In this study, the goal is to optimize the process and to reduce the clogging tendency during the continuous casting process. The focus is on clogging when the refractory base material (RBM) in the SEN is in contact with the liquid steel. It is difficult or impossible to avoid non-metallic inclusions in the liquid steel, but by a selection of a good RBM in the SEN clogging can be reduced.   Different process steps were evaluated during the casting process in order to reduce the clogging tendency. First, the preheating of the SEN was studied. The results showed that the SEN can be decarburized during the preheating process. In addition, decarburization of SEN causes a larger risk for clogging. Two types of plasma coatings were implemented to protect the RBM, to prevent reactions with the RBM, and to reduce the clogging tendency. Calcium titanate (CaTiO3) mixed with yttria stabilized zirconia (YSZ) plasma coatings were tested in laboratory and pilot plant trials, for casting of aluminium-killed low-carbon steels. For casting of cerium alloyed stainless steels, YSZ plasma coatings were tested in laboratory, pilot plant and industrial trials. The results showed that the clogging tendency was reduced when implementing both coating materials.   It is also of importance to produce clean steel in order to reduce clogging. Therefore, the steel cleanliness in the tundish was studied experimentally. The result showed that inclusions originated from the slag, deoxidation products and tundish refractory and that they were present in the tundish as well as in the final steel product. / VINNOVA

Cellular materials like aluminum foam which is the subject of interest here are generally characterized by high energy absorption capacity per unit weight. Materials of this category can be ideal for applications such as packaging and vehicle body structures for enhanced impact safety. A particularly well-known variety of closed-cell aluminum foam is designated as Alporas, which is studied here. From a viewpoint of mechanical behavior, the foam being considered can be represented using either a detailed cellular approach capturing the voids present in foam structure or a phenomenological approach in which experimental stress-strain response is assigned a-priori to solid elements filling up the space occupied by a foam geometry. Both modeling approaches are studied in the present work. It has been shown for the first time that stress-strain behavior under compression including densification can be predicted well with a Kelvin cell-based model, although scope for further improvement exists. Based on a novel combination of compression tests at low strain rates in a UTM and medium strain rates in low velocity impact tests, a relation between foam strength and strain rate has been proposed. This effect of strain rate on strength is captured in a finite element model for analysis using an explicit code with contact simulation capabilities and the predictions for projectile impact tests at higher strain rates using a gas gun-based device have been found to match commendably with results obtained from the said tests.

Orientador: Michel Daoud Yacoub / Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Elétrica e de Computação / Made available in DSpace on 2018-08-27T01:29:54Z (GMT). No. of bitstreams: 1 Barbin_ManoelVitorio_M.pdf: 5394528 bytes, checksum: f2e1dbef898be5580589baf0e2996f16 (MD5) Previous issue date: 2015 / Resumo: A identificação de objetos através de ondas de radiofrequência ou RFID (Radio Frequency Identification) é uma tecnologia onde uma etiqueta, colocada em um objeto, tem suas informações lidas por um sistema de processamento remoto. Embora esta não seja uma tecnologia recente, sua utilização tem apresentado constante crescimento nos últimos anos. Atualmente, RFID é apontada com uma das principais tecnologias habilitadoras da internet do futuro, a Internet das Coisas, IoT (Internet of Things). Operando principalmente em faixas destinadas para o uso de aplicações médicas, científicas e industriais, ISM (Industrial, Scientific and Medical), sistemas de RFID apresentam diferentes características em função da banda de frequências utilizada. Em UHF (Ultra High Frequency), os sistemas de RFID que fazem uso de etiquetas passivas, são considerados como uma solução com bom desempenho para a identificação de objetos em distâncias que variam de alguns poucos centímetros a vários metros. Contudo, a distância de identificação depende do material que constitui um dado objeto. Por exemplo, metais estão entre os materiais que degradam significativamente o desempenho de sistemas de RFID em UHF, reduzindo a distância de identificação. Diversas soluções de etiquetas têm sido desenvolvidas com o objetivo de torná-las, o máximo possível, insensíveis à presença do metal. Alguns diferentes tipos de antenas foram propostas, entre as quais se destacam as que possuem um plano-terra inerente a sua estrutura, como a de microfita e a planar de F-Invertido, PIFA (Planar Inverted-F Antenna). Uma revisão destas soluções é realizada nesta dissertação. Este trabalho descreve o projeto de uma etiqueta passiva de RFID em UHF, baseado em uma PIFA, para identificação de objetos metálicos colocados em distâncias maiores que oito metros, aproximadamente. O principal objetivo de uso da etiqueta é na identificação de objetos com razoáveis dimensões tais como containers, chapas, canos, etc., frequentemente encontrados em ambientes industriais e armazéns de estocagem. Uma forma diferente de alimentação do sinal de radiofrequência para a antena é desenvolvida. Simulações eletromagnéticas e medições indicam um bom desempenho da etiqueta em uma ampla faixa de frequências, que abrange as principais bandas de operação de RFID em UHF no mundo / Abstract: The identification of objects by radio waves or RFID (Radio Frequency Identification) is a technology where a tag is attached to an object and its information read by a remote processing system. Although it is not a new technology, its use has shown steady growth in recent years. Currently, RFID is identified as one of the main enabling technologies of the future Internet, the Internet of Things, IoT. Operating in the bands intended primarily for use in industrial, scientific and medical (ISM) applications, RFID systems have different characteristics depending on the frequency band used. In the UHF (Ultra High Frequency) band, RFID systems using passive tag are considered as a solution with good performance to identify objects at distances ranging from a few centimeters to several meters. However, the distance of identification depends on the material that the object is made of. For example, metals are materials which can significantly degrade the performance of UHF RFID systems by reducing the distance of identification. Several solutions for tags have been developed in order to make them, as far as possible, insensitive to the presence of metal. Some different types of antennas were proposed, among which are those with a ground plane inherent in its structure, such as the microstrip antenna and the PIFA (Planar Inverted-F Antenna). A review of these solutions is carried out in this dissertation. This document describes the design of a passive RFID tag in UHF, based on a PIFA for identification of metallic objects placed at distances greater than eight meters or so. The main use of the tag is to identify objects with medium or large dimensions such as containers, plates, pipes, etc., often found in industrial environments and storage warehouses. A different kind of RF feeder to the antenna is developed. Electromagnetic simulations and measurements indicate a good tag performance in a wide frequency band, which covers the main RFID UHF operation bands in the world / Mestrado / Telecomunicações e Telemática / Mestre em Engenharia Elétrica

This master thesis covers the development of a high-pressure fuel system for compression ignitedfuels such as diesel and diesel-like fuels that will be deployed into a single cylinder test cell at AVLMTC Södertälje, Sweden. The test cell is used by AVL to conduct research and testing of new fuelsfor their customers and this new fuel system will widen the span of fuels able to be tested by theequipment.This thesis focuses on pumping and pressurizing of the fuel, ensuring that all ingoing materialsare non-corrosive in this environment and compatible with the necessary fuels and lastly a safetyanalysis of the system with respect to operator and process safety. Other aspects of the projectsuch as mass flow measurements and fuel conditioning is covered in a sister thesis Mass flowrate measurement of compression ignition fuels in high-pressure stand-alone pump unit for singlecylinder test cell written by C. Aksoy [1].The goal of this thesis project was to deliver a finished manufactured fuel system and if the timeallowed for it, also validate its performance and finally installing and incorporating it into the singlecylinder test cell. The development process started with the writing of a product specificationoutlining the requirements and request on the product in a specification of requirements matrix andrelate these to product properties of the system using a quality function deployment (QFD) matrix.This document was then used as a base for further advancement in developing concepts to solveeach product property and weighing these concepts against each other using Pugh’s matrices. Thechosen concepts were then further developed, a flow chart for the system was developed as well asfuel lines and other supporting components were analyzed and chosen.In the end the high-pressure fuel pump from Scania’s XPI fuel system were chosen as well asa pressure transducer in the HP1000 series from ESI. Within the time frame of this thesis, theproject did not end up getting finished to the degree planned, but due to time constraints werehalted before starting manufacturing of the system. Some minor component choices remained aswell as documentation such as drawings and finalizing the physical layout of the system remained.All information regarding the remaining work needed to finalize the project and deploying thesystem in the test cell were outlined and with more time, the fuel system should fulfill its purposeof allowing testing and research of compression ignited fuel to be possible in the test cell. / Kontentan för denna mastersavhandling är utvecklingsprocessen för ett högtrycksbränslesystemför kompressionsbränslen såsom diesel och diesellika bränslen som kommer att installeras i enencylindertestcell hos AVL MTC Södertälje, Sverige. Testcellen används av AVL för forskningoch testning av nya bränslen åt deras kunder och detta nya bränslesystem kommer att utöka typernaav bränslen som kan testas med utrustningen till att inkludera kompressionsantända bränslen.Denna avhandling fokuserar på utvecklingen av tillförseln och trycksättnigen av bränslet, säkerställnigenav att ingående material är icke-korrosiva i den avsedda miljön och kompatibla med allanödvändiga bränsletyper och slutligen en säkerhetsanalys av systemet med avseende på operatörsochprocessäkerhet. Andra aspekter såsom massflödesmätning och bränslekonditionering presenterasi systeravhandlingen Flödesmätning och konditionering av högtryckantända bränslen för encylindertestcellskriven av C. Aksoy [1].Målet med denna avhandling var att leverera ett färdigtillverkad bränslesystem och om tiden tillät,även validera systemets prestanda och slutligen integrera och installera systemet i testcellen. Utvecklingsprocesseninleddes med att skriva en produktspecifikation som innehöll en sammanställningav kundens krav och önskemål för produkten och relaterade dessa till produktegenskaper med hjälpav en quality function deployment (QFD) matris. Detta dokument användes vidare som en bas förfortsatt utveckling av produkten i konceptgenereringsprocessen och för att väga de olika konceptenmot varandra med hjälp av Pugh’s matriser. De valda koncepten blev sedan analyserade ytterligare,ett flödesschema för de ingående komponenterna framtaget och övriga sekundära komponenteranalyserade och valda.Till slut valdes högtrycksbränslepumpen från Scanias XPI system och en tryckgivare från HP1000-serien från ESI. Inom tidsramen för avhandlingen färdigställdes aldrig projektet till den grad somhade planerats, men blev istället avbrutet innan tillverkningen av systemet han påbörjas på grund avtidsbegränsningar. Vissa sekundära komponentval, dokumentation såsom ritningar och färdigställningav den fysiska layouten av systemet kvarstod vid avhandlingens slut. All information angåendeallt nödvändigt fortsatt arbete för att färdigställa projektet och integrera systemet i encylindertestcellendokumenterades och med mer tid borde bränslesystemet kunna uppfylla sitt syfte att möjliggöratestning och forskning av kompressionsbränslen i testcellen.

The pores in pressed and sintered components constitute weak points in the material since the stress concentration is larger than the nominal stress there. Therefore, fatigue cracks initiate at the pores. Specifically, it can be assumed that the fatigue cracks initiate at the largest pore in the stressed volume. Studies have previously looked at finding ways to model the fatigue strength of the material based on the largest pore. This thesis looks at a model previously derived for hardened pressed and sintered materials that is based on linear elastic fracture mechanics and investigates if said model can be modified to include non-hardened pressed and sintered materials that do not necessarily behave linear elastically. A model describing the influence of the size of the largest pore on the fatigue limit using empirical coefficients is suggested. Furthermore, the area of the largest pore is modelled using extreme value statistics. The model proved successful in modelling the density effect of the porosity on the fatigue strength for two materials with different microstructures: one with a homogeneous microstructure and one with a heterogeneous microstructure. For the material with the homogenoeous microstructure the model also accounted well for the notch effect when tested on samples with a different geometry. However, for the heterogeneous material the model did not account for the notch effect. Deformation hardening due to local plastic deformation in the softer phases was suggested as a possible explanation and was supported by tensile tests.

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.

Competitive metallurgical production is almost impossible without the knowledge of the chemical composition of manufactured and finished melt, or the produced product. With growing customer demands for product quality and product characteristics, increasing technology speed and increasing product purity, there is growing demand for analyzes of chemical composition. These demands are very often against each other, especially the increasing demands on the speed and accuracy of analyzes. Analytical requirements may not only apply to the test technique, but also to the quality of the sample, which is inseparable from it. What is recently seen as the biggest drawback, the new technology is trying to use as its main priority. This is undoubtedly true of atomic emission spectrometry.

Kongsberg Automotive is developing a brand-new actuator for engaging and disengaging a clutch for different driveline applications. This master thesis research improves the concept design of the shift fork for the new Dog-Clutch Actuator using Design for Manufacturability (DFM). Initially, the knowledge about the mechanism of the product is gained with the aid of the design team and the proper boundary conditions for the boundary value problem are obtained. The conventional die-cast materials are investigated, and appropriate material is selected to create the material model. Most of the traditional HPDC aluminum alloys are aluminum-silicon system; therefore, a detailed study on the nucleation of Silicon in the melt and how it influences the mechanical properties of the alloy is conducted. During gear engagement, the two rotating gears of the dog-clutch collide and synchronize the angular velocity of the hub and the input gear. The synchronization force is dynamic; therefore, explicit time integration is used to capture the system's response with the assistance of FEM software. As the shift fork undergoes cyclic load during the gear shift, the fatigue analysis is performed to evaluate the life (Nf) of the component using Wohler's curve. The value of the maximum principal stress at the critical spots like notch and its direction are determined using the 3D Mohr's circle. In this analysis, the endurance limit correction factors and notch factor (Kf) are used for the S-N curve correction, and Goodman's criteria are used to incorporate the mean stress effect. Fatigue analysis requires a very fine mesh to estimate the precise stress magnitude at the critical locations and, the structural optimization algorithm requires many iterations to determine the optimal layout of the shift fork. Therefore, the explicit integration scheme is not efficient as it will be computationally expensive and time-consuming to solve the problem. Hence, the equivalent static load is determined for the gear shift force at the peak load and used for calculations and product development. As the initial concept design of the shift fork is asymmetrical, it requires varying stiffness in its structure to transfer the force efficiently to the shift sleeve. The FEA results state that one prong of the shift fork experience up to 75% of the total load, which increases the overall stress of the component (up to 0.9Sy). The shift fork also doesn't have adequate torsional stiffness, and as a result, stress concentration has occurred in one of the fillets in the shift fork. The iterative design is set up to improve the design of the shift fork by optimizing the stiffness of the two prongs which provided the key observations that describe the design changes which improved the design. In this phase, the overall stress of the component is reduced by 20% and minimizes the difference in the load between the two prongs by 27.5% compared to the initial design. The shift fork needs to be light to achieve the necessary acceleration during the gear shift. Therefore, topology optimization using the projected subgradient method is implemented to optimize the mass and compliance of the improved design in the iterative design phase. Then the design realization phase is set up to implement the results obtained from the topology optimization to conceptualize the viable product. The optimized result decreased the overall stress and maximum deflection by 20%. It also reduced the load difference in the two prongs of the shift fork by 35% by maintaining the same mass as the initial concept design.

Plasticity in crystalline solids is controlled by the microscopic line defects known as “dislocations”. Decisive role of dislocations in crystal plasticity in addition to fundamentals of plastic deformation are presented in the current thesis work. Moreover, major features of numerical modeling method “Discrete Dislocation Dynamics (DDD)” technique are described to elucidate a powerful computational method used in simulation of crystal plasticity. First part of the work is focused on the investigation of strain rate effect on the dynamic deformation of crystalline solids. Single crystal copper is chosen as a model crystal and discrete dislocation dynamics method is used to perform numerical uniaxial tensile test on the single crystal at various high strain rates. Twenty four straight dislocations of mixed character are randomly distributed inside a model crystal with an edge length of 1 µm subjected to periodic boundary conditions. Loading of the model crystal with the considered initial dislocation microstructure at constant strain rates ranging from 103 to 105s1 leads to a significant strain rate sensitivity of the plastic flow. In addition to the flow stress, microstructure evolution of the sample crystal demonstrates a considerable strain rate dependency. Furthermore, strain rate affects the strain induce microstructure heterogeneity such that more heterogeneous microstructure emerges as strain rate increases. Anisotropic characteristic of plasticity in single crystals is investigated in the second part of the study. Copper single crystal is selected to perform numerical tensile tests on the model crystal along two different loading directions of [001] and [111] at two high strain rates. Effect of loading orientation on the macroscopic behavior along with microstructure evolution of the model crystal is examined using DDD method. Investigation of dynamic response of single crystal to the mechanical loading demonstrates a substantial effect of loading orientation on the flow stress. Furthermore, plastic anisotropy is observed in dislocation density evolution such that more dislocations are generated as straining direction of single crystal is changed from [001] to [111] axis. Likewise, strain induced microstructure heterogeneity displays the effect of loading direction such that more heterogeneous microstructure evolve as single crystal is loaded along [111] direction. Formation of slip bands and consequently localization of plastic deformation are detected as model crystal is loaded along both directions. / <p>QC 20151015</p>

In stainless steelmaking, around 68% of the total greenhouse gas emissions come from the processing of raw materials. Thus, it is important for steelmakers to make efforts together with their raw material suppliers to implement low-carbon initiatives. To facilitate such initiatives, assessment of raw materials will provide guidance. In this work, the assessment of materials consists of two parts: i) different production scenarios are studied by using a static process model coupled with life cycle assessment approach to investigate the reduction potential of environmental impacts for Mo and Ni alloys; ii) assessment of the effect of trace element content (phosphorus) in stainless steel scrap on steel’s manufacturing cost, resource consumption and environmental impact using an online static process model. The results show that the overall GHG emission of FeMo production varies between 3.16-14.79 t CO2-eq/t FeMo (i.e. 5.3-24.7 tCO2-eq/t Mo). The main variance comes from the mining and beneficiation stages and depends mainly on the ore’s beneficiation degree. However, whether molybdenum is extracted as a co-product from copper mine or not can have an even greater effect on the total GHG emission of molybdenum due to the allocation of the impacts.  In the case of nickel alloys, the GHG emissions for producing nickel metal, nickel oxide, ferronickel and nickel pig iron are 14, 30, 6 and 7 tCO2-eq/t alloy (i.e. 14, 40, 18, and 69 tCO2-eq/t Ni), respectively. Extracting sulfide ore through flash smelting process has been shown to have the least energy requirement and greenhouse gas emissions. In comparison to sulfide ore processing, oxide ore processed in an electric furnace is much more energy intensive and less environmental friendly primarily due to high content of gangue. However, by using a sustainable electricity source such as hydro-powered electricity, or applying a thermal heat recovery, it is possible to reduce the impact from electric furnace smelting of laterite. Furthermore, the use of stainless steel scraps with low phosphorous contents reduces slag amount, alloy consumption, production cost and carbon footprint. An estimation equation between phosphorous content and scrap’s value-in-use is obtained in the study to support the development of purchasing strategy. To conclude, the application of static process model based on mass and energy balance provides the possibility to assess raw materials’ environmental impact (energy consumption and GHG emissions) and to identify potentials to realize sustainable stainless steelmaking. / Vid tillverkning av rostfritt stål kommer cirka 68% av växthusgaserna ifrån råvaruanvändningen. Därför är det viktigt för ståltillverkare att göra en samordnad insats med sina levenrantörer för att reducera dessa utsläpp. Den här avhandlingen ämnar att undersöka råvaror ur två perspektiv: i) att utvärdera olika produktionsscenarier för  molybden och nickelleggeringar genom en statisk processmodell i kombination med livscykelanalys för att undersöka potentialen för att minska miljöbelastningen; ii) att undersöka hur spårämnesinnehållet (fosfor) i rostfritt stålskrot påverkar ståltillverkningskostnaden, resursförbrukningen och miljöpåverkan med ett webbaserat verktyg för processmodellen. Resultaten visar att växthusgasutsläppen från produktionen av FeMo varierar mellan 3.16-14.79 t CO2-eq/t FeMo (d.v.s. 5.3-24.7 tCO2-eq/t Mo). Variationen beror främst på malmets anrikningsgrad under malmbrytnings- och anrikningsprocessen. När molybden förekommer  i kopparmalm och utvinns som en co-produkt så kan det ha en större effekt på molybdens energiförbrukning och växthusgasutsläpp än vad malmens anrikningsgrad har. I fallet för tillverkning av nickelmetall, nickeloxid, ferronickel och nickeltackjärn är växthusgasutsläppen 14, 30, 6 respektive 7 tCO2-eq/t legering (motsvarande 14, 40, 18, respektive 69 tCO2-eq/t Ni). Användningen av sulfidmalm i flashsmältningsprocessen har visat sig ha lägst energibehov och växhusgasutsläpp medan användningen av oxidmalm i ljusbågsugn både är mer energiintensiv och utsläppsintensiv  på grund av en stor mängd oxider i nickelmalmen. Dessa utsläpp kan dock förbättras genom användningen av hållbar energi (till exempel el från vattenkraft), eller genom värmeåtervinning under processen. Utöver detta kan skrot med lågt fosforinnenhåll också användas vid tillverkningen av rostfritt stål för att minska slaggmängden, förbrukningen av legeringar, produktionskostnaden och växthusgasutläppen.  En ekvation mellan fosforinnehållet och skrotets värde föreslås här som underlag för att utveckla en inköpsstrategi för skrot. Sammanfattningsvis så kan en statisk processmodell baserad på mass- och energibalans tillämpas för att utvärdera råvarors miljöbelastning (energiförbrukning och växthusgasutsläpp) och identifiera potentialen för en hållbar tillverkning av rostfritt stål.