When joining steel to aluminium there is a reaction between iron and aluminium which results in the formation of brittle intermetallic compounds (IMC). These compounds are usually the reason for the poor mechanical strength of the dissimilar metallic joints. The research on dissimilar metal joining is vast but is mainly focused on the automotive industry and therefore, the material in use is very thin, usually less than 1 mm. For materials with thicker sections the present solution is a transition joint made by explosion welding which permits joining of steel to aluminium and avoids the formation of IMCs. However, this solution brings additional costs and extra processing time to join the materials. The main goals of this project are to understand the mechanism of formation of the IMCs, control the formation of the IMCs, and understand their effects on the mechanical properties of the dissimilar Fe-Al joints during laser welding. Laser welding permits accurate and precise control of the welding thermal cycle and thereby the underpinning mechanism of IMC formation can be easily understood along with the factors which control the strength of the joints. The further goal of this project is to find an appropriate interlayer to restrict the Fe-Al reaction. The first stage of the work was focused on the formation and growth of the Fe-Al IMCs during laser welding. The understanding of how the processing conditions affect the IMC growth provides an opportunity to act and avoid its formation and thereby, to optimize the strength of the dissimilar metal joints. The results showed that even with a negligible amount of energy it was not possible to prevent the IMC formation which was composed of both Fe2Al5 and FeAl3 phases. The IMC growth increases exponentially with the applied specific point energy. However, for higher power densities the growth is more accentuated. The strength of the Fe-Al lap-joints was found to be not only dependent on the IMC layer thickness but also on the bonding area. In order to obtain sound joints it is necessary to achieve a balance between these two factors. The thermal model developed for the laser welding process in this joint configuration showed that for the same level of energy it is more efficient to use higher power densities than longer interaction iv times. Even though a thicker IMC layer is formed under this condition due to higher temperature there is also more melting of aluminium which creates a larger bonding area between the steel and the aluminium. The joint strength is thus improved ... [cont.].

L'objectif de ce manuscrit est de présenter mes travaux concernant la modélisation des ablations thermiques par ultrasons focalisés. La méthode de simulation du faisceau acoustique, fondée sur l'utilisation de la bibliothèque k-Wave, est appliquée à un cas concret de propagation des ultrasons à travers une couche de tissu superficiel. Des mesures à l'hydrophone réalisées dans différentes configurations sur des échantillons biologiques fournissent une validation en régime linéaire. A partir de ces résultats, l'influence des tissus superficiels sur la focalisation est évaluée en fonction de la géométrie du problème grâce à des simulations non linéaires.La modélisation thermique des traitements est ensuite discutée avec la volonté de réaliser des simulations thermiques réellement quantitatives. En particulier, un modèle équivalent de la déposition de chaleur en présence d'ébullition est proposé et validé grâce à l'utilisation de données expérimentales originales, diversifiées et peu coûteuses à acquérir.Finalement, un algorithme d'optimisation fondé sur le principe du maximum de Pontryagin est proposé afin d'optimiser la durée des traitements. L'approche étudiée consiste à optimiser la trajectoire du point focal pour maximiser l'efficacité de la déposition de chaleur. A travers une série d'exemples, les avantages et les limites de l'algorithme proposé sont discutés. / This manuscript aims at discussing the complex issue of modeling high-intensity focused ultrasound thermal ablations. An acoustical simulation method, based on the use of the k-Wave library, is described and applied to the description of the interaction between the acoustic beam and the superficial tissue layers. It is validated in the linear domain based on hydrophone measurements realized in different configurations with biological samples. Nonlinear simulations are subsequently used to evaluate the influence of the tissue geometry on the beam focusing.The thermal modeling of the treatment is then discussed with intent to design a truly quantitative model. An equivalent model of the modified heat deposition pattern in presence of boiling is presented and validated based on the use of original, diverse and unexpensive data.Finally, an algorithm is proposed to optimize the focal spot trajectory in order to maximize the heat deposition efficiency, thus reducing treatment time. The advantages and the limits of the approach are discussed based on different examples.

Hybrid Electric Vehicles (HEVs) and Electric Vehicles (EVs) are crucial technologies for the automotive industry to meet society’s demands for cleaner, more energy efficient transportation. Meeting the need to provide power which sustains HEVs and EVs is an immediate area of concern that research and development within the automotive community must address. Electric batteries and electrical motors are the key components in HEV and EV power generation and transmission, and their performance plays very important role in the overall performance of the modern high efficiency vehicles. Therefore, in this dissertation, we are motivated to study the electric batteries, interior permanent motor (IPM), in the context of modern hybrid electric/electric drive systems, from both multi-physics and system level perspectives. Electrical circuit theory, electromagnetic Finite Element Analysis (FEA), and Computational Fluid Dynamic (CFD) finite volume method will be used primarily in this work. The work has total of five parts, and they are introduced in the following. Firstly, Battery thermal management design is critical in HEV and EV development. Accurate temperature distribution of the battery cells during vehicle operation is required for achieving optimized design. We propose a novel electrical-thermal battery modeling technique that couples a temperature dependent battery circuit model and a physics-based CFD model to meet this need. The electrical circuit model serves as a heat generation mechanism for the CFD model, and the CFD model provides the temperature distribution of the battery cells, which can also impact the heat generation of the electrical battery model. In this part of work, simulation data has been derived from the model respective to electrical performance of the battery as well iv as the temperature distribution simultaneously in consideration of the physical dimensions, material properties, and cooling conditions. The proposed model is validated against a battery model that couples the same electrical model with a known equivalent thermal model. Secondly, we propose an accurate system level Foster network thermal model. The parameters of the model are extracted from step responses of the CFD battery thermal model. The Foster network model and the CFD model give the same results. The Foster network can couple with battery circuit model to form an electric-thermal battery model for system simulation. Thirdly, IPM electric machines are important in high performance drive systems. During normal operations, irreversible demagnetization can occur due to temperature rise and various loading conditions. We investigate the performance of an IPM using 3d time stepping electromagnetic FEA considering magnet’s temperature dependency. Torque, flux linkage, induced voltage, inductance and saliency of the IPM will be studied in details. Finally, we use CFD to predict the non-uniform temperature distribution of the IPM machine and the impact of this distribution on motor performance. Fourthly, we will switch gear to investigate the IPM motor on the system level. A reduced order IPM model is proposed to consider the effect of demagnetization of permanent magnet due to temperature effect. The proposed model is validated by comparing its results to the FEA results. Finally, a HEV is a vehicle that has both conventional mechanical (i.e. internal combustion engine) and electrical propulsion systems. The electrical powertrain is used to work with the conventional powertrain to achieve higher fuel economy and lower emissions. v Computer based modeling and simulation techniques are therefore essential to help reduce the design cost and optimize system performance. Due to the complexity of hybrid vehicles, multidomain modeling ability is preferred for both component modeling and system simulation. We present a HEV library developed using VHDL-AMS.

Interconnects in power module result in thermal interfaces. The thermal interfaces degrade under thermal cycling, or chemical loading. Moreover, the reliability of thermal interfaces can be especially problematic when the interconnecting area is large, which increases its predisposition to generate defects (voids, delamination, or nonuniform quality) during processing. In order to improve the quality of the bonding process, as well as to be able to accurately assess interface reliability, it would be desirable to have a simple, reliable, and nondestructive measurement technique that would produce a 2-d map of the interface thermal resistance across a large bonded area. Based on the transient thermal method of JEDEC standard 51-14, we developed a measurement technique that involves moving a thermal sensor discretely across a large-area bonded substrate and acquiring the interface thermal resistance at each location. As detailed herein, the sensor was fabricated by packaging an IGBT bare die. An analytical thermal model was built to investigate the effects of thermal sensor packaging materials and structural parameters on the sensitivity of the measurement technique. Based on this model, we increased the detection sensitivity of the sensor by modifying the size of the sensor substrate, the material of the sensor substrate, the size of the IGBT bare die, the size of the heat sink, and the thermal resistance between sample and the heat sink. The prototype of the thermal sensor was fabricated by mounting Si IGBT on copper substrate, after which the Al wires were ultrasonic bonded to connect the terminals to the electrodes. The sensor was also well protected with a 3-d printed fixture. Then the edge effect was investigated, indicating the application of the thermal sensor is suitable for samples thinner than the value in TABLE 2 3. The working principle of the movable thermal sensor – Zth measurement and its structure function analysis – was then evaluated by sequence. The Zth measurement was evaluated by measuring the Zth change of devices induced by degradation in sintered silver die-attach layer during temperature cycling. At the end of the temperature cycling, failure modes of the sintered silver layer were investigated by scanning electron microscope (SEM) and X-ray scanning, to construct a thermal model for FEA simulation. The simulation results showed good agreement with the measured Zth result, which verified the accuracy of the test setup. The sensitivity of structure function analysis was then evaluated by measuring thermal resistance (Rth) of interface layers with different thermal properties. The structure function analysis approach successfully detected the Rth change in the thermal interface layer. The movable thermal sensor was then applied for 2d-mapping of the interface Rth of a large-area bonded substrate. Examining the test coupons bonded by sintered silver showed good and uniform bonding quality. The standard deviation of Rth is about 0.005 K/W, indicating the 95% confidence interval is about 0.01 K/W, which is commonly chosen as the error of measurement. The sensitivity of the movable thermal sensor was evaluated by detecting defects/heat channels of differing sizes. The 2-d mapping confirmed that the thermal sensor was able to detect defect/heat channel sizes larger than 1x1 mm2. The accuracy of the sensitivity was verified by FEA simulation. Moreover, the simulated results were consistent with the measured results, which indicates that the movable sensor is accurate for assessing interface thermal resistance. In summary, based on structure function analysis of the transient thermal impedance, the concept of a movable thermal sensor was proposed for two-dimensional mapping of interface thermal resistance. (1) Preliminary evaluation of this method indicated both transient thermal impedance and structure function analysis were sensitive enough to detect the thermal resistance change of thermal interface layers. With the help of transient thermal impedance measurement, we non-destructively tested the reliability of sintered silver die-attach layer bonded on either Si3N4 AMB or AlN DBA substrates. (2) An analytical thermal model was constructed to evaluate the design parameters on the sensitivity and resolution of the movable thermal sensor. A detailed design flow chart was provided in this thesis. To avoid edge effect, requirements on thickness and materials of test coupon also existed. Test coupon with smaller thermal conductivity and larger thickness had a more severe edge effect. (3) The application of the movable sensor was demonstrated by measuring the 2-d thermal resistance map of interface layers. The results indicated for bonded copper plates (k = 400 W/mK) with thickness of 2 mm, the sensor was able to detect defect/heat channel with size larger than 1x1 mm2. / Doctor of Philosophy / Interconnects in power module result in thermal interfaces. The thermal interfaces degrade during operation and their reliability can be especially problematic when the interconnecting area is large. In order to improve the quality of the bonding process, as well as to be able to accurately assess interface reliability, it would be desirable to have a simple, reliable, and nondestructive measurement technique that would produce a 2-d map of the interface thermal resistance across a large bonded area. Based on the transient thermal method of JEDEC standard 51-14, we developed a measurement technique that involves moving a thermal sensor discretely across a large-area bonded substrate and acquiring the interface thermal resistance at each location. As detailed herein, the sensor was fabricated by packaging an IGBT bare die, which allowed us to get a 2-d map of the interface thermal resistance. A thermal model was also constructed to guide the design of the sensor, to increase its performance. Moreover, the preliminary test of the test setup was conducted to prove its feasibility for the sensor. Eventually, the sensor’s performance and application was demonstrated by measuring the 2-d thermal resistance map of the bonded interfaces.

No description available.

Buildings are currently controlled in a sub optimal way, using a WC controller that is dependent only on the external temperature. A rich amount of real-time data from installed sensors is available within the buildings and the network and can be used to counteract this. To better control the indoor temperature and the heat supply this degree-project develops a model and optimizer for control of the indoor temperature, where industry standard data streams are used as inputs. The model and optimizer can be implemented in a MPC which takes the future external temperature into consideration and enhances the ability to control the heat supply. There are two main reasons why enhanced control is interesting to look at, the economic aspects and the comfort of the occupancies. This degree project is focused on developing a general building model for the purpose of utilizing the building as an energy storage for peak-shaving.  The finalized model is a dynamic grey-box model developed using data from a multifamily building, Building A, located in Västerås Sweden. The training period is set to 408 hours, and the prediction horizon is set to 48 hours as a result of the verification. To demonstrate the utilization possibilities of using the building as a heat storage, an optimizer is constructed to evaluate a peak shaving control strategy. The control objective (Qsupply) is controlled by manipulating the indoor temperature (Tin) within a set interval. By setting a fixed interval for the indoor temperature within the comfort interval, the comfort is still maintained. For the peak shaving different flexibilities within the indoor temperature have been examined with a range from 22 +/- 0.25 degrees Celcius to 22 +/- 2.00 degrees Celcius.  The model is verified in 4 steps: prediction ability on the historic data, parametric verification on the time constant, simulation of heat supply separately from the historic data and model generality by implementing the model on a second multifamily building, Building B. The model has a RRMSE of 8% for Building A and 9% for Building B which is considered excellent.  Due to the lack of access to the real building, the developed model is not validated. Based on peak shaving and energy consumption, the preferred solution is 22+/- 1.25 degrees Celcius. But based on surveys about occupancies attitude toward flexibility in the indoor temperature and economical aspects, an indoor temperature of 22 +/- 0.50 degrees Celcius is considered the best choice with the maximum peak in the heat supplied decreased by 35% and the energy consumption is decreased by 10% compared to the historical case. We suggest allowing the customers to choose their preferred flexibility to ensure comfort.

This research aims to explore new ways of assessing energy performance within housing units. The mainobjective of this work is to propose a heat dynamics model based on monitoring data, to contribute towardsan energy-efficient transition in the building sector. An extensive study on the available mathematical and statistical tools is described in order to determine aholistic solution, found in grey-box models. This model approach offers the possibility of understandingmultivariate systems, which can be applied to a housing-unit heat flow dynamics. Through the iterative process of testing each possible model, this work determines the one with bestexplanatory power, defining the thermal characteristics of the studied housing unit. This method allows thedetection of underperforming dwellings among constructions with high energy-efficiency standards. This investigation reflects the feasibility of employing grey-box models to predict the dynamics of heatrelated systems. Moreover, it sets the basis for new ways of employing the monitoring data of dwellings. / Denna forskning syftar till att utforska nya sätt att bedöma energiprestanda inom bostäder. Huvudsyftetmed detta arbete är att föreslå en värmedynamikmodell baserad på övervakningsdata för att bidra till enenergieffektiv övergång inom byggsektorn. En omfattande studie av tillgängliga matematiska och statistiska verktyg beskrivs för att bestämma enhelhetslösning, som finns i gråboxmodeller. Denna modellstrategi ger möjlighet att förstå multivariatasystem, som kan tillämpas på en hushålls värmedynamik. Genom den iterativa processen att testa varje möjlig modell bestämmer detta arbete den med bästförklarande kraft, och definierar de studerade husenhetens termiska egenskaper. Denna metod gör detmöjligt att upptäcka underpresterande bostäder bland anläggningar med hög energieffektivitetsstandard. Denna undersökning återspeglar möjligheten att använda gråboxmodeller för att förutsäga dynamiken ivärmerelaterade system. Dessutom lägger den grunden för nya sätt att använda övervakningsdata förbostäder.

Laser metal deposition (LMD) offers a unique combination of process flexibility, time savings, and reduced cost in producing titanium alloy components. The current challenge in processing titanium alloys using LMD methods is understanding the complex microstructure evolution as a part is fabricated layer by layer. The current work focuses on the characterization, thermal, and microstructural modeling of multilayered Ti-6Al-4V deposits. A thermal model has been developed using finite difference techniques to predict the thermal history of LMD processes. A microstructure model that predicts the alpha phase fraction and morphology evolution was constructed to quantify the effect of thermal cycling on the as-deposited microstructure evolution. Alpha dissolution and growth are modeled assuming one-dimensional plate dissolution according to a parabolic rate law, and a Johnson-Mehl-Avrami-Kolmorgorov (JMAK) nucleation and growth model, respectively. Alpha morphology (colony-alpha and basketweave-alpha) evolution is tracked using a simplistic approach. Characterization of the deposit has shown that a complex microstructure evolves consisting of a two distinct regions: a transient region of undeveloped microstructure and a characteristic layer that is periodically repeated throughout the deposit. The transient region contains a fine basketweave and colony-alpha morphology. The characteristic layer contains a two phase mixture of alpha+beta, with the alpha phase exhibits regions of colony-alpha (layer band) and basketweave-alpha morphology. The different regions of microstructural contrast in the deposit are associated with thermal cycling. The thermal model results show that a heat affected zone defined by the beta transus extends approximately 3 layers into the deposit. The phase fraction model predicts the greatest variation in microstructural evolution to occur in a layer n after the deposition of layer n+3. The results of the morphology model show that increased amounts of colony-alpha form near the top of a characteristic layer. It follows that a layer band (colony-alpha region) forms as a result of heating a region of material to a peak temperature just below the beta transus, where a large amount of primary-alpha dissolves. Upon cooling, colony-alpha forms intragranularly. The coupled thermal and microstructure models offer a way to quantitatively map microstructure during LMD processing of Ti-6Al-4V. / Ph. D.

Les structures de combustion constituent un témoin de la fréquentation humaine et leur étude permet d’appréhender un aspect du mode d’occupation d’un lieu donné. Ainsi, pour compléter les approches classiques qui s’intéressent à la typologie des foyers, à la fréquence des feux, à la nature des combustibles, etc., une caractérisation thermique de ces structures a été proposée. Elle s’appuie sur les impacts thermiques enregistrés par les sédiments soumis aux feux et plus précisément sur les modifications des propriétés de thermoluminescence (TL) et de magnétisme avec la chauffe.Le site-laboratoire est celui de la grotte de Fraux (Dordogne), occupée à l’Âge du bronze, dont le statut et le mode d’occupation pose question puisqu’elle présente tant des vestiges domestiques (sols de circulation, foyers, mobiliers) que des vestiges symboliques (manifestations pariétales, dépôts de mobilier). La place importante des foyers parmi ces vestiges a induit une étude spécifique de ces structures. En effet, ce site recèle plus d’une soixantaine de structures de combustion et, aspect important pour notre approche archéométrique, présente un état de conservation exceptionnel puisque la grotte est restée fermée depuis l’occupation de l’Âge du bronze.L’étude de certains foyers de la grotte des Fraux a permis de tester le potentiel de paléothermomètres fondés sur ces deux propriétés indépendantes à savoir la TL des grains de quartz et le magnétisme des oxydes de fer contenus dans les sédiments. Le paléothermomètre TL a été élaboré en comparant les signaux TL d’échantillons provenant de foyers archéologiques à ceux de références thermiques chauffées en laboratoire. Pour le magnétisme deux pistes ont été exploitées : les températures de déblocage de l’aimantation rémanente et l’évolution de la signature magnétique -minéralogie et taille de grain) avec la chauffe. La détermination des paléotempératures atteintes par les sédiments substrats des structures de combustion apporte une première indication sur leur intensité de chauffe. Afin d’étalonner ces informations paléothermométriques en termes d’énergie mise en jeu, des feux expérimentaux ont été réalisés. Ils ont permis de comparer les impacts thermiques entre feux archéologiques et feux expérimentaux, de construire un échantillonnage d’histoire thermique connue, mais aussi d’estimer les températures atteintes, les épaisseurs de sédiments affectés, les quantités de combustibles consommés pendant un temps donné, la quantité d’énergie dégagée par la combustion… Ces expérimentations ont aussi servi de base à une modélisation de la propagation de la chaleur dans les sédiments. Les simulations effectuées dans ce modèle numérique permettent alors d’estimer un temps minimal de fonctionnement des structures de combustion.Nous disposons ainsi d’un nouvel outil pour la caractérisation thermique de foyers archéologiques. / The study of the combustion structures, which are a remaining evidence of the human occupation, can give information about the way of occupation of a site. In this research we decided to complete the classical approaches of combustion structures generally based on typological description of hearths, frequency of fires, nature of fuel, etc. by a a thermal characterisation. This study deals with the thermal impacts recorded by the fired sediment. More precisely, the modifications of both thermoluminescence (TL) and magnetism properties with heating were investigated.The laboratory-site is the cave of Les Fraux (Dordogne, France) which was occupied in the Bronze Age. The archaeologists were wandering about the function and the way of occupation of this cave because of the existence of both domestic vestiges (archaeological occupation grounds, hearths, and ceramics) and symbolic evidences (rock art and votive ceramic deposition). A specific study of the combustion structures had started considering the significant number of hearths, more than sixty, and their importance in the human occupation. In addition, as the cave remained closed since the Bronze Age, the hearths are in an excellent state of conservation and that is an important point for our archaeometric study. The thermal characterisation of some hearths from the cave of Les Fraux firstly consisted in studying the paleothermometer potential of two properties: the thermoluminescence of quartz grains and the magnetism of iron oxides taken from the sediments. The TL paleothermometer was established by comparing TL signals of samples from archaeological hearths and those of thermal references heated in laboratory. Two properties were explored for the magnetic paleothermometer: the unblocking temperatures of the remanent magnetization and the evolution of magnetic signature (mineralogy and grain size) with heating. The paleotemperatures determined for the sediment of the hearths give a first information about the heating intensity of fires.Then experimental fires were carried out to calibrate paleothermometric data in quantity of energy and wood consumption, to check the suitability of laboratory thermal references, and to characterise the process of heat transfer inside the sediment. Finally, a numerical modeling of heat propagation within the sediment was implemented from temperatures recorded during fire experimentations. Numerical simulations performed in this model allowed us to estimate a minimal duration of functioning of the combustion structures.A novel tool for the thermal characterisation of combustion structures is then available.

L’objectif de ce travail est l’étude du comportement des matériaux minéraux de grande diffusion lors du séchage convectif : étude expérimentale et modélisation. Une première étape a été consacrée à la caractérisation (physico-chimique et comportement en température) des matières premières de deux composés argileux tunisiens (AX et AR), d’un mélange argileux par porcelaine (BC) et de deux composés innovants commercialisés par la société BIBLIONTEK : un mélange argileux (MG) et un composite argilo-cellulosique (CA). La mesure des propriétés d’équilibre thermodynamique, des propriétés de transfert et des propriétés mécaniques a été effectuée, dans un second temps, afin de comprendre le comportement hydro-thermo-mécanique de ces matériaux. Les cinétiques de séchage expérimentales ont été ensuite établies pour le mélange argileux (MG) et le composite argilo-cellulosique (CA) sous forme de monocouche d’échantillons ou en échantillon individuel, à différentes températures sèches, humidités relatives et vitesses de l’air. Ces cinétiques ont servi à valider les deux modèles développés. Le premier modèle hydro-thermo-mécanique 2D d’un produit déformable saturé d’eau lors du séchage convectif a été appliqué à un échantillon du mélange argileux (MG). Partant de la validation de ce modèle, les distributions spatio-temporelles de la teneur en eau, de la température et de la contrainte mécanique ont été simulées et interprétées en termes d’endommagement potentiel du produit. Un deuxième modèle hydro-thermique spécifique à un produit capillaro-poreux non saturé et hygroscopique a été aussi établi. Le modèle est appliqué au composite argilo-cellulosique. L’endommagement mécanique du produit, qui est conditionné par la surpression interne de la phase gazeuse, a été évalué en cours du procédé. Les résultats de ces travaux de recherche pourront être exploités à moyen termes dans l’industrie, afin de réduire le coût énergétique du séchage et de contrôler la qualité du produit fini. / The aim of this work is to study behavior of low cost mineral materials during convective drying: experiment and theoretical modeling. A first part is devoted to the physical and chemical characterization of materials. These are two Tunisian clays (AX and AR), a porcelain clay mixture (BC) and two clay mixtures (MG and CA) commercialized by the company BIBLIONTEK, one of which is a composite of clay and cellulose fibers (CA). Measurements of thermodynamic equilibrium, transfer proprieties and the mechanical proprieties were then made in order to understand the continued hydric, thermal and mechanical behavior of the materials. Experimental characterization of the drying kinetics for the MG and CA clay mixtures (MG and CA) was made on single layer samples or individual samples at different dry temperatures, relative humidities and air speeds. These kinetics were used to validate two theoretical models. The first is two dimensions of a deformable material saturated in water during convective drying was applied to the case of MG clay mixture. The spatial distributions of water content in the material, temperature and mechanical stress were simulated as a function of time and interpreted in terms of possible damage to the material. A second model, specific to a hygroscopic material contuning non saturated capillary pore, was also established. The model was applied to the clay-cellulose fibers composite material (CA). The mechanical damage to the material, conditioned by internal pressure due to the gas phase, was evaluated during the drying process. The conclusions of this research can be exploited in on industrial context in order to reduce energy costs of drying and improve final product quality.