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Induction hardening is a complex process that requires regular verification of the case depth and the microstructure. Today this verification is done by destructive testing where a cross section is analysed. The case depth is measured by several Vickers hardness impressions and the microstructure is analysed by a light optic microscope. This master thesis was performed in collaboration with Volvo GTO in Skövde, with the target to find out if an ultrasonic backscattering method is usable for analysing the case depths on induction hardened crankshafts. This was done by verifying the results provided by ultrasonic testing with the results provided by destructive testing. The measurements were done on several crankshafts with different case depths and steel composition. The result, for crankshafts with normal case depths, shows a good correlation between the destructive testing (DT) and the ultrasonic testing (UT). The mean value for the discrepancy was 0.39 mm with a standard deviation of 0.20 mm. The reproducibility of the method has a standard deviation of 0.074 mm.

Additive Manufacturing (AM) for metals includes is a group of production methodst hat use a layer-by-layer approach to directly manufacture final parts. In recent years, the production rate and material quality of additive manufactured materials have improved rapidly which has gained increased interest from the industry to use AM not only for prototyping, but for serial production. AM offers a greater design freedom, compared to conventional production methods, which allows for parts with new innovative design. This is very attractive to the aerospace industry, in which parts could be designed to have reduced weight and improved performance contributing to reduced fuel consumption, increased payload and extended flight range. There are, however, challenges yet to solve before the potential of AM could be fully utilized in aerospace applications. One of the major challenges is how to deal with the poor fatigue behaviour of AM material with rough as-built surface. The aim of this thesis is to increase the knowledge of how AM can be used for high performance industrial parts by investigating the fatigue behaviour of the titanium alloy Ti6Al4V produced with different AM processes. Foremost, the intention is to improve the understanding of how rough as-built AM surfaces in combination with AM built geometrical notches affects the fatigue properties.This was done by performing constant amplitude fatigue testing to compare different combinations of AM material produced by Electron Beam Melting(EBM) and Laser Sintering (LS) with machined or rough as-built surfaces with or without geometrical notches and Hot Isostatic Pressing (HIP) treatment. Furthermore, the material response can be different between constant amplitude and variable amplitude fatigue loading due to effects of overloads and local plastic deformations. The results from constant amplitude testing were used to predict the fatigue life for variable amplitude loading by cumulative damage approach and these predictions were then verified by experimental variable amplitude testing. The constant amplitude fatigue strength of material with rough as-built surfaces was found to be 65-75 % lower, compared to conventional wrought bar, in which HIP treatments had neglectable influence on the fatigue strength. Furthermore, the fatigue life predictions with cumulative damage calculations showed good agreement with the experimental results which indicates that a cumulative damage approach can be used, at least for a tensile dominated load sequences, to predict the fatigue behaviour of additive manufactured Ti6Al4V.

Generating gear grinding is a method used for hard machining of gearbox gears. It facilitates a productive gear manufacturing with tight tolerances regarding surface roughness and geometrical accuracy. However, if the grinding is done with incorrect parameters, so called grinding burns can arise with consequences such as changes in surface hardness, changes in residual stress levels, surface embrittlement and compromised fatigue strength. This thesis investigates the gear tooth quality resulting from grinding parameters contributing to an improved grinding time. A literature study will cover gear geometries and material, grinding wheel properties, influences by grinding parameters and several verification methods. An experimental test will then be used to put four different grinding parameters to the test. The results showed that an increased cutting speed indicated finer surface roughness andincreased Barkhausen noise but showed no influence on gear geometry. Increasing both rough and fine feed rates resulted in a minor increase in geometry deviation but no significant difference in surface roughness. Large variations within the different verification method results related to grinding burns madeit difficult to draw conclusions regarding the experimental factors chosen. However, several factors apart from the experimental ones varied in the testing were believed to have significant influence, such as the flow of the cooling fluidand the amount of retained austenite from the carburizing process. In fact, the trends which seemed to be connected to these factors could be seen in both Barkhausen noise analysis, hardness measurementsand microstructure.

Additive manufacturing (AM) is the name given to the technology of building 3D parts by adding layer-by-layer of materials, including metals, plastics, concrete, etc. Of the different types of AM techniques, electron beam melting (EBM), as a powder bed fusion technology, has been used in this study. EBM is used to build parts by melting metallic powders by using a highly intense electron beam as the energy source. Compared to a conventional process, EBM offers enhanced efficiency for the production of customized and specific parts in aerospace, space, and medical fields. In addition, the EBM process is used to produce complex parts for which other technologies would be either expensive or difficult to apply. This thesis has been divided into three sections, starting from a wider window and proceeding to a smaller one. The first section reveals how the position-related parameters (distance between samples, height from build plate, and sample location on build plate) can affect the microstructural characteristics. It has been found that the gap between the samples and the height from the build plate can have significant effects on the defect content and niobium-rich phase fraction. In the second section, through a deeper investigation, the behavior of Alloy 718 during the EBM process as a function of different geometry-related parameters is examined by building single tracks adjacent to each other (track-by-track) andsingle-wall samples (single tracks on top of each other). In this section, the main focus is to understand the effect of successive thermal cycling on microstructural evolution. In the final section, the correlations between the main machine-related parameters (scanning speed, beam current, and focus offset) and the geometrical (melt pool width, track height, re-melted depth, and contact angle) and microstructural (grain structure, niobium-rich phase fraction, and primary dendrite arm spacing) characteristics of a single track of Alloy 718 have been investigated. It has been found that the most influential machine-related parameters are scanning speed and beam current, which have significant effects on the geometry and the microstructure of the single-melted tracks.

Laser is an efficient and widely used heat source in metal processing suchas welding and additive manufacturing. It has some great advantages compared to the other conventional heat sources like electron beam and arc namely: ability of handling complicated joint geometries and producing large components. Laser beam welding encompasses many complex physical phenomena such asheat transfer, metal melting, flow and solidification, free surface deformation, evaporation and possibly vaporization. The aim of this research work istwo-fold: gain deeper process understanding and improve the model reliability. Deeper process understanding is sought on the effect of beam shaping on themelt pool. To achieve improved model reliability, a good support consists in using qualitative experimental data representing the process. Thus, 3D validation of the melt pool geometry is performed while it was usually 2D inprevious research works. Furthermore, a new calculation procedure for laser absorption is introduced. To conduct this research work, a Computational Fluid Dynamics approach is used. A solver, capable of tracking the deformation of the melt free surface, is developed in OpenFOAM. Concerning beam shaping, it is found that not only the melt pool size as previously known but also the melt flow pattern is modified through elongating the beam shape.This last result could not be revealed by former studies as the non-transparent media hinders optical observation. New in-process quantitative measurements performed by a project partner are used to test the model. Weaknesses of the former absorptivity models are highlighted, as well as the limitations of the proposed model. Finally, the results show that the proposed absorptivity model function of local surface conditions leads to much better agreement with experimental results compared to the former constant absorptivity model. The maximum discrepancy compared to the experimental measurement, which is observed for the melt pool depth, can indeed be reduced to about 10%. / Laser är en effektiv och allmänt använd värmekälla vid svetsning och additiv tillverkning. Den har några viktiga fördelar jämfört med andra konventionella värmekällor såsom elektronstråle och elektrisk ljusbåge, nämligen: den kan ofta användas till komplicerade svetsgeometrier, och den kan producera stora komponenter. Lasersvetsning involverar olika sammansatta fysikaliska fenomen såsom värmeöverföring, metallsmältning, flöde, stelning, ytdeformation, avdunstning och i vissa fall förångning. Syftet med mitt forskningsarbete är tvåfaldigt: att få en djupare processförståelse och att förbättra modellens tillförlitlighet. Fördjupad processförståelse eftersträvades för att förstå hur formen på laserstrålen påverkar svetssmältan. För att uppnå förbättrad modellsäkerhet behövs experimentella data av hög kvalitet som representerar processen. Således utfördes 3D-validering av smältgeometrin medan det vanligtvis var 2D i tidigare forskningsarbeten. Dessutom har en ny modell för laserabsorption föreslagits. I forskningen har numerisk strömningssimulering (Computational Fluid Dynamics) använts för att simulera processen och en numerisk lösare, som kan spåra deformationen av den rörliga smälta ytan, är utveckladi programvaran OpenFOAM. Beträffande laserstrålens utbredning visar resultaten att svetssmältans storlek och även svetssmältansflöde modifieras genom att laserstråleformen förlängs. Medan den förra är känd från tidigare experimentella studier upptäcktes den senare inte före denna studie eftersomdet icke-transparenta mediet hindrar optisk observation. Nya (in-process) kvantitativa mätningar utförda av en projektpartner har använts för att testa modellerna. Svagheter i den tidigare absorptionsmodellen framhävdes, liksom begränsningarna i den föreslagna modellen. Slutligen visade resultaten att den föreslagna modellen där laserabsorptionen är en funktion av lokala ytförhållanden ledde till en bättre overensstämmelse med mätningar jämfört med den tidigare modellen med konstant laserabsorbtion. Den maximala avvikelsen jämfört med experimentell mätning, som observerades med avseende på smältbassängsdjupet, kunde reduceras till cirka 10%. / <p>Till licentiatuppsats hör 2 inskickade artiklar, som inte visas nu.</p>

Nickel-based alloys are used in components such gas turbines within the aerospace industry and electric power generation due to its high tensile, rapture and creep strength. Increasing the efficiency of gas turbines are crucial to reduce emissions within the aerospace industry and increasing power gain for electric power generation. Innovation to increase the efficiency relies in part on the development of new nickel-based alloys with beneficial material properties. But also on stable and predictable material behavior during processing and post-processing of the components in the gas turbine. In two prominent material processing fields of precipitation hardened nickel-based alloys, additive manufacturing and welding, strain-age cracking (SAC) is a common phenomenon. SAC is a solid state phenomenon that generally occurs in alloys strengthened with 𝛾′, L12(Pm3m), or 𝛾′′, D022(I4/mmm), phase precipitates during post weld heat treatment or reheating where it manifests as intergranular cracking. Even though the existence of SAC has been known for several decades, its dominant mechanisms are still under considerable debate and the undertaken modeling efforts to gain insight on the phenomenon are virtually non-existent. This study aims to clarify the dominant mechanisms behind strain-age cracking. Breaching this gap would allow for new development for nickel-based alloys within both additive manufacturing and welding. To that extent the goal of this study is to provide tools to aid in clarifying the dominant mechanisms behind strain-age cracking. This is done by implementing the recently developed structural phase-field crystal (XPFC) model and examining the capabilities to model a precipitation event during reheating for a reference binary alloy in two dimensions. To evaluate the strain because of precipitation, a simple method based on the principles of neutron and synchrotron strain scanning is outlined and tested on the limited precipitation event achieved within the study. The XPFC model is capable of modeling precipitation with some restrictions that need further development with extended computational recourses. Lastly, the possibilities to extend the implemented XPFC model to cover nickel-based alloys is discussed.

Additive manufacturing (AM) is a quickly rising method of manufacturing due to its ability to increase design freedom. This allows the manufacturing of components not possible by traditional subtractive manufacturing. AM can greatly reduce lead time and material waste, therefore decreasing the cost and environmental impact. The adoption of AM in the aerospace industry requires strict control and predictability of the material deposition to ensure safe flights.  The method of AM for this thesis is Laser Metal Deposition with wire (LMD-w). Using wire as a feedstock introduces a potential problem, the material transfer from the wire to the substrate. This requires all process parameters to be in balance to produce a stable deposition. The first sign of unbalanced process parameters are the material transfer stabilities; stubbing and dripping. Stubbing occurs when the energy to melt the wire is too low and the wire melts slower than required. Dripping occurs when too much energy is applied and the wire melts earlier than required.  These two reduce the predictability and stability that is required for robust manufacturing.  Therefore, the use of thermal simulations to predict the material transfer stability for LMD-w using Waspaloy as the deposition material has been studied.  It has been shown that it is possible to predict the material transfer stability using thermal simulations and criterions based on preexisting experimental data. The criterion for stubbing checks if the completed simulation result produces a wire that ends below the melt pool. For dripping two criterions shows good results, the dilution ratio is a good predictor if the tool elevation remains constant. If there is a change in tool elevation the dimensionless slenderness number is a better predictor.  Using these predictive criterions it is possible to qualitatively map the process window and better understand the influence of tool elevation and the cross-section of the deposited material. / Additiv tillverkning (AT) är en kraftigt växande tillverkningsmetod på grund av sin flexibilitet kring design och möjligheten att skapa komponenter som inte är tillverkningsbara med traditionell avverkande bearbetning.  AT kan kraftigt minska tid- och materialåtgång och på så sett minskas kostnader och miljöpåverkan. Införandet av AT i flyg- och rymdindustrin kräver strikt kontroll och förutsägbarhet av processen för att försäkra sig om säkra flygningar.  Lasermetalldeponering av tråd är den AT metod som hanteras i denna uppsats. Användandet av tråd som tillsatsmaterial skapar ett potentiellt problem, materialöverföringen från tråden till substratet. Detta kräver att alla processparametrar är i balans för att få en jämn materialöverföring. Är processen inte balanserad syns detta genom materialöverföringsstabiliteterna stubbning och droppning. Stubbning uppkommer då energin som tillförs på tråden är för låg och droppning uppkommer då energin som tillförs är för hög jämfört med vad som krävs för en stabil process. Dessa två fenomen minskar möjligheterna för en kontrollerbar och stabil tillverkning.  På grund av detta har användandet utav termiska simuleringar för att prediktera materialöverföringsstabiliteten för lasermetalldeponering av tråd med Waspaloy som deponeringsmaterial undersökts. Det har visat sig vara möjligt att prediktera materialöverföringsstabiliteten med användning av termiska simuleringar och kriterier baserat på tidigare experimentell data. Kriteriet för stubbning kontrolleras om en slutförd simulering resulterar i en tråd som når under smältan.  För droppning finns två fungerande kriterier, förhållandet mellan svetshöjd och penetrationsdjup om verktygshöjden är konstant, sker förändringar i verktygshöjden är det dimensionslös ”slenderness” talet ett bättre kriterium.  Genom att använda dessa kriterier är det möjligt att kvalitativt kartlägga processfönstret och skapa en bättre förståelse för förhållandet mellan verktygshöjden och den deponerade tvärsnittsarean.

Fügen und Montieren spielt seit jeher eine entscheidende Rolle in der Herstellung von Alltags- bis hin zu Hochtechnologieprodukten. Die Füge- und Montagetechnik ist an der Technischen Universität Chemnitz fast seit ihrer Gründung eine etablierte Wissenschaftsdisziplin. So wurde bereits 1922 an der damaligen staatlichen Gewerbeakademie als erste Hochschule Deutschlands das Fachgebiet Schweißtechnik in Lehre und Forschung eingerichtet. Mit der wissenschaftlichen Fachkonferenzreihe FüMoTeC will das Institut für Füge- und Montagetechnik (IFMT) der Technischen Universität Chemnitz seine laufenden Erkenntnisse in Wissenschaft und Forschung einem breiten Publikum zugänglich machen aber auch eine Plattform für Industrie und Wissenschaft zur Diskussion füge- und montagetechnischer Aspekte bieten. / Joining and Assembly has always played a crucial role in the production of everyday up to high-technology products. These research priorities are well-established scientific disciplines at the Technische Universität Chemnitz almost since its foundation. Already in 1922 at the former state “Gewerbeakademie” the field of welding technology was set up in teaching and research for the first time in Germany. With the scientific conference series FüMoTeC the institute for joining and assembly technology (IFMT) of the Technische Universität Chemnitz wants to present current findings in science and research to a broad audience as well as offering a platform for industry and academia for discussions.

Continuous fibre-reinforced thermoplastics often are offered as impregnated and consolidated semi-finished products which are known as organic sheets. The thermoplastic matrix leads to several advantages including the thermoformability and weldability. Parts made of organic sheets are frequently produced by forming the semi-finished product into half-shells and stiffening those shells in the course of the process e.g. by the injection moulding of ribs. Larger and more complex parts with hollow body structures can be manufactured e.g. by forming the semi-finished products into half-shells and joining the half-shells. However, the currently available manufacturing technologies for parts made of organic sheets have cap profile shaped joints which prevent the use of the reinforcing fibres across the joint plane. Investigations have proven that overlapping weld joints in organic sheets show much higher strengths than cap profile shaped joints which can be explained by the fibre use across the joint plane. Furthermore, the infrared welding technology was verified as an appropriate process for the welding of organic sheets since no need for additional welding material is given, short heating times can be realized and no contact of the infrared emitters to the joining parts is required. Therefore, the present study shall reveal the high potential of the overlapping welding of organic sheets. Influences on the weld strengths of infrared welded organic sheets are described and potential improvements concerning the materials to be welded as well as the welding process are shown.