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  • 1.
    Gonapati, Santosh Reddy
    et al.
    Jönköping University, School of Engineering, JTH, Industrial Product Development, Production and Design.
    Talur Chandrashekar, Gnanesh
    Jönköping University, School of Engineering, JTH, Industrial Product Development, Production and Design.
    On the possibility to increase the maximum operating temperature(MOT) of Al-20%SiC composites for wear friction and thermophysical properties.2019Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
    Abstract [en]

    Aluminium is one of the prominent metals used in the automobile industries apart from cast-iron. Aluminium is used for lightweight material properties and, it meets some of the prominent mechanical properties. When aluminium is combined with silicon carbide, it improves some of the mechanical properties and provides similar strength as that of the cast-iron. The purpose of aluminium silicon carbide is to recover some of the mechanical properties and the thermal properties for the disc brakes. Aluminium is enhanced with 20% silicon carbide is cast using stir casting. In this paper, two different compositions are compared. The hardness of the samples was analyzed with the help of the Nano-indentation test. Alloy-1 shows better hardness values compared to Alloy-2. The scratch resistivity of the sample surfaces was analyzed under the microscope with the help of the Nano-scratch test. The presence of SiC particles in the aluminium matrix withstands the indenter to penetrate deep into the surface.

  • 2.
    Gustafsson, Tim
    et al.
    Jönköping University, School of Engineering, JTH. Research area Product Development - Simulation and Optimization.
    Jansson, Johan
    Jönköping University, School of Engineering, JTH. Research area Product Development - Simulation and Optimization.
    Development and Implementation of an Anisotropic Material Model based on the Fibre Orientation in GFRPs2016Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
    Abstract [en]

    Based on the fibre orientation distribution of a glass fibre reinforced polymer (GFRP) an anisotropic material model is developed and implemented in the commercial Finite Element code LS-Dyna. The material model is coupled with the fibre orientation extracted from flow filling simulations performed in Moldex3D. Central mathematical models used are the Eshelby-Mori-Tanaka model for calculating a composites effective stiffness, Advani and Tucker’s orientation averaging method for considering the fibre orientation tensors, a Lagrange polynomial controlled radial return algorithm for the application of nonlinear hardening and finally Hashin’s damage initiation criterion to establish the initiation and evolution of damage. The material model is calibrated by adjusting Lagrange polynomial data points, until the simulation response corresponds to that of experimental tensile tests. Two different glass fibre reinforced composites are evaluated, and it is concluded that the model can capture the behaviour of the experimental curves with high accuracy. By validation against experimental results, it is shown that the material model performs well. The model is also compared to other advanced commercial material modelling software’s.

  • 3.
    Jammula, Chaitanya Krishna
    Jönköping University, School of Engineering, JTH, Industrial Product Development, Production and Design. Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Correlating the microstructure with wear properties of aluminium silicon carbides2019Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
    Abstract [en]

    Aluminium is one of the metals playing a prominent role in automobile industry after cast iron. Because of its light weight property and good mechanical properties. When aluminium reinforced with silicon carbide showing good tribological properties and improved strength. Aluminium silicon carbide needs some good wear and frictional properties to use it as break disc. Aluminium reinforced with 15% and 20% silicon carbide and casted in two different ways, liquid casting and stir casting. Four different composites are compared in this paper. Hardness test was carried out on the samples. Increase in the Vickers hardness with increase in silicon carbide reinforcement for both the castings is observed. Rockwell C hardness is showing decreasing trend with increase in SiC reinforcement. The scratch resistance of the surface under micro level was analysed with the help of nano scratch test. The SiC particles in the aluminium matrix are resisting the indenter from deep deformation of the surface. Frictional forces are dropped whenever the indenter met the SiC particles. In other cases, SiC particles are deforming the aluminium matrix in the form of broken particles. The plastic deformation of aluminium is observed, and material is piled up on sideways of groove at high load.Sliding wear behaviour of the composites are investigated by means of reciprocating pin on plate wear rig. The test was carried out at load of 20N for five different sliding duration. Aluminium with 20% silicon carbide of liquid casting is used as a base metal. The worn-out surface of the samples is analysed in SEM. The metallography of the worn-out samples is showing some deep grooves and abrasion of the material. Wear debris from both the surfaces are forming into a cluster of layers. These layers are protecting the surface from wear in some areas were observed. Composition of tribo layer formed during the test was investigated with the help of EDS analysis. The tribo layer are rich in aluminium and silicon elements because both the samples are made of aluminium silicon carbide.

  • 4.
    Manjunath, Tushar
    et al.
    Jönköping University, School of Engineering, JTH, Industrial Product Development, Production and Design.
    Nixon, Nirmal
    Jönköping University, School of Engineering, JTH, Industrial Product Development, Production and Design.
    On the Possibility to Increase Maximum Operating Temperature (MOT) of Al 20%SiC Composites for Mechanical Properties2020Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
    Abstract [en]

    The main objective of this project is to seek the possibility to increase the maximum temperature, to improve mechanical properties and also analyse the microstructure of Al-20%SiC composite by manipulating its transition metals using four different additions of Zr, Ni, Si, Ti, Mg, Mn, Cr, Fe and Cu and conduct tensile and compression test to find out the mechanical properties of the composite of Brake Discs at ambient and elevated temperatures as company’s requirements(AC Floby) the casting will be done using vertical high pressure die casting process at Jönköping University which is collaborated with AC Floby for the materials and machining. The tensile and compression tests were conducted at Jönköping University in accordance to standard ASTM B557M for standard tension test of metals at room temperature and ASTM E21 for the tensile test of metal at elevated temperature, ASTM E9 for compression test.

    The scope of this project is to obtain stronger brake discs that can withstand high temperature and loads, to reduce vehicle’s weight and emissions by using the Al-20%SiC alloy since it has low density, high thermal conductivity, good corrosion resistance, strength and wear property.

    This project is part of a large project which was done by the next group that handles with the possibility to increase the maximum operating temperature of Al-20%SiC alloys to obtain wear friction and thermal physical properties. Hence, this gives the opportunity to understand the mechanical properties and thermal physical properties of the same newly developed Al-20%SiC alloys that is shared with the other group to validate the outcome of compositions of alloy 1 and alloy2 used in the project and compare between the two alloys. The operating temperature will rise, and the alloy strength falls due to elevated temperature and other microstructure defects hence our aim is to make the properties of alloy sustain at elevated temperature and reduce coarsening and wear in Brake Discs. Hence, we initiated by narrowing down the additions into the metal matrix Aluminium by using Thermo calc software to study the effect of each element on the Aluminium and the binary phase diagram of each alloying element in aluminium primary matrix. And to determine the effect of reinforcing SiC particles that provides strength, tensile and compressive properties at elevated temperature and came up with the satisfying additions for the alloy which will be explained further below in the report. A validation of the alloy was carried out against the tensile and compression experimental results to evaluate the predictive and better properties of the newly developed alloy for brake discs by comparing with the alloy 1 and alloy 2 compositions.

     

  • 5.
    Manne, Akhil
    et al.
    Jönköping University, School of Engineering, JTH. Research area Product Development - Simulation and Optimization.
    Hiregoudra, Pramod S
    Jönköping University, School of Engineering, JTH. Research area Product Development - Simulation and Optimization.
    Modelling and Simulation of Mold filling in gravity casting of Aluminium and MMC alloys.2018Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
  • 6.
    Pakkam Gabriel, Vivek Richards
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    FATIGUE MODEL: Stiffness prediction of damaged laminates based on the concept of damaged layers' effective stiffness2019Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
    Abstract [en]

    Despite composite materials are widely used in many applications, prediction on damage mechanism of the composite materials is still very difficult. Using the findings from the research on damage mechanism under fatigue loading, its transverse cracking and its crack opening and sliding displacement, a mathematical model has been developed. The model showed results closer to the real-time experimental results in crack initiation and growth. The aim of the thesis is to develop a computational tool using the mathematical model and effective stiffness concept of the layers with cracks to predict the degradation of the longitudinal young’s modulus and shear modulus of the composite laminate. In addition to that, graphical user interface is also created making the user control the tool easily. The tool developed shows promising results but still lacks the information on the effects of delamination on crack opening displacement and effective shear modulus.

  • 7.
    Puthukuttyparambil Ravi, Vishnu
    et al.
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing. Jönköping University, School of Engineering, JTH, Industrial Product Development, Production and Design.
    Varghese, Antony
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing. Jönköping University, School of Engineering, JTH, Industrial Product Development, Production and Design.
    Comparing the mechanical properties and tribological behaviour of squeeze cast Al-20%SiC and hypereutectic Al-Si alloy2019Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
    Abstract [en]

    For the booming automobile industry, the demand for the light weight and more efficient materials are increasing day by day. Grey cast irons have been playing a crucial role in the manufacturing of the disc brake rotors. But the material of grey cast have many drawbacks such as the weight, and corrosion factors, which will have a great influence on meeting the market demands and also from the environmental point of view. Aluminium plays a vital role in meeting these demands for the growing industry, but the metal aluminium has its own limitations and then arise the demand for the alloying elements. The alloying elements considered in the current thesis work are the Al-20%SiC and the Al-Hypereutectic alloy. The Al-20%SiC alloy is currently used by the manufacturer for the production of their lightweight disc brakes and it is currently manufactured with the process of squeeze casting. The metal exhibits better mechanical properties and other factors that the manufacturer look into. But as the industry is growing in a rapid phase and there is an increasing demand for more reliable alloying elements. The manufacturer considers about the usage of Al-hypereutectic alloy to replace the usage of Al-20%SiC alloy. The current thesis work is focused on the study of the mechanical properties and tribological behaviour of both of these alloys and to verify, if the new alloy can meet the demands of the manufacturer.

  • 8.
    Sarius, N.G.
    et al.
    Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing - Surface technology.
    Lauridsen, J.
    Thin Film Physics Division, Department of Physics, Chemistry, and Biology, IFM, Linköping University, Linköping, Sweden .
    Lewin, E.
    Department of Materials Chemistry, The Ångström Laboratory, Uppsala University, Uppsala, Sweden .
    Jansson, U.
    Department of Materials Chemistry, The Ångström Laboratory, Uppsala University, Uppsala, Sweden.
    Högberg, H.
    Thin Film Physics Division, Department of Physics, Chemistry, and Biology, IFM, Linköping University, Linköping, Sweden.
    Öberg, Å.
    ABB Corporate Research, Västerås, Sweden .
    Sarova, G.
    Harting, Corporate Technology Services, Espelkamp, Germany .
    Staperfeld, G.
    Harting, Corporate Technology Services, Espelkamp, Germany.
    Leisner, Peter
    Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing - Surface technology.
    Eklund, P.
    Thin Film Physics Division, Department of Physics, Chemistry, and Biology, IFM, Linköping University, Linköping, Sweden.
    Hultman, L.
    Thin Film Physics Division, Department of Physics, Chemistry, and Biology, IFM, Linköping University, Linköping, Sweden.
    Contact Resistance of Ti-Si-C-Ag and Ti-Si-C-Ag-Pd Nanocomposite Coatings2012In: Journal of Electronic Materials, ISSN 0361-5235, E-ISSN 1543-186X, Vol. 41, no 3, p. 560-567Article in journal (Refereed)
    Abstract [en]

    Ti-Si-C-Ag-Pd and Ti-Si-C-Ag nanocomposite coatings were deposited by direct-current magnetron sputtering on Cu substrates with an electroplated Ni layer. Analytical electron microscopy, x-ray diffraction, and x-ray photoelectron spectroscopy show that the nanocomposites consist of TiC, Ag:Pd, and amorphous SiC. The contact resistance of these coatings against a spherical Au-Co surface was measured for applied contact forces up to 5 N. Ti-Si-C-Ag-Pd coatings with Ag:Pd top coating had ~10 times lower contact resistance at contact forces below 1 N (~10 mΩ at ~0.1 N), and 2 to 3 times lower for contact forces around 5 N (<1 mΩ at 5 N), compared with the Ti-Si-C-Ag coating.

  • 9.
    Sarius, N.G.
    et al.
    Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing - Surface technology.
    Lauridsen, J.
    Thin Film Physics Division, Department of Physics, IFM, Linköping University, Linköping, Sweden.
    Lewin, E.
    Department of Materials Chemistry, The Ångström Laboratory, Uppsala University, Uppsala, Sweden.
    Lu, J.
    Thin Film Physics Division, Department of Physics, IFM, Linköping University, Linköping, Sweden.
    Högberg, H.
    Thin Film Physics Division, Department of Physics, IFM, Linköping University, Linköping, Sweden.
    Öberg, Å.
    ABB Corporate Research, Västerås, Sweden.
    Ljungcrantz, H.
    Impact Coatings AB, Linköping, Sweden.
    Leisner, Peter
    Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing - Surface technology.
    Eklund, P.
    Thin Film Physics Division, Department of Physics, IFM, Linköping University, Linköping, Sweden.
    Hultman, L.
    Thin Film Physics Division, Department of Physics, IFM, Linköping University, Linköping, Sweden.
    Ni and Ti diffusion barrier layers between Ti-Si-C and Ti-Si-C-Ag nanocomposite coatings and Cu-based substrates2012In: Surface & Coatings Technology, ISSN 0257-8972, E-ISSN 1879-3347, Vol. 206, no 8-9, p. 2558-2565Article in journal (Refereed)
    Abstract [en]

    Sputtered Ni and Ti layers were investigated as a diffusion barrier to substitute electroplated Ni between Ti–Si–C and Ti–Si–C–Ag nanocomposite coatings and Cu or CuSn substrates. Samples were subjected to thermal annealing studies by exposure to 400 °C for 11 h. Dense diffusion barrier and coating hindered Cu from diffusing to the surface. This condition was achieved for electroplated Ni in combination with magnetron-sputtered Ti–Si–C and Ti–Si–C–Ag layers deposited at 230 °C and 300 °C, and sputtered Ti or Ni layers in combination with Ti–Si–C–Ag deposited at 300 °C.

  • 10.
    Staaw, Fredrik
    et al.
    Jönköping University, School of Engineering, JTH, Product Development.
    Rappner Ståhlkrantz, Filip
    Jönköping University, School of Engineering, JTH, Product Development.
    Förstudie för fjädringsanordning på el-moped2016Independent thesis Basic level (degree of Bachelor), 10 credits / 15 HE creditsStudent thesis
    Abstract [en]

    The work has been carried out for ten weeks and has gone on to find out whether it is appropriate to make use of fiber composites in a suspension device on an electric mopeds rear-wheel. This in order to reduce vehicle weight. If it is appropriate to make use of these materials is a difficult issue that must be dealt with and angled in different ways. There are safety issues to consider, but also the environment and sustainability. To find materials that can withstand the loads that the structure will be exposed to, interviews and even literary studies were made in cycles repeatedly. The requirements of the design says that it will withstand external interference factors such as moisture, UV light, but of course also the loads that occur during acceleration, braking, cornering, etc. The requirements that should be imposed on the design is that it must be sufficiently resistant to bending to take up the forces but yet spring. It should also be rigid when cornering. The stroke, according to a competitor analysis, varies between 44-100 mm. It depends a lot on the design and the weight of the vehicle, driver included. All of the materials found in CES (a material database) have a yield strength higher than that of a regular spring steel. The manufacturing methods found in CES were based on the materials found. The materials were evaluated against each other in a Pugh-matrix to get a ranking, the same was done for the manufacturing methods. The materials and manufacturing methods were scored, based on their rankings, and then compared against each other. The final ranking shows the materials that are more or less versatile in terms of manufacturing. Even two common suspension types are compared together with manufacturing methods to investigate the methods that could produce these geometries.

  • 11.
    SUNIL, SOORAJ
    Jönköping University, School of Engineering, JTH, Materials and Manufacturing.
    Numerical  Tool to Simulate Forming of Lamera HybrixTM2019Independent thesis Advanced level (degree of Master (One Year)), 20 credits / 30 HE creditsStudent thesis
    Abstract [en]

    Composite materials are playing an essential role in construction industries, automobile industries, and mechanical industries which have better physical properties than original materials. Hybrix material is a kind of Composite sandwich material which have better properties like lightweight, durable, eco-friendly than original material. In an attempt to prove the quality in finite element analysis Hybrix material, creating a numerical tool to simulate the metal forming conditions. Spring back effect and residual stress are also taken into account in the method.

  • 12.
    Ödlund, Martin
    Jönköping University, School of Engineering.
    Optimization Driven Development of Stringer to Leisure Boat2015Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
    Abstract [en]

    The increasing demand for products of light weight and high performance to be produced and developed in shorter periods of times has put high pressure on the product development process. Much research is done in order to find ways on how to speed up this process at the same time as delivering products of higher quality to the customer. Much of the literature focuses on how important it is to “tear down the walls” between departments at a company by integrating as much different knowledge as early in the process as possible. Thereby, much of the costly problems found late in the process can be avoided leading to shorter development times and cost savings.

    Commonly companies use simulation software to verify their final designs before the products pass forward to prototyping and test production. In some cases products need to be redesigned and big changes of the product geometry might be necessary which often is very costly in such a late stage of the process.

    Eker Design in Fredrikstad, Norway, wants to investigate the potential of using simulation driven design in an early stage of the product development process. In order to make this investigation this exam work has been carried out on a real design case by the development of a new “stringer” totally from scratch. A stringer is what gives rise to the stiffness of the boat and is a structure mounted in-between the hull and the deck. The stringer was developed to the Hydrolift SX22 leisure boat by using simulations and topology optimization software as the driving force for the design. The research questions to be answered were:

    • Is it possible to develop a stringer through a design process based on topology optimization and simulation software with equal performance as the existing stringer?
    • How does the optimized result perform in comparison to the existing stringer?
    • Can any weight reduction be achieved with a new stringer design?

    In the end of the work the existing stringer and the new stringer design was compared and evaluated. The results showed that the new stringer with a weight reduction of 30% performed very well in comparison to the existing one. This proves that the topology optimization and simulation driven design process beneficially can be used in marine architecture. It has also proven to be an efficient method to lower the material usage and increase the strength of the stringer. 

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