proper termination technology in order to squeeze air out of the insulation system is demonstrated. Finally, E-field shielding technology is applied along the heatsink edges in order to make the E-field distribution uniform and to shrink the insulation distance between the heatsink and the cooling system. After improving the insulation, this work shrinks the converter unit size by around 50% while maintaining its PD-free status under normal operation conditions. Besides the significant increase in power density and weight reduction, the entire converter system has less ringing and better current-sharing performance due to reductions of the parasitic inductance. Targeting the PD online monitoring for power converter applications, two novel types of sensors have been proposed and fabricated. In order to verify the concepts, one example with experimental results has been given for each type of sensor. The experimental data demonstrates that such sensors can be placed inside the converter and online monitoring can be realized for surface or corona discharges by capturing either the acoustic signal or the photons that are generated by discharge events.

The thesis deals with the analysis of quality management system in a selected organization and with tasks assigned by the organization's quality manager. The company is Aspera, spol. s r.o., specifically its metal manufacturing centre Aspera Technology in České Budějovice. The thesis is divided into a theoretical and a practical part. The theoretical part is based on study of scientific literature and focuses on quality definition, history of quality management, quality management system principles and concepts and quality management tools, especially process flowchart, Pareto diagram and FMEA. The practical part describes the company, its manufacturing centre and its quality management system. The next part deals with the three assigned tasks. First, designated company processes are described and visualized in the form of flowcharts. Second, weak points and risks of these processes are analysed using FMEA and corrective actions are recommended. Third, the most significant internal defects are identified using Pareto chart and cost analysis. At the end of the thesis some suggestions for improvement are provided. The suggestions were observed during an internship in the company and should enhance the quality management system and help the overall operation of the company processes.

L’excellente coulabilité, les coûts de production relativement bas, et ratio poids/résistance mécanique élevé des alliages de fonderie Al-Si-Mg en font une des solutions les plus intéressantes dans le secteur automobile ainsi que dans le domaine aérospatial. Toutefois, il est bien connu que la durée de vie de ces composants moulés à grand nombre de cycles (105 < Nf < 107 cycles) est sévèrement réduite lorsque des défauts de fonderie (notamment pores et oxydes) sont débouchants et/ou subsurfaciques sont présents. Ces défauts concentrent les contraintes et peuvent considérablement réduire la période d’amorçage des fissures de fatigue en fonction de leur taille, forme et des caractéristiques microstructurales du matériau. Les défauts internes (à partir desquels les fissures peuvent amorcer et propager sans interaction avec l’air ambiant) ainsi que les défauts de surface (ceux qui sont placés à la surface et en contact direct avec l’air ambiant) vont également nuire la durée de vie des composants moulés. Toutefois, dans le cas des défauts internes, les coefficients de sécurité préconisés par les règles de conception ne font pas intervenir la distance de défaut par rapport à la surface. Le suivi de fissures de fatigue effectué à la surface d’éprouvettes macroscopiques de traction indique que la présence d’un défaut avec une taille supérieure à celle des fissures microstructuralement courtes (√A ≈ 500 μm, taille contrôlée par la SDAS) produit une remarquable réduction de la durée vie. En revanche, la durée de vie n’est pas affectée lorsqu’un défaut plus petit (√A ≈ 300 μm) est présent à la surface car l’amorçage et les premiers stades de propagation sont encore influencés par la SDAS. Les essais de fatigue en torsion pure montrent que la morphologie des surfaces de rupture est fortement influencée par le niveau de contrainte. De plus, le nombre de cycles à l’amorçage est réduit par rapport à la traction. Cet amorçage est multi-site et plusieurs fissures peuvent croitre simultanément au cours de la durée de vie d’une éprouvette, la rupture finale se produisant lors de la jonction de certaines de ces fissures. La propagation des fissures en torsion est largement influencée par la cristallographie locale et les retassures ne semblent pas être des sites de nucléation préférentiels. Les durées de vie odes échantillons macroscopiques contenant défauts artificiel internes (Øeq ≈ 2 mm) sont pratiquement similaires à celles obtenues avec un matériau de référence. L’amorçage et la propagation de fissures internes a été rarement observé lors des expériences de tomographie synchrotron. Dans les rares cas où de telles fissures ont pu être observées, le chemin de fissuration semble fortement influencé par la cristallographie alors que les fissures amorcées depuis la surface se propagent globalement en mode I. La vitesse de propagation des fissures internes est très inférieure à celle des fissures se propageant à partir de la surface. / The excellent castability, relatively low production costs, and high strength to weight ratios make Al-Si-Mg cast alloys an attractive choice for use in cheaper and lighter engineering components, in both automotive and aerospace industries. However, it is well known that High Cycle Fatigue (HCF) lives (105 < Nf < 107 cycles) of cast components are severely reduced when casting defects (notably pores and oxides) are present at the free surface or subsurface. They act as stress raisers which can considerably reduce the crack incubation period depending on their size, shape and the microstructural features of the surrounding material. Internal casting defects are of special interest to this work. The application of safety coefficients considers that all casting defects present in a component have the same deleterious effect and no attention is paid, for example, to their distance to the free surface. In other words, internal defects (corresponding to the case where the depth of the defect allows crack nucleation and propagation to essentially occur without interaction with the air environment) are considered as damaging to fatigue life as surface defects (those placed at the free surface and in contact with the air environment). Surface crack monitoring performed on uniaxial fatigue specimens indicates that the presence of a surface microshrinkage exceeding the size of microstructurally small cracks (√A ≈ 500 μm, controlled by the SDAS) readily nucleates a fatigue cracks producing steady crack propagation and remarkable reduction in the expected fatigue life. A smaller surface defect (√A ≈ 300 μm) nucleated a crack that did not reduced the expected fatigue life as in this case early stages of propagation are still nfluenced by the SDAS. Pure torsional cycling reveals that the morphology of fracture surfaces is highly influenced by the stress level. In general, torsional fatigue behaviour is described by having reduced (with respect to uniaxial testing) and multisite crack nucleation periods. Several dominant cracks can evolve simultaneously and the final failure occurs by the linkage of some of those cracks. Crack propagation is controlled by the crystallography and pores do not appear to be preferential nucleation sites. S-N curves show that macroscopic specimens containing Øeq ≈ 2 mm internal artificial defect produce similar fatigue lives to those obtained with a defect-free material. Internal crack nucleation was rarely observed during synchrotron tomography experiments; instead the fatal cracks initiated from much smaller surface defects. Tomographic images show that, in the case of internal propagation, crystallographic paths are formed while surface cracks propagate in mode I. The crack growth rate of internal cracks is much smaller than that of cracks propagating from the free surface.

This thesis deals with solving the most serious internal defects in castings made of aluminum alloys which are cast in sand molds in Slévárna a modelárna Nové Ransko Ltd. The problem solving contains a description of the problematic castings with the investigation of the structure and phases and subsequent detailed analysis of their production. The Author of this thesis also examines the influence of Fe and Mn on a possible formation of the internal porosity with the help of test meltings with the evaluation of the internal structural change. The Author’s design solution is a close checking of chemical composition with regard to the ratio Mn / Fe present in the alloy, the purchase of Foundry Degassing Unit to reduce gassiness of melted metals and better control of gassiness with the help of the appropriate equipment for the density Dichte index.