This projects aims to develop design automation in product development. Design automation causes increase in producibility and decrease in product cost and manufacturing lead time.

The study at hand is proposed to provide a new method and to introduce procedure to the design of wiring pattern for a car seat heater for Kongsberg Automotive, KA. KA is a Norwegian company and a global provider of engineering, design, and manufacture for seat comfort, driver and motion control systems, fluid assemblies, and industrial driver interface products. The method that currently is used in the company to create a wiring pattern is neither sufficient enough nor automated.

In order to design the wiring pattern, at first procedure is handled by the designer. Secondly, car seat heater 2D layout is imported and then, the dimensions of the elements are defined as constraints. Then VBA codes are opened and the program is run. The result will be a wiring pattern in different 2D layouts. To make the design process easier, we have modeled five different layouts; wiring pattern of one element, two elements, three elements, five elements (with two back sides) and one element trapezoidal 2D layout.

The algorithm written in VBA (Visual basic for application) creates the pattern according to the dimensions of the elements which are used as inputs to define constrained parameters. The created macros are simple to use and easy to modify, independent from the programming knowledge. The user is only responsible with parameter input and running the program. The solution gives wiring pattern for a car seat heater.

High-pressure torsion (HPT) processing was applied to cast pure Mg pieces and its effects on microstructure, hardness and tensile properties as well as corrosion resistance were evaluated. The microstructure of the processed samples was examined by electron backscatter diffraction (EBSD) and the mechanical properties were determined by microhardness and tensile tests. Corrosion resistance of the samples was studied via electrochemical impedance spectroscopy (EIS) in 3.5% NaCl solution. The results showed that HPT refined the grain size of Mg very effectively from millimeters in the cast structure to a few micrometers homogeneously through the thickness and created a basal texture on the surface. One or five turns of HPT produced no significant difference in the grain size of the processed Mg but the hardness was a maximum after one turn. The yield strength of the cast Mg was increased by seven times whereas the corrosion resistance was not affected by the HPT processing.

The use of recommended S-N curves, presented in current literature, to analyse and determine the fatigue life of a part is common practice in, inter alia, the construction industry.However, the recommended S-N curves are generally created for larger components used in mainly the construction industry. Hence, the use of S-N curves for the evaluation of smaller parts, may result in over-dimensioning of such parts. For this reason, evaluation and designing of smaller parts could benefit from the development of an in house S-N curve specific for the part.

The purpose of this thesis is to generate and validate an in-house method for creating a S-N curve, for a specific part to be compared with recommended S-N curves in the literature. The specific part used for the generating of the method is a welded steel joint with the geometry of two steel pipes, welded together in a t-formation and which has been provided by Thule AB for the purpose of the thesis.

The method presented uses the results from 1) physical fatigue tests using a fatigue testing machine and 2) static FEA to derive a S-N curve for the specific part using the least squares method. A fatigue testing rig enables the gathering of data of the number of cycles to failure when the part is subject to a given cyclic load. The rig uses pneumatics to control the forces applied onto the part with the use of a cylinder. Furthermore, the fatigue testing rig was designed to be controlled by the applied force, meaning, that the rig ensured a homogeneous load cycle by measuring the force from a load cell and alternating the direction of the cylinder with an electrically controlled pressure valve. The performance of static FEA evaluations aim at locating stresses in the part. For this thesis the stresses were evaluated using the hot spot method due to the part's welded geometry.

The data gathered from the physical fatigue tests and the static FEA evaluations are subsequently combined deriving S-N curves applicable to the part.

From the fatigue tests and FEA evaluations for the t-shaped welded steel part, four S-N curves were derived of which two curves showed the results of a linear fitted curve whereas the other curves used the recommended slope of $-1/3$. The results showed that the S-N curves derived, using a set slope, resulted in similar curves to the recommended S-N curve provided by the literature. However, the linear fitted S-N curve showed that the part, according to the S-N curve, had a higher fatigue resistance than recommended.

 Due to limitations in the thesis work, the S-N curves derived within the framework of this thesis should be regarded as theoretical and have been strictly used to identify whether the method generated is applicable for deriving of S-N curves.

In a quest to develop new light metal alloys that can perform excellently at elevated-temperatures (from 300°C to 400°C), a ternary eutectic Al-Cu-Si alloy was exploited to gain a deeper understanding of the alloy system and its suitability for high temperature applications. The alloys studied, with chemical composition of Al-27%Cu-5%Si (by weight percent) with Ni addition in the range of 0 to 1.5%wt, were cast in a rapid solidification casting technique. The solidification characteristics of the alloy was studied using the Thermo-Calc software. Microstructures were characterized in a scanning electron microscope coupled with energy dispersive spectrometry (SEM-EDS). Finally, the elevated-temperatures tensile properties of the alloys were investigated. Comparing the microstructures and mechanical properties of these Al-Cu-Si(-Ni) alloys with conventional Al-Si alloy A319, the refined microstructure with dispersed Ni intermetallic particles formed in the as-cast Al-Cu-Si(-Ni) alloys deliver improved elevated temperature properties. In particular, the yield strength and ultimate tensile strength of the new alloy with 1.5% Ni at 400?C were observed to be 220% and 309% higher, respectively, than for conventional A319 alloy.

The crushers are used by mining and aggregate industries for crushing the rocks. Wear in these crushers wear parts causes a great wear loss and significant economic loss. This work aims to find the worn geometry, hardness and behavior of the wear parts as function of rock type.To perform this research, a series of tests such as scratch test, rock-crushing test, microstructural analysis and hardness test were carried out. From the scratch test, hardness test and microstructural analysis, wear mechanism and work hardening effects were studied using LOM, SEM and Vickers hardness measurement. The crushing test was carried out by crushing quartzite, diabase and gneiss rocks in a mini jaw crusher with respect to M1, M2 and M7 samples proposed by the company, which provides data to calculate volumetric loss, wear ratio and data for power consumption. The data collected from the experiments are used to create model to get a clear picture of the performance of each material with respect to different rock type.During pouring the rocks into the jaw crusher, several types of wear are expected to be occur, which substantially results in change of the geometry of the jaw crusher plates and hence the performance of the crusher will be affected. Controlling of such harsh wear situations requires introducing a material with high-performance wear resistance (particularly abrasion) and fundamentally modifying the operating conditions to minimize the risk of severe wear degradation. For this reason, it is desirable to simulate how the geometry and performance are changing due to wear.The results from the scratch test and microstructural analysis showed that at low applied loads severe plastic deformation is seen but as the load increases, the work hardening mechanism develops and provides wear resistance properties. The results from hardness test and modeling, M7 sample shows good wear resistance properties against hard and abrasive rocks which in this case is diabase and quartzite rocks, M2 sample shows good wear resistance against only quartzite rocks and gneiss rocks. M1 sample shows less volumetric loss against quartzite but when compared to M2 and M7’s mechanical property, M1 showed low wear resistance against all three rocks.

Key words: Wear mechanism, work hardening, wear ratio, volumetric loss, power consumption, M1, M2, M7 samples, quartzite, diabase and gneiss rock.

The increase of new and ever more stringent emission legislation has brought about with it a surge in the demand for more sustainable automotive solutions. This has particularly been the case for automobiles, including heavy-duty vehicles like trucks and buses, with internal combustion engines, which now require the design and manufacturing of more durable and reliable components. An important component of internal combustion engine automobiles, which helps achieve this target, is the exhaust after-treatment system. Exhaust after-treatment systems are usually equipped with some type of catalytic converter, treating the combustion gases from the engine exhaust manifold to reduce the concentration of pollutants. The catalytic converter assembly usually consists of an assembly of an outer metallic canning, an inner substrate and a packaging mat in between the two. The packaging mat, commonly known as the support mat, is an important component in the assembly, protecting the ceramic substrate from road induced and thermal loads, thereby preventing any damage to the latter. This thesis involves further development of a finite element model for the support mat that could be used in catalytic converter simulations with a reasonable degree of accuracy and reliability. In line with this objective, the characteristic mechanical response of the mat is first studied through a series of material tests: namely compression, friction, and shear tests. Different non-linear material models like hyperfoam, hyperelastic and viscoelastic models, are then created in ABAQUS to simulate the mat behaviour in the tests. The material model correlating most closely with the test is then implemented in the simulation of the assembly process, canning of a catalytic converter. This report includes the material tests conducted on the mats in new and aged condition, findings of the characteristic response of the mats in these tests as well as the constitutive material modelling and finite element simulations carried out for correlation with test data from the new mats. The most appropriate material model was also implemented in a canning assembly simulation to evaluate the efficacy of the material model in predicting the mat pressure, gap bulk density, and push-in force.

This master's thesis project investigates the impact of hydrophobicity and topology on dry and wet macroscopic particle accumulation on surfaces. The report begins by outlining the challenges associated with this phenomenon and the existing theories and methods used to study it, including adhesion, surface engineering, the Lotus effect, and humidity. The method chapter presents the case study of grass accumulation for robotic lawn mowing application and describes experiments conducted to simulate the accumulation of grass during robotic lawn mowing. These experiments explore two different phenomena: the accumulation of grass that is already stuck to a surface and the process by which grass initially sticks to a surface. Experiments have been done to change the hydrophobicity level of certain specimens and investigate how hydrophobicity and humidity affect the stickiness of grass when already accumulated on a surface. In addition, experiments are conducted by throwing grass towards surfaces with different hydrophobicity and topology to determine the influence of these variables on accumulation. Finally, a physical field test is conducted. The findings indicate that hydrophobicity up to 108,2° water contact angle has a low impact on both static and dynamic grass accumulation. Increased hydrophobicity does not tend to decrease grass accumulation, even showing increased accumulation in some experiments. Humidity and the wetness of the grass are more important factors. Experiments have shown that a textured surface can decrease the accumulation, showing significant results in a controlled environment. However, these results did not transfer over in a significant way to a real robotic lawn mowing situation.

Thermo-mechanical deformation, thermal resistance, and lateral temperature distribution were experimentally studied for a high-power AlGaInN LED chip-on-board array at three different input powers. A fullscale CFD model of the LED assembly was developed and correlated with the temperature and average thermal resistance measurements to enable prediction of the temperature distribution on the surface of a thermally deformed LED assembly. Application of the thermal resistance partitioning approach to thermal modeling of the deformed LED assemblies was discussed. It can be useful for design engineers for estimation of the temperature distribution across the deformed LED array, at the minimum number of temperature measurements required for model calibration.

Vatten är en livsviktig faktor för allt liv på jorden. Men kan också vara farligt, rent livsfarligt, om det är förorenat. Hela 60 procent av barndödligheten jan direkt härledas till smutsigt vatten. Inte bara u-länder är drabbad, även i västvärlden bryter epidemier ut på grund av intag eller badande i smutsigt/förorenat vatten.

MIP, Molecularly Imprinted Polymers, är en biosensorteknik som kan ge snabbare och mer tillförlitligare svar på vattenprover än dagens analysmetoder. Det är även billigare och därmed kan fler prov tas och analyseras, det vill säga med större frekvens. Genom dessa tre variabler kan antalet insjuknade minska till följd av att föroreningar upptäcks snabbare och nödvändiga åtgärder sätts in tidigare.

Detta projekt söker efter formgivningen på ett automatiskt testinstrument baserat på MIP-tekninken. Konceptförslagen förmedla ska förmedla innovation, hög kvalité och tydlighet. De skall kunna användas i laborationsmiljö samt ute i fält.

Projektet har resulterat i ett konceptförslag på den yttre formgivningen av testinstrument för vattendetektion baserad på MIP. Koncepten bygger på en uppbyggnad av inre komponenter som har så låg höjd som möjligt (20 centimeter) och är något bredare än dess djup (40 vs 30 centimeter). MIP- och NIP behållarna är placerade intill ena kortsidan och batteriet finns intill kanten på främre långsidan. Placeringen är gjord för att underlätta påfyllning och utbyte.

Det slutkoncept som presenteras svarar mot alla de uppställda kraven och två av tre önskemål. Det är utformat utefter dess tilltänkta användare. Dessa har även varit med i konceptframtagningen. Slutkonceptet härstammar utefter idégeneringens utgångspunkt ”Vad är det slutanvändaren vill uppleva när de ser och använder produkten/instrumentet?”. Med de tankar som framkom togs idéskisser fram och utvärderades mot de samma. De mest intressanta idéerna utvecklades till tre olika koncept. Dessa utvärderades med hjälp av tilltänkta användare mot de framtagna kanseiorden samt diskussioner. Konceptvalet visade att ett koncept var överlägsets mest lämpat för vidareutveckling.

Slutkonceptet är smidigt koncept med greppytor utformade för bästa kortvarande grepp. Användaren kan själv söka upp ett individuellt optimalt grepp. Instrumentet har inga utstående delar som kan skada användaren. De inre komponenterna som behövs för påfyllning av MIP- och NIPbuffertlösningarna, batteri med mera finns i en låda som skjuts ut automatiskt på ena kortsidan. Åtkomsten till dessa styrs via en pekskärm. Själva upplåsningen styrs av en handscanner på pekskärmen. Detta ökar känslan av högteknologi och ”hjältekänslan”. Ett halvtransparant ”fönster” medför att själva analysen av testen kan övervakas/studeras, vilket medför ökad tillförlitlighet, lyfter fram funktionerna, ger högteknologikänsla och är roligt för användarna

Detta examensarbete är utfört på VSM Group AB i Huskvarna som tillverkar symaskiner under varumärkena Pfaff och Husqvarna Viking. På dessa symaskiner finns en applikation som hjälper användaren att trä tråden genom nålen kallad nålträdare. Syftet med arbetet har varit att studera dagens nålträdningssystem på VSM och deras konkurrenters symaskiner för att sedan utveckla en ny applikation som skiljer sig från samtliga idag använda nålträdare. Målet med arbetet har varit att ta fram ett nytt koncept med en fungerande prototyp.

Som grund till arbetet gjordes en konkurrentanalys där dagens nålträdare studerades för att identifiera positiva och negativa aspekter hos dessa. Med det som förlaga skapades ett antal ”konceptfamiljer” där olika varianter på samma idéer samlades och utvärderades.

Valet föll på koncepten med luftsug som ansågs mest unika och genomförbara. Olika applikationer för att skapa luftsug testades och den bästa valdes ut för prototypbygge.

Den slutgiltiga prototypen suger tråden genom nålsögat med hjälp av ett munstycke som positioneras bakom nålen. Suget skapas då ett membran pumpar ut luften ur ett lufttätt skal vars enda insug är munstycket.

Av de koncept som testats i detta arbete är det denna lösning som är mest realistisk att kunna användas i framtida symaskiner.

I arbetet undersöktes ersättning av metallprodukter med plast inom byggindustrin. Första delen är en enkel marknadsundersökning där produkter som kan vara lämpliga och lönsamma att ersätta söks. Marknadsundersökningen ledde till att flera lämpliga produkter hittades och efter sållning valdes dörrmekanismen till innedörrar för vidareutveckling.

I den andra delen som kallas Re-design har dörrmekanismen omkonstruerats och en ny funktion har utvecklats för att passa för tillverkning i plast och för att kunna dra nytta av de fördelar som plastmaterialet erbjuder. Efter idégenerering och sållning har modeller byggts för att testa funktioner. Därefter anpassades de utvalda mekanismerna för tillverkning med formsprutning.

Beräkningar av mekanismens mest belastade delar utfördes i beräkningsprogrammet Abaqus. Arbetet resulterade i tre varianter av innerdörrsmekanismen som alla passar i dörrens standarduttag, dessa fick namnen Classic, Magneto och Push/pull. Classic har samma funktion som den existerande varianten men antalet delar är mindre än hälften och monteringen och tillverkning är enklare. Magneto liknar i stor utsträckning Classic men vid öppen dörr ligger kolven jämns med dörren och dras in i låsblecket av en magnet istället för av en fjäder som i Classic. Push/pull har en annorlunda öppningsfunktion där drag/tryck används för att öppna dörren istället för en vridrörelse.

Aim: The aim of this study is to evaluate if additive manufacturing (AM) is an appropriate manufacturing method for insoles in comparison to vacuum forming (VF) and subtractive manufacturing (SM) in regards of material properties such as abrasion resistance. Background: Traditionally insoles are manufactured with either VF or SM. AM has been around for some decades but implementation into orthotic and prosthetic (O&P) business has not been accomplished yet. Therefore, the quality of the products produced with AM must be tested in comparison with traditional methods. Method: A comparison of samples for the mentioned manufacturing methods was done with the help of an abrasion testing machine with the standard ASTM G133. Two samples were produced from each manufacturing method and respectively tested for one and two hours. All the samples were weighed before and after the tests with the help of a four decimal scale. The difference in weight before and after the test and coefficient of friction was evaluated. The weight difference was analyzed to see how much material had been removed from the sample. The percentage of wear loss was calculated for each specific sample, both for one hour and two hours of testing. No statistical analysis could be made due to the limited amount of samples and testing time. Result: No statistically significant could be found for either wear loss or the coefficient of friction as mentioned above. Conclusion: A conclusion whether which material having the best abrasion resistance for respectively manufacturing method could not be drawn due to limited results. This study can be seen as a pilot study where the methodology can be used in further studies. Further research on AM needs to be conducted.

Introduktion (och mål) – Parisavtalet är en överenskommelse där länder såsom Sverige enats om målet att hålla den globala temperaturökningen under 2 °C och sträva mot att begränsa den till 1,5 °C. För att nå detta mål måste växthusgasutsläppen halveras till 2030 jämfört med 2019. Bygg- och fastighetssektorn står för 22 % av Sveriges totala utsläpp av växthusgaser och genomtänkta materialval är en potentiell åtgärd för att minska dessa utsläpp. Ett material med goda klimategenskaper är en cellulosabaserad isolering såsom hampafiberisolering, Målet med studien var att undersöka om hampafiberisolering kan bli ett etablerat isoleringsmaterial i sandwichpaneler avsedda för lager- och logistikhallar.

Metod – Metoden för studien var en fallstudie då fokus låg på en specifik analysenhet. Datainsamlingen skedde genom triangulering där intervjuer och dokumentstudie användes som insamlingstekniker. Sju intervjuer genomfördes med personer representerade av företag i form av fastighetsinvesterare, tillverkare av sandwichpaneler, tillverkare av hampafiberisolering och byggföretag. Utifrån det som framgick i intervjuerna skedde en tematisk analys. Därefter granskades aktuella dokument deduktivt utifrån respondentsvar för att utmana eller styrka dessa teman.

Resultat – I studien framgick att det krävs att flera aspekter behöver uppnås för att hampafiberisolering ska kunna användas i sandwichpaneler. Detta var aspekter gällande funktionen på panelen, övriga aspekter och miljöaspekter.

Den största fördelen med hampafiberisolering är dess klimatpositiva egenskaper och detta var också anledningen till att isoleringen använts av respondenterna i studien. De nackdelar som framgick i studien var priset, ovana, få referensobjekt och ovissheten gällande fukt.

Det framgick att oskadad hampafiberisolering kan återanvändas efter en väggelements livstid genom att den kan användas i sin helhet eller blandas ut till ny isolering. Det finns även möjlighet att skapa biokol av isoleringen med hjälp av förbränningsugnar.

Analys – Utgångspunkten för analysen var empirin från intervjuerna, vilket lade grund för en riktad innehållsanalys i aktuella dokument. I analysen sammanfattades och jämfördes empirin från dokumenten med intervjuerna för att styrka och utmana det som framkommit. Det framgick att en del faktorer gick att styrka som krav alternativt trovärdiga konklusioner från respondenter. Andra aspekter gick inte styrka i dokument.

Diskussion – Resultatet från intervjuerna och dokumentstudien i studien visar ett stort fokus på miljö. Då datainsamlingen var utformad utifrån frågeställningar hölls studien aktuell till undersökningsområdet. Ett genomtänkt respondenturval bidrog till hög reliabilitet vid datainsamlingen.

Eeffect of Boron addition on the microstructure and mechanical properties of ductile iron, GJS-500-7 grade was studied. Three cast batches with the Boron content of 10, 49 and 131ppm were cast in a casting geometry containing plates with thicknesses of 7, 15, 30, 50 and 75mm. Microstructure analysis, tensile test, and hardness test were performed on the samples which were machined from the casting plates. Addition of 49 ppm Boron decreased pearlite fraction by an average of 34±6% in all the cast plates. However, minor changes were observed in the pearlite fraction by increasing Boron from 49 to 131 ppm. Variation in the plate thickness did not affect the pearlite fraction. The 0.2% offset yield and ultimate tensile strength was decreased by an average of 11±1% and 18±2%, respectively. Addition of 49 ppm Boron decreased Brinell hardness by 16±1%, while 11±2% reduction was obtained by addition of 131ppm Boron.

Abstract 

This report contains an investigation of the annealing process of an aluminium coil in industrial furnace environment. The main result of this investigation is a predictive FE simulation model within adequate accuracy which aids in annealing process design.

The procedure starts with a literature study of both the key parameters in general and the modelling and experimental methods related to heat transfer in industrial coils. Additional CAE tools are identified to support the research.

The procedure follows the implementation of the existing radial thermal conductivity model in a FE simulation, for different coil thicknesses and winding forces. The measured strip surface roughness and the crowning slope serve as input parameters in the effective radial thermal conductivity model.

Furthermore, the effective heat transfer coefficient models for coil sides have been developed and calibrated. Both the radial thermal conductivity and convective heat transfer models are integrated in the FE model of the coil annealing process.

The coil annealing experiments have been conducted in an industrial furnace at Gränges AB. The experimental data support the creation and validation of the FE simulation model.

The simulation-based parametric study evaluates the importance of considering the relevant physical phenomena in the model.

The FE model of the annealing process has been validated against the temperature measurements within 10% at the target material temperature. The model can be applied for coil temperature predictions as part of the annealing process design.

The overall method generates engineering guidelines to design the annealing process with the help of simulation tools.

The automotive industry needs more lightweight materials, prompting the focuson optimising aluminium alloys to achieve the highest mechanical performance.This project investigates the assumption that variations in location andthickness within a component leads to different mechanical properties. Anunderstanding of varying mechanical properties and their correlation withmicrostructure is essential for optimising these alloys.The research utilised tensile testing and Digital Image Correlation (DIC)methods to observe strain concentrations, aiming at defect identification.The analysis of the fracture surface was performed using Scanning ElectronMicroscopy (SEM), which revealed hidden damages such as oxides, bi-films, andporosity shrinkage. Energy Dispersive Spectroscopy (EDS) was employed toidentify the elemental composition of fracture surfaces. The study alsoexplored the correlation between Secondary Dendrite Arm Spacing (SDAS) andmechanical performance, with measurements of SDAS compared with the tensiletest results. Image analysis quantified average porosity percentages aroundthe component, which were then compared to casting simulation results. In-situ tensile testing, performed using SEM, allowed for the observation ofcrack propagation in various locations and thicknesses.Statistical analysis indicated that variations in thickness and location didnot result in significantly different mechanical characteristics within thecomponent. The exception was observed in the pillars of the sample, whichhad the greatest thickness and cylindrical shape, that exhibited poorermechanical performance. Thicker samples showed increased porosity and oxideformation, which correlates with lower solidification rates and higher SDAS,thereby weakening the material. DIC analysis supported these observations,identifying high strain concentrations linked to hidden defects in the melt.In-situ tensile testing further corroborated these findings with the presenceof oxides, showing more frequent crack propagation in thicker samples.The study highlights the critical impact of sample thickness and coolingrates on the mechanical properties of aluminium alloys, revealing areas forpotential optimisation in high-performance applications.

During the casting process and solidification of ductile iron castings, a heterogeneous microstructure is formed throughout the casting. This distribution is highly controlled by process related factors, as chemical composition, local solidification conditions, and the geometry of the casting. Geometrical changes to the geometry of the casting thus alters the local mechanical behaviour, as well as the distribution of stresses and strains when the casting is subjected to load. In order to find an optimal geometry, e.g. with reduced weight and increased load-bearing capacity, this interdependency between geometry and local material behaviour needs to be considered and integrated into the optimization method. In this contribution, recent developments in the multidisciplinary integration of casting process simulation, solidification and microstructure modelling, microstructure-based material characterization, Finite Element Analyses (FEA) with local material behaviour and structural optimization techniques are presented and discussed. The effect and relevance of considering the local material behaviour in shape optimization of ductile iron castings is discussed and evidenced by an industrial application. It is shown that by adopting a multidisciplinary optimization approach by integration of casting simulation and local material behaviour into shape optimization, the potential of the casting process to obtain components with high performance and reliability can be enabled and utilized.

Vitreous enamel is an inorganic coating applied on metallic substrates as powder and fired at relatively high temperature in order to cover the surface forming the coating. This kind of layer shows, at the same time, very good functional and aesthetical properties. In several applications, good mechanical resistance together with corrosion protection is required and enamel is a good alternative to other coatings. Enamel presents optimum corrosion protection and high hardness values but the low fracture toughness reduces its resistance to abrasive wear related to brittle fracture. The microstructure of enamel, the chemical composition of the frit, and the deposition parameters are crucial for the final properties. Moreover, it is possible to introduce mill additives in the frit or hard particles inside the layers to improve final resistance. In this paper, abrasion resistance of enamel is tested by Taber Abraser test. Mill additives (spodumene or quartz), hard (WC or SiC) or solid lubricant (graphite) particles have been added to the frit to study their influence on the abrasion resistance. The abrasion resistance of modified enamels was evaluated through mass loss after abrasion and wear track were observed by SEM in order to evaluate the abrasion damage. An improvement of the abrasion resistance was obtained modifying the frit with mill additives. The introduction of SiC and WC particles produced an important modification in wear mechanism of the glassy coating, reducing the crack nucleation due to the low pores quantity and good interface between vitreous matrix and particles. In these cases the wear mechanism is limited to scratches on the surface.

There is a high demand for implementing simulations in the design and product devel-opment processes, avoiding the execution of costly tests on prototypes and giving thechance of discarding unsuitable designs, as well as exploring possible ones without much cost added.This project assignment is to find a suitable way to simulate drop tests on two typesof PMMA sheets, a material widely used on luminaire covers. Therefore, it becomesnecessary to study the mechanical behavior of these materials, using experimental tests,in order to calibrate the material models used in the simulations.During the experimental testing, common polymer behaviors were found on the twostudied materials, such as rate dependence, non-linear elasticity, viscoelasticity and vis-coplasticy. Behaviors which presented several challenges regarding the choice and cali-bration of the material models.The two di?erent polymers were calibrated for the simulations using two di?erentmaterial models. An elastic-plastic (Drucker Prager Plasticity) model was used for oneof the materials, whereas an hyperelastic-viscoelastic model was used for the other one.Finally, several drop tests simulations were conducted and compared with experimentaltests

The effect of ultrasonics on filling properties has been studied by Ni electroplating from a sulphamate electrolyte in high aspect ratio grooves. The experiments have been performed with two different modes of ultrasound: a) 25 kHz ultrasound with an effect of 225 W directed perpendicular to the substrate surface; b) ultrasonic standing waves of 100 kHz and 400 kHz parallel to the substrate surface. It was found that both methods improve the filling in grooves that are between 0.35 and 1 mm wide with aspect ratios between 0.6 and 3, compared to electroplating with conventional agitation. Under the investigated conditions the 400 kHz standing wave parallel to the surface was most efficient to improve filling of grooves.

The influence of 25 kHz ultrasound and cathode rotation during electroplating of Ni films on Si wafers has been studied with respect to intrinsic stress formation. Current densities from 1·6 up to 28·3 A dm⁻² were used in an additive free Ni sulphamate electrolyte. In general, more efficient agitation by either ultrasound or cathode rotation was found to reduce intrinsic stress towards compressive levels compared with conventional agitation with an electrolyte circulation pump. Furthermore, intrinsic stresses become less dependent on changes in current density. The latter effect is most pronounced for ultrasonic agitation. Structure analysis of samples deposited by ultrasonic agitation shows dense deposits with initially smaller grains at high ultrasonic effect. Locally increased temperature at the substrate surface could be an important effect of ultrasound agitation.

The simulation of microstructure and mechanical properties is of great importance as a lead in bringing the foundry process and cast materials closer to the casting designer. Prediction of the formation of the microstructure during solidification is a supporting factor for strength optimization of cast aluminium components that allows an improved performance and increased competitiveness of cast engineering components.

The deformation behaviour and the integrity of cast components depends mostly on the chemical composition of the material, especially the iron content, solidification behaviour and the resulting microstructural characteristics. This paper aims to demonstrate the capabilities of microstructure and mechanical properties modelling of aluminium cast materials and components. The validation of the models includes investigation of cast cylinder head and measured microstructure and mechanical properties as well as their distributions. The effect of iron-rich compound’s morphology and fraction on the plastic deformation behaviour has been studied and modelled in terms of strain hardening exponent and strength coefficient. This approach enables the prediction of local microstructure and mechanical properties. The developed models have been implemented in a cast simulation software for simulation of the cast cylinder head.

The model predictions of microstructural quantities and mechanical properties are in good agreement with experimental measurements.

The influence of solidification rate on the solution treatment response for an Al–8Si–3.1Cu alloy has been investigated. The alloy was cast using the gradient solidification technique to produce samples with three different solidification rates. The samples were solution treated at 495 C for various times between 10 min and 10 h. The concentration of copper in the matrix was measured using the wavelength dispersive spectroscopy technique, WDS.

The results show that the coarseness of the microstructure clearly affects the solution treatment time needed to dissolve particles and obtain a homogenous distribution of copper in the matrix. A short solution treatment time of 10 min is enough to achieve a high and homogenous copper concentration for a material with a fine microstructure (secondary dendrite arm spacing, SDAS of 10 μm), while more than 10 h is needed for a coarse microstructure (SDAS of 50 μm). A model was developed to describe the dissolution and homogenisation process. The model shows good agreement with the experimental results.

Heat treatment of gravity cast aluminium components normally involve a solution heat treatment followed by quenching and subsequent ageing, either naturally or artificially. The mechanical properties of aluminium castings containing Cu and Mg are clearly improved by heat treatment but there are still some uncertainties and contradictions about the phase dissolution, formation of precipitates and the influence of natural and artificial ageing parameters such as time and temperature, on the peak strength of these materials. The present paper reviews over 60 papers in attempt to clarify and map out the influence of each and every sequence that is involved in the heat treatment process on the evolution and kind of precipitates, which in turn determines the mechanical properties of cast aluminium components.

This thesis was conducted in cooperation with a Swedish company that develops and manufactures plastic compounds. An increasing need for identifying material properties is seen within the industry in order to predict the outcome of the extrusion process by using simulations. The purpose of this study was to expand a material database with the results obtained through various measurements of the material parameters in order to enable simulations. The numerical descriptions would be analyzed and validated in relation to the obtained results and conducted methods to enable implementation of the material data into the industry. In order to fulfill the purpose, scientific methods was applied by chosen literature studies, research approaches and experimental research. Machine tests were conducted to collect relevant output data that was compared with the results obtained during the simulation process where the experimentally determined material parameters were applied in a material database. Typical injection molding qualities of PET, POM, PC/ABS, SAN and PA66 has been investigated by conducting measurement methods described by standards of the melt flow rate, specific heats, viscosity, crystallinity and melt- and glass transition temperatures. With exception of the viscosity, the material parameters are considered to have high external validity and high reliability and can be implemented into the industry. The bulk- and melt density was determined by adapted methods that need further investigations. The external validity is reduced until these methods and measurements have been validated. The determined material parameters proved to be able to generate reliable simulation results that indicate of how the extrusion process will turn out based on the output values investigated. The data obtained through machine tests was compared with the results that were achieved through simulations and deviated at most 10.9% from the actual outcomes. The viscosity is considered to be the main factor that affects the differences of the output data between the machine tests and the simulation results. 

With increasing emphasis and regulations on the environmental footprint in industries, the integration of reduced carbon dioxide equivalent (CO₂eq) plastic materials is desirable. Fiber-reinforced plastic materials mechanical properties differ with varying fiber orientations. Similarly, the welding line phenomenon, commonly present in more complex injection molded parts, decreases the mechanical performance. This thesis aims to experimentally investigate tensile behavior on reduced CO₂eq reinforced plastics in different fiber orientations and weld line configurations. 

Ten materials with reduced CO₂eq are investigated, the types of materials are as follows: PA6 (Polyamide6), PP (Polypropylene), and PA6/PP blend materials. Both short fiber-reinforced polymers (SFRP) and long fiber-reinforced polymers (LFRP) are investigated. The screening resulted in three selected materials for further investigation: one recycled PA6, one bio-based PA6/PP, and one alternative PP. The further investigation involves tensile testing in the five directions and three weld line configurations with non-standardized geometry specimens punched out from an injection molded plate with controlled fiber orientation. Two types of uniform fiber orientation plates are manufactured for the testing conditions, one with holes for weld line testing and one without for testing of orientation. The evaluated fiber orientations are 0° (fibers parallel to load direction), 22.5°, 45°, 67.5°, and 90° (fibers transverse to load direction). The weld line configuration consists of three consecutive holes with 96.5, 146.5, and 196.5 mm distances from the gating system. Three weld line test specimens are generated from each plate, they are denoted W1, W2, and W3 from their respective distance from the gating system, with W1 being closest to the gate. Optical microscopy of fiber orientation and failure modes for the test specimens are performed to investigate and validate the testing conditions. 

Varying fiber orientation was found to greatly affect the stress-strain behavior in all four materials investigated. The tensile strength was reduced from longitudinal to transverse fiber orientation, with the most significant reduction near flow direction. High variations were present for the brittle materials supposedly from their weakness to stress concentrations. Strain tended to increase from the lowest at 0° to the maximum at 45°, from which it again decreased to a mid-value at 90° for all materials. The weld line strength reduced significantly for the brittle materials, whereas the ductile materials experienced a much smaller reduction. The three weld line cases failed at similar stresses, while having different stiffness.

In the present study, nickel phosphorous alloys (Ni-P) and Ni-P/ silicon carbide (SiC) nanocomposite coatings were deposited by electrodeposition on steel substrates in order for their microstructural properties to be assessed while using SEM, XRD, and three-dimensional (3D) profilometry as well as nanoindentation. The amorphisation of the as-plated coatings was observed in all cases, whereas subsequent heat treatment induced crystallization and Ni3P intermetallic phase precipitation. Examination of the surface topology revealed that the surface roughness follows the deposition characteristics and heat treatment induced microstructural changes. Additionally, substantial improvements in mechanical properties, including hardness, yield stress, and elasticity modulus, were obtained for the Ni-P, Ni-P/SiC nanocomposites when heat treated as seen from the nanoindentation results. A Finite Element Analysis (FEA) was developed to simulate the nanoindentation tests that enable the precise extraction of the Ni-P and Ni-P/SiC nanocomposite coatings’ stress-strain behavior. It is shown that the correlation between the nanoindentation tests and the computational models was satisfactory, while the stress-strain curves revealed higher yield points for the heat-treated samples.

Huvudsyftet med avhandlingen är att undersöka hur smält metall tränger in isandformen och hur man kan minimera detta problem. Samtidigt har det genomundersökningen avslöjats vilka materialparametrar som påverkarpenetrationsfenomenet och vilka orsakerna till denna typ av gjutningsfel är.Mikrostrukturen på ytan av värme- och slitstarka gjutgods observerades medenergidispersiv röntgenspektroskopi (EDS) och svepelektronmikroskop (SEM) ochanalyserades för att identifiera de olika faserna.En teoretisk modell, kapillärmodellen, användes för att beräkna hur de relevantafaktorerna påverkar penetrationsfenomenet. Baserat på kapillärmodellenuppskattades kvantitativt hur det yttre trycket, kontaktvinkeln och ytspänningenpåverkar penetrationsdjupet. Det andra sättet att minimera penetrationen är att ökakontaktvinkeln och ytspänningen. Genom att minska det yttre trycket kan manuppnå samma mål.

The aim of the present study is to selectively extract antimony and arsenic from decopperization slime through alkaline sulfide hydrometallurgy with a view to recycle the obtained solid residue within the copper smelter, and also regenerate the sulfide lixiviant during the process. Rechtschaffner experimental design was used to evaluate the joint influence of several experimental parameters such as leaching temperature, Na2S concentration, solid concentration, and reaction time on the extraction of antimony and arsenic from the material. The most active parameters influencing the extraction of the metals are solid concentration and reaction period. In addition, the results show that solid concentration interacted strongly with the leaching time and slightly with reaction temperature, which is an indication that solid concentration is the predominant influencing factor in removing antimony and arsenic from the material. It is also indicated from the results that about 95% Sb and 89% As were extracted when 50 g/L of the decopperization slime was dissolved in alkaline sulfide lixiviant containing 200 g/ L Na2S ? 20 g/L NaOH at 60 C for 24 h. Moreover, analysis of the leach residue reveals that copper sulfide and lead sulfide remain as the main constituents of the residue. The bismuth-containing mineral phase was not observed in the residue because of its low concentration, and also the Sb/As-bearing mineral phases were not detected due to the selectivity of the leaching reagent to the metals. Based on the experimental results from this investigation, a process flowsheet for the alkaline sulfide treatment of a decopperization slime was proposed with a view to eliminating its antimony and arsenic contents in a sustainable manner.

In copper metallurgy, antimony impurities usually form alloys and compounds with the transition metals to make up the basic building blocks of a speiss phase. This speiss phase is generally rich in copper and precious metals, which are desirable to recycle and recover at the smelter. The presence of this impurity unfortunately creates a build-up of this metal in the copper circuit, leading to problems during copper refining processes. Therefore, a removal or reduction of the antimony impurity to an acceptable level is a necessary step before the speiss can be recycled at the smelter for the recovery of its valuable metals. A lead silicate slag that was obtained after smelting a copper speiss admixed with silica, soda and lead oxide, was leached in alkaline sulphide solution to selectively dissolve its antimony content. Furthermore, the pregnant sulphide leachate was purified by precipitation and crystallization techniques to recover antimony as sodium thioantimonate and sodium hydroxyl antimonate using synthetic Na2S-NaOH-Sb2S3 solutions. The leaching results indicate that the highest amount of antimony and arsenic extracted from the material after 24 h at 100 °C and reagent concentration of 30 g/L NaOH + 30 g/L S2− was 83% and 90%, respectively. In the precipitation process, the addition of hydrogen peroxide to the alkaline sulphide leachate prompts the precipitation of antimony as NaSb(OH)6. The result also implies that b100% of stoichiometric hydrogen peroxide is required to completely oxidize the total amounts of both Sb3+ and S2− in the solution and to quantitatively precipitate N90% of the antimony in solution. The influence of catalytic agents and temperature on the process was not clearly reflected in this investigation due to the exothermic reaction with hydrogen peroxide. Moreover, the addition of elemental sulphur to the sulphide leachate also in- fluences the precipitation of antimony as sodium thioantimonate.