The project elaborated as a part of engineering studies branch M2307: Engineering Technology, Specialization 02: Forming and Welding Technology deals with the optimization of arc spraying parameters for TAFA 9935 facility.The theoretical part presents the principle of arc spraying, the description of the technological process and the types of additional materials. The practical part proposes the diffrent possibilities of TAFA 9935 arc spraying facility and the suitable additional materials. Several samples with diffrent parameters of spraying were created in order to test and analyse the coating quality.

Parameters affecting the z-strength of liquid paperboard (LPB) has been analyzed and identifiedusing data mining and machine learning on 6 years of operational data from a multi-ply LPB mill, and control and stabilizing of them was proposed. Linear regression models were built for 9 articles with satisfactory results, and whose attributes were further analyzed as the most important parameters for the z-strength. The results show that generally only parameters affecting the weakest position in the paperboard has any influence on the z-strength, with unbleached softwood pulp refining work affecting the strength the most, while bleached hardwood refining work has a lower influence, and refining work of bleached softwood has almost no influence on the z-strength. Among the other parameters shown to influence the z-strength are kappa number, headbox concentration, broke ratio, strength and retention starches, fractionation and degree thereof, and the conductivity of the process water.

The purpose of this research was to investigate the effect of ultra-high temperature process parameters on age gelation of milk concentrate. Skim milk was concentrated to 2X (volume reduction) using reverse osmosis. The milk concentrate was preheated at 75 or 90°C for 20 or 50 s and UHT-processed at 138 or 145°C for 4 or 16 s. Sterilizing methods used were direct steam injection and indirect plate heat exchanger. The samples were aseptically collected in presterilized plastic containers and stored at 15 or 35°C. At 15°C storage temperature, the steam-injected samples gelled in 5 months when 4 s UHT time was used. When UHT time was increased to 16 s, the samples gelled in 6 months. Of the samples that were UHT processed by indirect plate heat exchanger for 4 s and stored at 15°C, all gelled after 7 months. When UHT time was increased to 16 s, all the 138°C samples gelled after 7 months as did the samples that were preheated for 50 s and UHT-processed at 138°C. The samples preheated at 75°C for 50 sand UHT-processed at 145°C gelled after 8 months, whereas at 90°C preheat temperature the samples gelled after 9 months. The samples stored at 35°C did not gel but showed different sedimentation levels. The sediment depth in the container was always greater for the steam-injected samples. The samples that received higher heat treatments by the two processing methods had a higher sedimentation depth. The pH decreased during storage and the extent of reduction was higher at 35°C storage temperature . Maillard browning occurred at both storage temperatures. Browning was greater in samples stored at 35°C and processed by indirect plate heat exchanger.

Indiana University-Purdue University Indianapolis (IUPUI) / Fused deposition modeling (FDM) represents one of the most common techniques for rapid proto-typing in additive manufacturing (AM). This work applies image based thermography to monitor the FDM process in-situ. The nozzle temperature, print speed and print orientation were adjusted during the fabrication process of each specimen. Experimental and numerical analysis were performed on the fabricated specimens. The combination of the layer wise temperature profile plot and temporal plot provide insights for specimens fabricated in x, y and z-axis orientation. For the x-axis orientation build possessing 35 layers, Specimens B16 and B7 printed with nozzle temperature of 225 C and 235 C respectively, and at printing speed of 60 mm/s and 100 mm/s respectively with the former possessing the highest modulus, yield strength, and ultimate tensile strength. For the y-axis orientation build possessing 59 layers, Specimens B23, B14 and B8 printed with nozzle temperature of 215 C, 225 C and 235 C respectively, and at printing speed of 80 mm/s, 80 mm/s and 60 mm/s respectively with the former possessing the highest modulus and yield strength, while the latter the highest ultimate tensile strength. For the z-axis orientation build possessing 1256 layers, Specimens B6, B24 and B9 printed with nozzle temperature of 235 C, 235 C and 235 ➦C respectively, and at printing speed of 80 mm/s, 80 mm/s and 60 mm/s respectively with the former possessing the highest modulus and ultimate tensile strength, while B24 had the highest yield strength and B9 the lowest modulus, yield strength and ultimate tensile strength. The results show that the prints oriented in the y-axis orientation perform relatively better than prints in the x-axis and z-axis orientation.

It is known that altering different processing parameters will yield completely different results in additive manufacturing. Some of the most common ones to alter to increase material quality or to increase productivity are laser power, hatch distance, layer thickness and scan speed. These parameters directly affect the material quality and are well understood. This study investigates how the process for additive manufacturing is being affected by the more unexplored minor process parameters stripe width, stripe overlap, and gas flow, with a goal to increase to knowledge of the process stability in additive manufacturing. Density measurements and investigations in optical tomography were made to determine the minor process parameters effect on the material density and process stability. The density is measured using white light interferometry and the results from the density analysis showed that the minor process parameters does not affect the density of the produced material within the interval used in this study. The minor process parameters effect on the process stability were investigated using the measured gray value obtained from optical tomography. A higher gray value means that the process is kept at a higher temperature for a longer period of time. A decrease in stripe width increased the measured gray value, while an increase of the stripe overlap increased the measured gray value. To understand what the measured gray value means for the process, the spatter area was measured using ImageJ, and a strong correlation between measured spatter area and measured gray value was found, showing that a larger spatter area will be visible as higher measured gray value. The effect of the scan angle was investigated in optical tomography, comparing the mean gray value to the scan angle. Results showed that the mean gray value increases when the angle is close to perpendicular to the gas flow at higher stripe widths and higher stripe overlaps. / Det är känt att olika processparametrar erhåller olika materialkvalitéter när de ändras. Några av de vanligaste att variera för att öka materialkvalitén eller öka produktiviteten är lasereffekten, hatch-avståndet, lagertjocklek and skannhastighet. Dessa parametrar påverkar materialkvalitén och är väl undersökta. Denna studie undersöker hur processen påverkas av de mer okända parametrarna skannbredd, överlapp och gasflödet, med målet att utöka kunskapen kring processtabiliteten i additiv tillverkning. Densitetsmätningar och undersökningar i optisk tomografi gjordes för att bestämma påverkan av de sekundära processparametrarnas påverkan på materialdensiteten och processtabiliteten. Densiteten mäts med en vit-ljus interferometer och resultatet från densitetsanalysen visade att de sekundära parametrarna inte påverkade densiteten av de producerade materialet inom intervallen som användes i denna studie. Påverkan av de sekundära parametrarna på processtabiliteten undersöktes med det uppmätta gråvärdet från optisk tomografi. Ett högra gråvärde innebär att temperaturen är högre under en längre period. En ökning av skannbredden sänkte det uppmätta gråvärdet och en ökning av överlappet ökade de uppmätta gråvärdet. För att förstå vad gråvärdet innebär för processen så mättes arean av stänk i ImageJ. En stark korrelation mellan uppmätt area av stänk och uppmätt gråvärde upptäcktes, vilket visades i att det uppmätta gråvärdet var högre när arean av stänk var större. Påverkan av skannvinkeln undersöktes också i optisk tomografi där jämföranden mellan gråvärdet och skannvinkeln gjordes. Resultatet visade att gråvärdet ökar när skannvinkeln är nära vinkelrät mot gasflödets vid höga värden på skannbredden och överlappet.

A two-dimensional axisymmetric thermo-mechanical model of the Refill Friction Stir Spot Welding (RFSSW) process was developed and validated with experimental data. Welding temperatures, tool forces, and material flow including defect formation, were accurately predicted by the model. Qualified repair techniques are critical for successful implementation of a welding process for use on large weldments with a significant number of spot joints, and this work demonstrates a repair technique for RFSSW that is validated both experimentally and numerically. Repaired properties are shown to exceed 90% of the original mechanical properties of the RFSSW process. RFSSW has different process parameters for every combination of material alloy, material thickness, weld duration, and machine force limits. Numerical modeling develops the process parameters for any RFSSW iteration in a fraction of the time with the same amount of accuracy. The model can effectively simulate how to determine the optimal weld duration given any experimental parameters.

The Powder Bed Fusion using Electron Beam (PBF-EB) process is a highly complex additive manufacturing process. There are a very limited number of materials that have been used successfully, which limits the applications of the process, despite its well-documented advantages over conventional manufacturing. However, the development of new materials is hindered due to a lack of understanding of the fundamental phenomena in the process. The goal of this work has been to develop a model that is able to predict the process parameters that will lead to the manufacture of a fully dense component.   The model is based on 1285 empirical datasets of process parameters and the physical properties of the printed materials. Nine different materials were included in the data. By inputting a pre-defined set of process parameters and materials properties the model will output the beam power at which it is predicted a dense component may be manufactured. This novel approach will shorten the development of new process parameters by providing a first approximation of suitable parameters to iterate from. A tool steel powder supplied by Uddeholms AB was printed, using parameters proposed by the model. Two sets of pre-defined process parameters were used with several beam velocities and resulted in a number of correct predictions.   This model is a first step in predicting process parameters and presents a simple, transparent and new method of obtaining the process window for novel materials in Powder Bed Fusion using Electron Beam. / Powder Bed Fusion med Electron Beam (PBF-EB) är en mycket komplex additiv tillverkningsprocess. Det finns ett fåtal antal material som går att använda i processen. Detta är ett förhinder för applikationer trots processens väldokumenterade fördelar över konventionell framställning. Framtagning av nya material är dock hejdad på grund av okunskap kring de grundläggande fenomenen inom processen. Målet med detta arbete har varit att utveckla en modell som kan förutse processparametrar vilka ger helt kompakta komponenter.   Modellen är baserad på totalt 1285 data uppsättningar av processparametrar och de fysiska egenskaperna av de printade materialen. Data på nio olika material har samlats in. Genom att mata in ett par förbestämda processparametrar och materialets specifika materialegenskaper så beräknar modellen kraften på strålen vid vilken det förutspås att goda resultat framställs. Denna nya metod kortar ned tiden inom traditionell processparameterutveckling genom att bistå med en första iteration att arbeta utifrån. Ett verktygsstålspulver tillverkat av Uddeholms AB vart printat med hjälp av modellen. Två uppsättningar av förbestämda processparametrar användes vid flera olika stråles hastigheter och resulterade i åtskilliga lyckade förutsägelser.   Denna modell är ett första steg i att förutspå processparametrar och presenterar en simpel, transparant och ny metod till att finna process fönstret för nya material i Powder Bed Fusion med Electron Beam processen.

The plastics industry is one of the fastest growing major industries in the world. There is an increase in the amount of plastic used for all types of products due to its light weight and ability to reprocess. For this reason, the reprocessing of thermoplastics and the usability of reprocessed materials are gaining significance, and it is important to produce and consume plastic materials in an environmentally friendly way. In addition, rising raw material cost linked to the increased oil prices encouraged for reusing of the plastic materials. The aim of this research was to study and optimize the injection moulding process parameters to achieve a trade-off between the product cost and product quality, measured through mechanical properties and geometry, based on using regrind ratios. The work was underpinned by a comprehensive study of multiple reprocessing effects in order to evaluate the effect of process parameters, material behaviour, reprocessing effects and possible links between the processing parameters and key properties. Experimental investigations were carried out, in particular, focused on the melt preparation phase to identify key process parameters and settings. Multiple reprocessing stages were carried out; using two types of PP material: unfilled and short glass filled. A series of tests were used to examine product quality (mass, colour and shrinkage) and physical properties (density, crystallinity, thermal stability, fibre length, molecular weight, in-line and off-line viscosity, tensile strength, modulus of elasticity, elongation (%) and flexural strength). This investigation showed that the mouldability of the filled and unfilled PP materials, through the successive reprocessing stages (using 100 % regrind), was observed to be relatively consistent. Given the link between the processing parameters and key product and material properties, it is possible to manufacture products with minimal loss to part quality and mechanical properties. The final phase of the work focused on process optimisation study for short glass fibre filled PP material and the identified key process parameters (melt temperature, screw rotational speed, holding pressure, holding time and injection rate). A response surface experiment was planned and carried out for three reprocessing stages (0 %, 25 % and 50 % regrind). The fitted response surface models were utilised to carry out the trade-off analysis between the operating cost (material cost, energy cost and labour cost) and product quality (dimensions and tensile strength) Based on the optimal moulding conditions, the operating cost was reduced (from stage I as a reference), by 24% and 30 % for stage II and stage III respectively. A small, perhaps undetectable, change in product dimensions was noted. In addition, a small reduction in tensile strength was noted (from stage I as a reference), by 0.4% and 0.1 % for stage II and stage III respectively. The same data was applied in other countries (Australia, USA, Brazil, Libya and China) to manufacture the same product; and it was observed that the cost was reduced with increasing of regrind ratio. But the significant reduction of the cost, essentially, depended on those countries which have low wage rates (e.g. Brazil, Libya and China). For example, the cost of moulded product manufactured in China is £ 0.025 (using 50% of regrind), while the cost of the same product produced in Australia is £ 0.12, hence giving a total saving of 79 % and making it a valuable issue to be considered in industry. / Libyan Embassy

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Electron Beam Powder Bed Fusion manufacturing of components is an additive manufacturing process that is complex and has widespread advantages for aerospace and many industrial processes. It reduces costs and has a larger powder particle size requirement. This gives the benefit of a higher mass deposition rate and thus faster production time compared to Laser-Powder Bed Fusion process. Powder bed manufacturing processes often lead to columnar grain structure formation along the build direction, resulting in components that have anisotropic physical and mechanical properties. This is a major problem that limits the applications of this technique. In order to promote equiaxed grains, as well as refine the columnar morphology and eliminate anisotropic properties, the roles of process conditions and presence of inoculants or heterogeneous nucleating sites are considered. In this study, the addition of titanium nitride inoculants is used to promote columnar to equiaxed grain transition in ferritic stainless steel with the use of melting strategies and variable process parameters. It has been found that the thermal gradient (G) to solidification rate (R) ratio (G/R ratio) controls grain morphology and texture: a low G/R ratio has been shown to promote the formation of equiaxed grains. The process conditions for this transition were investigated. The samples were analyzed after printing single line tracks in the Freemelt One machine, and thereafter studied with the aid of optical microscopy to ascertain the combination of machine parameters that results in a successful transition from columnar grains to equiaxed. The study concluded that there was an increase in the fraction of equiaxed grains under these conditions; a low thermal gradient, high scanning velocity and low area energy. Ultimately, further investigation will be needed to establish the exact process parameters that will promote the transition from columnar to equiaxed grains in ferritic stainless steel. The findings from this study can be used by future researchers to create solidification maps for this steel grade and assist industry to tailor specific textures in ferritic stainless steel to achieved desired microstructures and mechanical properties. / Electron  Beam  Powder  Bed  Fusion  (E-PBF)  tillverkning  av  komponenter  är en  additiv tillverkningsprocess  som  är  komplex  och  har  omfattande fördelar  för  flyg  och  många industriella processer. Det minskar kostnaderna och har ett större krav på pulverpartikelstorlek. Detta ger fördelen av en högre massavsättningshastighet och därmed snabbare produktionstid jämfört med Laser-Powder Bed Fusion-processen. Tillverkningsprocesser för pulverbädd leder ofta  till  att en kolumnformig  kornstruktur  bildas  längs  byggriktningen, vilket resulterar  i komponenter  som  har  anisotropa  fysikaliska  och mekaniska egenskaper.  Detta  är  ett  stort problem som begränsar tillämpningarna av denna teknik. För att främja likaxliga korn, samt förfina den kolumnära morfologin och eliminera anisotropa egenskaper, övervägs rollerna för processbetingelser och närvaron av ympmedel eller heterogena kärnbildningsställen. I denna studie  används  tillsatsen  av  inokulanter  av  titannitrid  för  att  främja  kolumnär  till  likaxlig kornövergång  i  ferritiskt rostfritt  stål  med  användning  av  smältstrategier  och  variabla processparametrar.  Det  har  visat  sig  att  förhållandet  mellan  termisk gradient  (G)  och stelningshastighet   (R)   (G/R-förhållande)   styr   kornmorfologi   och   textur:   ett   lågt   G/R- förhållande har visat sig främja bildningen av likaxliga korn. Processförhållandena för denna övergång undersöktes. Proverna analyserades efter att ha skrivit ut spår med en rad i Freemelt One-maskinen  och  studerades  därefter  med  hjälp  av  optisk mikroskopi  för  att  fastställa kombinationen   av   maskinparametrar   som   resulterar   i   en   framgångsrik   övergång   från kolumnära  korn till  likaxliga.  Studien  drog  slutsatsen  att  det  fanns  en  ökning  av andelen likaxliga korn under dessa förhållanden; en låg termisk gradient, hög avsökningshastighet och låg areaenergi. I slutändan kommer ytterligare undersökningar att behövas för att fastställa de exakta processparametrarna som kommer att främja övergången från kolumnära till likaxliga korn i ferritiskt rostfritt stål. Resultaten från denna studie kan användas av framtida forskare för att skapa stelningskartor för denna stålkvalitet och hjälpa industrin att skräddarsy specifika texturer i ferritiskt rostfritt stål för att uppnå önskade mikrostrukturer och mekaniska egenskaper.