Increased interest in and use of additive manufacturing has made it an important component of advanced manufacturing in the last decade. Material Extrusion Additive Manufacturing (MatEx) has seen a shift from a rapid prototyping method harnessed only in parts of industry due to machine costs, to something widely available and employed at the consumer level, for hobbyists and craftspeople, and industrial level, because falling machine costs have simplified investment decisions. At the same time MatEx systems have been scaled up in size from desktop scale Fused Filament Fabrication (FFF) systems to room scale Big Area Additive Manufacturing (BAAM). Today MatEx is still used for rapid prototyping, but it has also found application in molds for fiber layup processes up to the scale of wind turbine blades. Despite this expansion in interest and use, MatEx continues to be held back by poor part performance, relative to more traditional methods such as injection molding, and lack of reliability and user expertise. In this dissertation, a previously unreported phenomenon, irreversible thermal strain (ITε), is described and explored. Understanding ITε improves our understanding of MatEx and allows for tighter dimensional control of parts over time (each of which speaks to extant challenges in MatEx adoption). It was found that ITε occurs in multiple materials: ABS, an amorphous polymer, and PLA, a semi-crystalline one, suggesting a number of polymers may exhibit it. Control over ITε was achieved by tying its magnitude back to part layer thickness and its directionality to the direction of roads within parts. This was explained in a detail by a micromechanical model for MatEx described in this document. The model also allows for better description of stress-strain response in MatEx parts broadly. Expanding MatEx into new areas, one-way shape memory in a commodity thermoplastic, ABS, was shown. Thermal history of polymers heavily influences their performance and MatEx thermal histories are difficult to measure experimentally. To this end, a finite element model of heat transfer in the part during a MatEx build was developed and validated against experimental data for a simple geometry. The application of the model to more complex geometries was also shown. Print speed was predicted to have little impact on bonds within parts, consistent with work in the literature. Thermal diffusivity was also predicted to have a small impact, though larger than print speed. Comparisons of FFF and BAAM demonstrated that, while the processes are similar, the size scale difference changes how they respond to process parameter and material property changes, such as print speed or thermal diffusivity, with FFF having a larger response to thermal diffusivity and a smaller response to print speed. From this experimental and simulation work, understanding of MatEx has been improved. New applications have been shown and rational design of both MatEx processes and materials for MatEx has been enabled.

Increased interest in and use of additive manufacturing has made it an important component of advanced manufacturing in the last decade. Material Extrusion Additive Manufacturing (MatEx) has seen a shift from a rapid prototyping method harnessed only in parts of industry due to machine costs, to something widely available and employed at the consumer level, for hobbyists and craftspeople, and industrial level, because falling machine costs have simplified investment decisions. At the same time MatEx systems have been scaled up in size from desktop scale Fused Filament Fabrication (FFF) systems to room scale Big Area Additive Manufacturing (BAAM). Today MatEx is still used for rapid prototyping, but it has also found application in molds for fiber layup processes up to the scale of wind turbine blades. Despite this expansion in interest and use, MatEx continues to be held back by poor part performance, relative to more traditional methods such as injection molding, and lack of reliability and user expertise. In this dissertation, a previously unreported phenomenon, irreversible thermal strain (ITε), is described and explored. Understanding ITε improves our understanding of MatEx and allows for tighter dimensional control of parts over time (each of which speaks to extant challenges in MatEx adoption). It was found that ITε occurs in multiple materials: ABS, an amorphous polymer, and PLA, a semi-crystalline one, suggesting a number of polymers may exhibit it. Control over ITε was achieved by tying its magnitude back to part layer thickness and its directionality to the direction of roads within parts. This was explained in a detail by a micromechanical model for MatEx described in this document. The model also allows for better description of stress-strain response in MatEx parts broadly. Expanding MatEx into new areas, one-way shape memory in a commodity thermoplastic, ABS, was shown. Thermal history of polymers heavily influences their performance and MatEx thermal histories are difficult to measure experimentally. To this end, a finite element model of heat transfer in the part during a MatEx build was developed and validated against experimental data for a simple geometry. The application of the model to more complex geometries was also shown. Print speed was predicted to have little impact on bonds within parts, consistent with work in the literature. Thermal diffusivity was also predicted to have a small impact, though larger than print speed. Comparisons of FFF and BAAM demonstrated that, while the processes are similar, the size scale difference changes how they respond to process parameter and material property changes, such as print speed or thermal diffusivity, with FFF having a larger response to thermal diffusivity and a smaller response to print speed. From this experimental and simulation work, understanding of MatEx has been improved. New applications have been shown and rational design of both MatEx processes and materials for MatEx has been enabled.

New stricter environmental legislation requires lower emissions and fuel consumption of automotive engines. Therefore the fuel efficiency must be increased but this leads to higher loads in the engine. As for the exhaust system it is affected by higher thermomechanical loads. Until today the turbo manifold has been nitrocarburized in order to increase the wear resistance in slip joints with other exhaust components. The problem is that there is no knowledge of how the nitrocarburizing affects the thermomechanical properties of the material. The purpose of this thesis work is to examine the difference in thermomechanical properties with and without nitrocarburizing on the three different ductile irons High Silicon, SiMo51 and SiMo1000 intended for exhaust components. Thermo-mechanical fatigue (TMF) experiments were performed on test rods to evaluate difference in number of cycles to failure. In each cycle the test-rod was affected by a combination of mechanical loads and thermal loads resembling those found on exhaust components. Light optical microscopy, scanning electron microscopy and x-ray radiography were used to examine microcracks and damage mechanisms of the materials. It was found that the nitrocarburizing did not affect the number of cycles to failure in any large extent. Further, it was also found that SiMo1000 on average has the longest lifetime followed by SiMo51 and High Silicon. Although, the difference is small for many loadings and taking a 95% confidence band into account the curves overlap for many loading cases.

In an engine component the repeated start-stop cycles cause temporal and local inhomogeneous temperatures, which in turn lead to a type of low-frequency loading, plastic deformation and eventually failure due to thermo-mechanical fatigue. Simultaneously, high-frequency mechanical loading arises from the cyclic combustion pressure and from road induced vibrations. These types of loadings that mainly are in the elastic region are usually denoted high cycle fatigue (HCF). In order to improve efficiency, power density and to reduce emissions, future truck engines will be subjected to higher temperatures and higher combustion pressures which will affect the service life of the different engine components. As a consequence, there is a need to determine the limitations of the used alloys under these service conditions as exactly as possible. In this master thesis work the fatigue properties of one grey iron (EN-GJL 250) and one compacted graphite iron (EN-GJV 400) has been investigated under realistic loading conditions. The results show that a change from the grey iron to the compacted graphite iron will result in a significant increase of the fatigue life. The investigation also reveal that the life will increase significantly if the maximum temperature can be decreased tens of degrees. Further, the results indicate that addition of a relatively small HCF load may give a large decrease of the fatigue life. / Motorkomponenter utsätts för upprepade start och stopp, vilka skapar tillfälliga och lokala temperaturvariationer. Dessa resulterar i lågfrekventa lastväxlingar, plastiska deformationer och eventuella brott i form av termodynamisk utmattning (TMF). Det sker dessutom en högfrekvent mekanisk last, genererad av förbränningen och från vägvibrationer. Dessa laster är mestadels elastiska och benämns högcykelutmattning (HCF). För att kunna förbättra verkningsgrad och minska emissioner kommer framtida lastbilsmotorer att utsättas för högre förbränningstryck och högre temperaturer, vilket kommer påverka motorernas livslängd. För detta krävs det att materialens begränsningar utreds under ett verklighetstroget förhållande. I detta exjobb kommer utmattningsegenskaperna för ett gråjärn (EN-GJL 250) och ett kompaktgrafikjärn (EN-GJV 400) utredas under realistiska lastförhållanden. Resultatet påvisar att ett byte från gråjärn till kompaktgrafitjärn ger en signifikant ökad livslängd. Det framkommer också att livslängden kan ökas genom att sänka den maximala temperaturen ett tiotal grader. Analysen påvisar även att en relativt liten HCF last kan ge kraftigt förkortad livslängd.

In an engine component the repeated start-stop cycles cause temporal and local inhomogeneous temperatures, which in turn lead to a type of low-frequency loading, plastic deformation and eventually failure due to thermo-mechanical fatigue. Simultaneously, high-frequency mechanical loading arises from the cyclic combustion pressure and from road induced vibrations. These types of loadings that mainly are in the elastic region are usually denoted high cycle fatigue (HCF). In order to improve efficiency, power density and to reduce emissions, future truck engines will be subjected to higher temperatures and higher combustion pressures which will affect the service life of the different engine components. As a consequence, there is a need to determine the limitations of the used alloys under these service conditions as exactly as possible. In this master thesis work the fatigue properties of one grey iron (EN-GJL 250) and one compacted graphite iron (EN-GJV 400) has been investigated under realistic loading conditions. The results show that a change from the grey iron to the compacted graphite iron will result in a significant increase of the fatigue life. The investigation also reveal that the life will increase significantly if the maximum temperature can be decreased tens of degrees. Further, the results indicate that addition of a relatively small HCF load may give a large decrease of the fatigue life. Keywords:Thermo-mechanical fatigue, TMF, CGI, LGI, fatigue, thermal strain. / Motorkomponenter utsätts för upprepade start och stopp, vilka skapar tillfälliga och lokala temperaturvariationer. Dessa resulterar i lågfrekventa lastväxlingar, plastiska deformationer och eventuella brott i form av termomekanisk utmattning (TMF). Det sker dessutom en högfrekvent mekanisk last, genererad av förbränningen och från vägvibrationer. Dessa laster är mestadels elastiska och benämns högcykelutmattning (HCF). För att kunna förbättra verkningsgrad och minska emissioner kommer framtida lastbilsmotorer att utsättas för högre förbränningstryck och högre temperaturer, vilket kommer påverka motorernas livslängd. För detta krävs det att materialens begränsningar utreds under ett verklighetstroget förhållande. I detta exjobb kommer utmattningsegenskaperna för ett gråjärn (EN-GJL 250) och ett kompaktgrafikjärn (EN-GJV 400) utredas under realistiska lastförhållanden. Resultatet påvisar att ett byte från gråjärn till kompaktgrafitjärn ger en signifikant ökad livslängd. Det framkommer också att livslängden kan ökas genom att sänka den maximala temperaturen ett tiotal grader. Analysen påvisar även att en relativt liten HCF last kan ge kraftigt förkortad livslängd. Nyckelord: Termomekanisk utmattning, TMF, CGI, LGI, termisk töjning.

学位プログラム名: 京都大学大学院思修館 / 京都大学 / 新制・課程博士 / 博士(総合学術) / 甲第23347号 / 総総博第20号 / 新制||総総||4(附属図書館) / 京都大学大学院総合生存学館総合生存学専攻 / (主査)教授 山敷 庸亮, 教授 山本 貴士, 教授 寶 馨, 教授 齋藤 敬 / 学位規則第4条第1項該当 / Doctor of Philosophy / Kyoto University / DFAM

This diploma thesis is focused on behavior of cement concrete at high temperatures. The theoretical part describes processes, which take place in concrete at thermal loading and effect of this thermal load to mechanical and physical properties of concrete. Also there was described recommendation for testing physical and mechanical of concrete at high temperatures according to RILEM TC. In experimental part mixes were made with greywacke aggregate, amphibolite aggregate and with the addition of polypropylene fibers or cellulose fibers. In these mixes was determined the effect of high temperatures on the density of concrete, compressive strength of concrete and thermal strain of concrete. Further there was tested addition of 2 kg/m3 polypropylene fibers to concrete with basalt aggregate and siliceous aggregate and influence of these fibers to density of concrete, compressive strength of concrete and dynamic modulus of elasticity.

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Représentant 43% des décès rapportés au cours des dix dernières années, la mort subite due à un événement cardiaque est la cause de décès au travail la plus fréquente chez les pompiers américains. Des études démontrent que le risque d’événements cardiaques au travail chez les pompiers est accentué par deux causes principales, la première étant la présence d’une maladie coronarienne, d’une cardiomégalie/hypertrophie ventriculaire gauche (HVG) ou de dommages occasionnés antérieurement par un infarctus du myocarde, la seconde étant l’importante contrainte cardiovasculaire subie au travail. Aucune étude n’a été réalisée pour évaluer l’état de santé cardiovasculaire des pompiers et pompières du Québec. Une telle étude permettrait d’en connaître davantage sur leur risque de maladies et d’événements cardiovasculaires. Par ailleurs, on constate que la prévalence des facteurs de risque des maladies cardiovasculaires (MCV) est élevée chez les pompiers américains, ce qui corrèle avec le nombre élevé d’événements cardiaques au travail. Le premier objectif de cette thèse était donc de dresser un portrait de la santé cardiovasculaire des pompiers et pompières du Québec. Ensuite, dans le but de réduire le risque d’événements cardiaques au travail, il était pertinent d’étudier une stratégie de prévention des MCV chez les pompiers. Le risque de développer une maladie coronarienne ou une cardiomégalie/HVG pourrait être réduit en adoptant et maintenant de saines habitudes de vie, dont une pratique régulière d’activités physiques. Plusieurs services de sécurité incendie au Québec permettent aux pompiers de faire du conditionnement physique en caserne pendant les heures de travail. Cette pratique pourrait contribuer à augmenter leur quantité d’activités physiques hebdomadaire et à améliorer leur santé cardiovasculaire. Le deuxième objectif de cette thèse était donc de comparer la pratique d’activités physiques hebdomadaire et différents indicateurs de santé cardiovasculaire chez les pompiers qui font et ceux qui ne font pas de conditionnement physique pendant les heures de travail. Enfin, dans le but de réduire le risque d’événements cardiaques au travail, il semblait pertinent de s’intéresser à la prévention de la contrainte cardiovasculaire subie au travail chez les pompiers, considérant qu’elle agit comme « déclencheur ». Cette contrainte pourrait être réduite en évitant d’écourter les périodes de repos octroyées entre les phases de travail lors d’une intervention. Le troisième objectif de cette thèse était de comparer et de caractériser la contrainte cardiaque engendrée par deux interventions simulant les tâches du métier de pompiers, soit deux phases de travail identiques entrecoupées d’une période de récupération passive courte versus prolongée. Les résultats principaux de cette thèse montrent qu’une proportion importante de pompiers (Chapitre 2) et pompières (Chapitre 3) du Québec sont à risque moyen/élevé de MCV. Ils montrent aussi que les pompiers qui font du conditionnement physique pendant les heures de travail pratiquent plus d’activité physique par semaine et présentent de meilleurs indicateurs de santé cardiovasculaire que les pompiers qui n’en font pas (Chapitre 4). Finalement, les résultats montrent qu’une période de récupération passive d’une durée de 5 minutes entre deux phases de travail de 25 minutes lors d’une simulation d’intervention engendre une contrainte cardiaque largement plus importante qu’une période de 20 minutes et que cette différence semble être principalement redevable à une contrainte thermique et une déshydratation plus importantes (Chapitre 5). Ces projets de recherche ont été subventionnés par les Fonds de recherche du Québec – Santé sous la forme d'une bourse d'étude de formation de doctorat. / Accounting for 43% of deaths reported in the past decade, sudden cardiac death is the most common cause of on-duty deaths among US firefighters. Studies show that the risk of on-duty cardiac events in firefighters is accentuated by two main causes: the first is the presence of coronary heart disease, cardiomegaly/left ventricular hypertrophy (LVH) and/or damage caused previously by a myocardial infarction, the second being the important cardiovascular strain suffered at work. No studies have been conducted to assess the cardiovascular health status of Québec firefighters. Such a study would allow us to know more about their risk of cardiovascular diseases (CVD) and on-duty cardiac events. Futhermore, the prevalence of CVD risk factors was shown to be high among US firefighters, consistent with the high number of on-duty cardiac events. The first objective of this thesis was thus to assess the cardiovascular health profile of Québec male and female firefighters. Second, in order to reduce the risk of on-duty cardiac events, it was relevant to pore over the prevention of CVD in firefighters. The risk of developing coronary heart disease and/or cardiomegaly/LVH could be reduced by engaging in and maintaining healthy lifestyle behavior including regular physical activity. Several fire departments in Québec allow firefighters to do on-duty physical training in fire stations. This could help increase their weekly physical activity level and improve their cardiovascular health. The second objective of this thesis was to compare the weekly physical activity level and various cardiovascular health indicators in firefighters who physically train on duty in the fire station and those who do not. Lastly, in order to reduce the risk of on-duty cardiac events, it was also relevant to look at the prevention of cardiovascular strain suffered by firefighters, considering that it acts as a "trigger". This could be reduced by avoiding shortened recovery periods between periods of work during interventions. The third objective of this thesis was to compare and characterize the cardiac strain generated by two firefighting simulations consisting of two identical work bouts intercalated with a short vs. extended passive recovery period. iv The main results of this thesis show that a high proportion of Québec male and female firefighters are at moderate to high risk of CVD. They also show that firefighters who physically train on duty in fire stations have a higher weekly physical activity level and have better cardiovascular health indicators compared to firefighters who do not. Finally, the results show that a passive recovery period of 5 minutes between two 25-minute work bouts during a firefighting simulation results in a greater cardiac strain than a 20-minute recovery period and that this difference seems to be mainly due to a greater thermal strain and dehydration. These projects were funded by Fonds de recherche du Québec – Santé in the form of a doctoral research scholarship.