Numerical modeling and experimental validation of the recrystallization behaviour in the extrusion of 6XXX aluminum alloys

The microstructure of 6XXX aluminum alloys deeply affects mechanical, crash, corrosion and aesthetic properties of extruded profiles. Unfortunately, grain structure evolution during manufacturing processes is a complex phenomenon because several process and material parameters such as alloy chemical composition, temperature, extrusion speed, tools geometries, quenching and thermal treatment parameters affect the grain evolution during the manufacturing process. The aim of the present PhD thesis was the analysis of the recrystallization kinetics during the hot extrusion of 6XXX aluminum alloys and the development of reliable recrystallization models to be used in FEM codes for the microstructure prediction at a die design stage. Experimental activities have been carried out in order to acquire data for the recrystallization models development, validation and also to investigate the effect of process parameters and die design on the microstructure of the final component. The experimental campaign reported in this thesis involved the extrusion of AA6063, AA6060 and AA6082 profiles with different process parameters in order to provide a reliable amount of data for the models validation. A particular focus was made to investigate the PCG defect evolution during the extrusion of medium-strength alloys such as AA6082. Several die designs and process conditions were analysed in order to understand the influence of each of them on the recrystallization behaviour of the investigated alloy. From the numerical point of view, innovative models for the microstructure prediction were developed and validated over the extrusion of industrial-scale profiles with complex geometries, showing a good matching in terms of the grain size and surface recrystallization prediction. The achieved results suggest the reliability of the developed models and their application in the industrial field for process and material properties optimization at a die-design stage.

Advanced X-ray techniques for the structural characterisation of Prussian Blue Analogue cathode materials

The thesis is dedicated to the implementation of advanced x-ray-based techniques for the investigation of the battery systems, more predominantly, the cathode materials. The implemented characterisation methods include synchrotron based x-ray absorption spectroscopy, powder x-ray diffraction, 2-dimensional x-ray fluorescence, full field transmission soft x-ray microscopy, and laboratory x-ray photoelectron spectroscopy. The research highlights the different areas of expertise for each described method, in terms of material characterisation, exploring their complementarities and intersections. The results are focused over manganese hexacyanoferrate and partially Ni substituted manganese hexacyanoferrate, through both organic and aqueous battery systems. In aqueous system, the modification of cathode composition has been observed with various techniques, indicating to the processes occurring in bulk, surface, locally or in long-range, including with the speciation by 2-dimensional scanning, and the time-resolution, by the implementation of the operando measurements. In organic media, the inhomogenisation of the cathode material during the aging process was investigated by the development of the special image treatment procedure for the maps, obtained from the transmission soft x-ray microscopy. It worth mentioning, that apart from the combination of the outcomes from the various x-ray measurements, the exploration of the new capabilities was also conducted, namely, probing the oxidation state of the element with the synchrotron-based 2-dimensional x-ray fluorescence technique, which, generally, with conventional set up, is not possible to achieve. The results and methodology from this thesis can, of course, be generalised on the characterisation of the other battery systems, and not only, as the x-ray techniques are one of the most informative and sophisticated methods for advanced structural investigation of the materials.