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Ahmadkhaniha, D., Sieber, M. & Zanella, C. (2024). Controlling coating thickness distribution for a complex geometry with the help of simulation. The International Journal of Advanced Manufacturing Technology, 134, 3703-3717
Open this publication in new window or tab >>Controlling coating thickness distribution for a complex geometry with the help of simulation
2024 (English)In: The International Journal of Advanced Manufacturing Technology, ISSN 0268-3768, E-ISSN 1433-3015, Vol. 134, p. 3703-3717Article in journal (Refereed) Published
Abstract [en]

This paper aims to develop a proper and valid simulation model for electroplating complex geometries. Since many variables influence the quality of the deposited coating and its thickness distribution, it is challenging to conduct efficient research only through experiments. In contrast, simulation can be an efficient way to optimize the electroplating experiments. Despite its potential, simulation has seen limited commercial use in the electroplating industry due to its inherent complexity and difficulty in achieving accurate precision for intricate geometries. The present study addresses the aspects that can enhance the electroplating simulation's accuracy, which has been typically overlooked in the literature, such as the effect of current efficiency and its dependency on the current density, the input data for the electrode kinetics, the surface topology changes, and the differences between 2 and 3D simulations. The simulation model was validated by experimental results related to the coating thickness of Ni plating on a T-joint geometry. The results showed good agreement with the experimental ones, confirming the model's ability to precisely predict the coating thickness and distribution and promote its broader utilization in the industry. Finally, the developed model was used to determine the optimal current density regime for achieving uniform coating thickness distribution on a T-joint sample.

Place, publisher, year, edition, pages
Springer, 2024
Keywords
Electroplating, Simulation, Moving boundary, Coating thickness, Level set
National Category
Materials Engineering
Identifiers
urn:nbn:se:hj:diva-66220 (URN)10.1007/s00170-024-14337-6 (DOI)001308090300005 ()2-s2.0-85203148374 (Scopus ID)HOA;;972125 (Local ID)HOA;;972125 (Archive number)HOA;;972125 (OAI)
Funder
Vinnova, 2021–01904
Available from: 2024-09-16 Created: 2024-09-16 Last updated: 2024-09-16Bibliographically approved
Krawiec, H., Kozina, I., Starowicz, M., Lekka, M., Zanella, C., Fedrizzi, L., . . . Deflorian, F. (2024). Corrosion Rate and Mechanism of Degradation of Chitosan/TiO2 Coatings Deposited on MgZnCa Alloy in Hank's Solution. International Journal of Molecular Sciences, 25(10), Article ID 5313.
Open this publication in new window or tab >>Corrosion Rate and Mechanism of Degradation of Chitosan/TiO2 Coatings Deposited on MgZnCa Alloy in Hank's Solution
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2024 (English)In: International Journal of Molecular Sciences, ISSN 1661-6596, E-ISSN 1422-0067, Vol. 25, no 10, article id 5313Article in journal (Refereed) Published
Abstract [en]

Overly fast corrosion degradation of biodegradable magnesium alloys has been a major problem over the last several years. The development of protective coatings by using biocompatible, biodegradable, and non-toxic material such as chitosan ensures a reduction in the rate of corrosion of Mg alloys in simulated body fluids. In this study, chitosan/TiO2 nanocomposite coating was used for the first time to hinder the corrosion rate of Mg19Zn1Ca alloy in Hank's solution. The main goal of this research is to investigate and explain the corrosion degradation mechanism of Mg19Zn1Ca alloy coated by nanocomposite chitosan-based coating. The chemical composition, structural analyses, and corrosion tests were used to evaluate the protective properties of the chitosan/TiO2 coating deposited on the Mg19Zn1Ca substrate. The chitosan/TiO2 coating slows down the corrosion rate of the magnesium alloy by more than threefold (3.6 times). The interaction of TiO2 (NPs) with the hydroxy and amine groups present in the chitosan molecule cause their uniform distribution in the chitosan matrix. The chitosan/TiO2 coating limits the contact of the substrate with Hank's solution.

Place, publisher, year, edition, pages
MDPI, 2024
Keywords
TiO2 nanoparticles, chitosan, coating, corrosion rate, magnesium alloy
National Category
Surface- and Corrosion Engineering
Identifiers
urn:nbn:se:hj:diva-64578 (URN)10.3390/ijms25105313 (DOI)001233311300001 ()38791360 (PubMedID)2-s2.0-85194219928 (Scopus ID)GOA;intsam;954467 (Local ID)GOA;intsam;954467 (Archive number)GOA;intsam;954467 (OAI)
Funder
European Commission, H2020-MSCA-ITN-2017, 764977
Available from: 2024-06-03 Created: 2024-06-03 Last updated: 2025-02-09Bibliographically approved
Linder, C., Mehta, B., Sainis, S., Lindén, J. B., Zanella, C. & Nyborg, L. (2024). Corrosion resistance of additively manufactured aluminium alloys for marine applications. npj Materials Degradation, 8(1), Article ID 46.
Open this publication in new window or tab >>Corrosion resistance of additively manufactured aluminium alloys for marine applications
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2024 (English)In: npj Materials Degradation, ISSN 2397-2106, Vol. 8, no 1, article id 46Article in journal (Refereed) Published
Abstract [en]

Additive manufacturing opens new possibilities for designing light-weight structures using aluminium alloys. The microstructure of two Al alloys and their corrosion resistance in NaCl and natural seawater environments were investigated. The newly designed Al-Mn-Cr-Zr based alloy showed a higher corrosion resistance than reference AlSi10Mg alloy in both environments in as printed and heat-treated conditions. The corrosion initiated in the Al matrix along the precipitates in the alloys where the Volta potential difference was found the highest. The coarser microstructure and precipitate composition of the new Al-alloy led to the formation of a resistant passive film which extended the passivity region of the Al-Mn-Cr-Zr alloy compared to the AlSi10Mg alloy. The effect of heat treatment could be seen in the microstructure as more precipitates were found in between the melt pool boundaries, which affected the corrosion initiation and slightly the pitting resistance. Overall, this study shows that a newly designed Al-alloy for additive manufacturing has a suitable corrosion resistance for applications in marine environments.

Place, publisher, year, edition, pages
Springer, 2024
Keywords
3D printing, Additives, Aluminum alloys, Aluminum corrosion, Chromium alloys, Corrosion resistant alloys, Heat resistance, Manganese alloys, Marine applications, Microstructure, Seawater corrosion, Silicon, Silicon alloys, Sodium chloride, Al-alloy, Coarse microstructure, Coarser precipitates, Heat treated condition, Lightweight structures, matrix, New Al alloys, Seawater environment, Volta-potential difference, Zr-based alloy, Corrosion resistance
National Category
Materials Engineering
Identifiers
urn:nbn:se:hj:diva-64169 (URN)10.1038/s41529-024-00459-5 (DOI)001214456900003 ()2-s2.0-85192079065 (Scopus ID)GOA;;950588 (Local ID)GOA;;950588 (Archive number)GOA;;950588 (OAI)
Funder
EU, Horizon 2020, 820774
Available from: 2024-05-13 Created: 2024-05-13 Last updated: 2025-01-31Bibliographically approved
State, S. P., Costovici, S., Mousavi, M., Garcia, Y. G., Zanella, C., Cojocaru, A., . . . Enachescu, M. (2024). Electrodeposited Sn-Cu-Ni alloys as lead-free solders on copper substrate using deep eutectic solvents: The influence of electrodeposition mode on the morphology, composition and corrosion behaviour. Surface & Coatings Technology, 477, Article ID 130324.
Open this publication in new window or tab >>Electrodeposited Sn-Cu-Ni alloys as lead-free solders on copper substrate using deep eutectic solvents: The influence of electrodeposition mode on the morphology, composition and corrosion behaviour
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2024 (English)In: Surface & Coatings Technology, ISSN 0257-8972, E-ISSN 1879-3347, Vol. 477, article id 130324Article in journal (Refereed) Published
Abstract [en]

In this work we present the pulsed current (PC) electrodeposition of Sn-Cu-Ni alloy as lead-free solder candidate, from choline chloride – ethylene glycol eutectic mixtures (1:2 molar ratio) onto copper metallic substrates. Electrolytes containing Sn2+, Cu2+ and Ni2+ salts in the selected deep eutectic solvent have been considered. The effect of the applied frequency of PC on the morphology, composition and melting point of the alloy is discussed and compared to the ones obtained using direct current (DC) plating mode. A refinement of the grain size and lower melting temperature of the alloy were noticed when pulsed current was applied. A comparative analysis of the electrochemical corrosion behaviour at macro- and micro- scale has been performed in 0.5 M and 0.1 M NaCl solutions involving potentiodynamic polarization curves, electrochemical impedance spectroscopy (EIS) and scanning vibrating electrode (SVET) techniques. Furthermore, an analysis after 96 h of exposure to salt mist test simulating a corrosive attack in harsh environment is presented, too. The obtained results showed enhanced corrosion resistance of the ternary alloys electrodeposited under PC conditions (the best for 1.67 Hz frequency) as compared to those using DC. Additionally, Raman spectroscopy evidenced the presence of tin oxi/hydroxy chloride and tin oxides as surface corrosion products. A corrosion mechanism has been proposed.

Place, publisher, year, edition, pages
Elsevier, 2024
Keywords
Corrosion behaviour, Deep eutectic solvents, Electrodeposition, Sn-Cu-Ni ternary alloy, SVET, Copper alloys, Copper corrosion, Corrosion resistance, Corrosion resistant alloys, Corrosive effects, Electrochemical corrosion, Electrochemical impedance spectroscopy, Electrodes, Ethylene, Ethylene glycol, Eutectics, Lead-free solders, Melting point, Molar ratio, Morphology, Nickel alloys, Organic solvents, Sodium chloride, Substrates, Tin alloys, Tin oxides, Choline chloride, Copper substrates, Electrodeposition mode, Morphology behavior, Pulsed currents, Pulsed-current electrodeposition, Scanning vibrating electrodes, Ternary alloys
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-63273 (URN)10.1016/j.surfcoat.2023.130324 (DOI)001148267500001 ()2-s2.0-85180943601 (Scopus ID);intsam;926129 (Local ID);intsam;926129 (Archive number);intsam;926129 (OAI)
Funder
EU, Horizon 2020
Available from: 2024-01-10 Created: 2024-01-10 Last updated: 2024-02-12Bibliographically approved
Bruschi, S., Bertolini, R., Ghiotti, A., Mahmood, H. & Zanella, C. (2024). Machinability of recycled aluminum alloys. Paper presented at 52nd SME North American Manufacturing Research Conference (NAMRC 52, 2024). Manufacturing Letters, 41(Supplement), 1669-1675
Open this publication in new window or tab >>Machinability of recycled aluminum alloys
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2024 (English)In: Manufacturing Letters, ISSN 2213-8463, Vol. 41, no Supplement, p. 1669-1675Article in journal (Refereed) Published
Abstract [en]

The use of recycled (hereafter called secondary) aluminum alloys is increasing more and more in light of sustainability as the energy needed for their production is much lower than in the case of the primary alloys and they may have mechanical properties comparable to those of the latter. Most of the secondary aluminum alloys are used to fabricate parts through casting processes, which may need further machining operations to get the part's final shape. While the mechanical properties of the secondary aluminum alloys have been comprehensively addressed in the literature and correlated to the different intermetallic particles that characterize their microstructure, the same is not true when addressing machinability. In this framework, the paper investigates the machinability of one primary and two secondary aluminum alloys in terms of cutting forces and surface finish after turning trials carried out at fixed cutting parameters. A detailed characterization of the alloys’ microstructure was carried out making use of both optical and scanning electron microscopy to identify the size, morphology, and distribution of intermetallics. The highest cutting force was registered when machining the primary alloy, being characterized by the highest specific cutting energy. The surface damage in terms of tearings induced by cutting was comparable between the primary and secondary alloys. In contrast, the different roughness features that characterize the machined surfaces of the considered alloys can be partly ascribed to the different intermetallics they present. Nevertheless, the surface topography analysis results must be interpreted based on the specific application.

Place, publisher, year, edition, pages
Elsevier, 2024
Keywords
Machining, Recycled aluminum alloys, Surface integrity, Machinability, Machining centers, Casting process, Cutting forces, Energy, Machining operations, Mechanical, Property, Recycled aluminum, Recycled aluminum alloy, Secondary aluminum, Aluminum alloys
National Category
Materials Engineering
Identifiers
urn:nbn:se:hj:diva-66455 (URN)10.1016/j.mfglet.2024.09.194 (DOI)001336722300191 ()2-s2.0-85206244892 (Scopus ID)HOA;intsam;979158 (Local ID)HOA;intsam;979158 (Archive number)HOA;intsam;979158 (OAI)
Conference
52nd SME North American Manufacturing Research Conference (NAMRC 52, 2024)
Available from: 2024-10-22 Created: 2024-10-22 Last updated: 2025-01-14Bibliographically approved
Belov, I., Ahmadkhaniha, D., Zanella, C. & Matsushita, T. (2024). Simulation and experimental methodology for prediction of laser power and penetration depth in surface cladding/alloying. In: 11th International Conference on High Temperature Capillarity: Book of abstracts. Paper presented at HTC2024, 11th International Conference on High Temperature Capillarity, May 26–30, 2024, Sweden (pp. 23-23). Jönköping: Jönköping University, School of Engineering
Open this publication in new window or tab >>Simulation and experimental methodology for prediction of laser power and penetration depth in surface cladding/alloying
2024 (English)In: 11th International Conference on High Temperature Capillarity: Book of abstracts, Jönköping: Jönköping University, School of Engineering , 2024, p. 23-23Conference paper, Oral presentation with published abstract (Refereed)
Abstract [en]

Understanding and evaluating the performance of different powder and substrate materials combined in the laser cladding/alloying layer is prioritised by process and material engineers to obtain high-quality durable surfaces. The surface quality is usually determined by the combination of various process parameters, such as laser power, powder feeding rate, and scanning speed, that result in different dilution ratios. Furthermore, process parameter calibration highly depends on the surface geometry and alignment of the deposited tracks. The application of simulation tools for the manufacturing process design tends to reduce experimental efforts. However, laser surface cladding and alloying represents a complex manufacturing process, where powder deposited on the surface of a material solidifies and forms an alloy with the substrate. Full-scale process simulation is often not feasible for parametric studies aiming at tuning the process parameters.  

The present work introduces an experimentally validated simulation methodology, including a simplified three-dimensional finite-element heat transfer model of the laser surface cladding/alloying process, Figure 1. Cladding/alloying of a nickel-based superalloy powder on the grey cast iron substrate has been studied. With the help of laser cladding experiments and measurements on cross-section images, it has been shown that the model is capable to predict the actual laser power to obtain the desired penetration depth into the substrate, heat-affected zone size and dilution ratio. It is shown by introducing a laser power scaling factor that the model input and comparison data can be obtained from a single cladding/alloying experiment. 

Place, publisher, year, edition, pages
Jönköping: Jönköping University, School of Engineering, 2024
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-67006 (URN)978-91-989295-0-8 (ISBN)
Conference
HTC2024, 11th International Conference on High Temperature Capillarity, May 26–30, 2024, Sweden
Funder
Knowledge Foundation, 20200059
Note

Oral session.

Available from: 2025-01-13 Created: 2025-01-13 Last updated: 2025-01-13Bibliographically approved
Ahmadkhaniha, D., Zanella, C., Belov, I. & Matsushita, T. (2024). Study of the process parameters influence on crack formation in laser alloying of grey cast iron. Optics and Laser Technology, 179, Article ID 111373.
Open this publication in new window or tab >>Study of the process parameters influence on crack formation in laser alloying of grey cast iron
2024 (English)In: Optics and Laser Technology, ISSN 0030-3992, E-ISSN 1879-2545, Vol. 179, article id 111373Article in journal (Refereed) Published
Abstract [en]

This study aimed to investigate the influence of process parameters on crack formation in laser alloying or cladding of grey cast iron. For this purpose, the effects of laser power and feeding rate of Ni-based alloying powders were examined. The microstructure and hardness of the coating and the interface of the coating with cast iron (bonding zone) were studied. The results showed that the dilution ratio is crucial in crack formation, explaining the challenges in achieving a defect-free laser alloying coating on cast iron. The higher dilution ratio of laser alloying resulted in higher dissolved carbon and bigger (Nb, Ti)C carbides formation than in laser cladding coatings. In this study, cracks appeared in the coating due to the combination of the high amount of carbide in the layer and a sharp hardness gradient at the interface with the cast iron substrate. An empirical relation was proposed for dilution ratio as a function of specific energy density, which combined the most critical process parameters on crack formation.

Place, publisher, year, edition, pages
Elsevier, 2024
Keywords
Cracks, Grey cast iron, Laser alloying, Laser cladding, Microstructure, Ni alloy, Alloying, Carbides, Cast iron, Coatings, Hardness, Nickel alloys, Titanium compounds, Dilution ratio, Feeding rate, Gray cast iron, Influence of process parameters, Laser power, Ni alloys, Parameter influences, Power rates, Process parameters
National Category
Materials Engineering
Identifiers
urn:nbn:se:hj:diva-65530 (URN)10.1016/j.optlastec.2024.111373 (DOI)001260568300001 ()2-s2.0-85196782760 (Scopus ID)HOA;;961812 (Local ID)HOA;;961812 (Archive number)HOA;;961812 (OAI)
Funder
Knowledge Foundation, 20200059
Available from: 2024-07-03 Created: 2024-07-03 Last updated: 2024-07-18Bibliographically approved
Ahmadkhaniha, D., Lattanzi, L., Sjölander, E., Bjurenstedt, A. & Zanella, C. (2024). The effect of alloying element on corrosion resistance of recycled Al alloy. In: : . Paper presented at EUROCORR2024, 1-5 September 2024, Paris, France.
Open this publication in new window or tab >>The effect of alloying element on corrosion resistance of recycled Al alloy
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2024 (English)Conference paper, Oral presentation with published abstract (Refereed)
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-67034 (URN)
Conference
EUROCORR2024, 1-5 September 2024, Paris, France
Available from: 2025-01-14 Created: 2025-01-14 Last updated: 2025-01-14Bibliographically approved
Ahmadkhaniha, D., Ascani, D. & Zanella, C. (2023). High entropy alloy deposition from an aqueous bath. In: : . Paper presented at 244th ECS Meeting (ECS 244), Gothenburg, Sweden, 8–12 October 2023.
Open this publication in new window or tab >>High entropy alloy deposition from an aqueous bath
2023 (English)Conference paper, Oral presentation with published abstract (Refereed)
National Category
Metallurgy and Metallic Materials
Identifiers
urn:nbn:se:hj:diva-63243 (URN)
Conference
244th ECS Meeting (ECS 244), Gothenburg, Sweden, 8–12 October 2023
Available from: 2024-01-09 Created: 2024-01-09 Last updated: 2024-01-09Bibliographically approved
Ahmadkhaniha, D., Sieber, M. & Zanella, C. (2023). Improving the electroplating simulation model for producing uniform coating thickness distribution. In: : . Paper presented at 35th Conference on Surface Modification Technologies (SMT 35), Hamburg, Germany, 18 - 22 September 2023.
Open this publication in new window or tab >>Improving the electroplating simulation model for producing uniform coating thickness distribution
2023 (English)Conference paper, Oral presentation only (Refereed)
National Category
Materials Engineering
Identifiers
urn:nbn:se:hj:diva-63248 (URN)
Conference
35th Conference on Surface Modification Technologies (SMT 35), Hamburg, Germany, 18 - 22 September 2023
Available from: 2024-01-09 Created: 2024-01-09 Last updated: 2024-01-09Bibliographically approved
Organisations
Identifiers
ORCID iD: ORCID iD iconorcid.org/0000-0003-2924-137X

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